Service 2005 OCTOBER Wi EValer) SM4014EN Allison Transmission ALLISON 4TH GENERATION CONTROLS VOCATIONAL MODELS 4000 EVS 4500 EVS 4700 EVS 4800 EVS B500 4000 HS 4500 HS 4700 RDS 4800SP 1425 4000 MH 4500 RDS 4700 SP T 450 4000 RDS 4500 SP T525 4000 SP 4000 TRV Allison ‘Transmission. (raeamosa —] ‘Copyright © 2007 Ailton Tanariaon, neINTRODUCTION ELECTRONIC CONTROL UNIT AND DIAGNOSTIC DATA READER/TOOL, DISPLAYS AND BUTTON NAMES Shift Selector, Allison DOC™ button, and display names are printed in bold capital leters—T (Upp, 4 (Down), MODE, MONITOR, SELECT, ete ‘Transmission range shifts are indicated by the letter or number on the shift selector, in bold text, followed by the ‘ante Of the range in parentheses—D (Drive), N (Neutral), etc, References to diagnostic messages displayed are printed within double quotation marks (“OL,""OK,” ete.). TRADEMARK USAGE ‘The following trademarks are the property of the companies indicated: * Allison DOC™ (Allison Diagnostic Ope ‘of General Motors Corp. + DEXRON' isa regisioned trademark of General Motors Corp, * Biobor® JF is the registered trademark for a biological inhibitor manufactured by U.S. Borax and Chemical Conporation, * Loctite® is a registered trademark of the Loctite Corporation, ‘ Teflon® iss registered trademark of the DuPont Corpor ‘TranSynd™ is a trademark of Castrol, Lid. ‘+ Vespel® is a registered traclemark of DuPont Corporation ized Camnection Tool) is a trademark ion, NOTE ‘This publication is revised periodically to include improvements, new models, special tools, and procedures. A revision is indicated by the date on the title page. Check with your Allison Transmission service outlet far the currently applicatile Publication, Additional eopies of this publication may be purchased from authorized Allison ‘Transmission service outlets. Look in your telephone directory under the heading of ‘Transmissions—Truck, Tractor, ete. ii Copyright © 2007 Allison Transmission, Ine,IMPORTANT SAFETY NOTICE EP IS YOUR RESPONSIBILITY to he completely familiar with the Warnings and Cau- tions described in this Service Manual, These Warnings and Cautions advise against the use of specific serviee methods that can result in personal injury, damage to the equip- ment, or cause the equipment to become unsafe. It is, however, important to understand that these Warnings and Cautions are not exhaustive. Allison Transmission could not possibly know, evaluate, and advise the service trade of all conceivable ways in which service might be done or of the passible hazardous consequences of each way, Conse- quently, Allison Transmission has not undertaken any such broad evaluation. Accord- ingly, ANYONE WHO USES A SERVICE PROCEDURE OR TOOL WHICH IS NOT RECOMMENDED BY ALLISON TRANSMISSION MUST first be thoroughly satisfied that neither personal safety nor equipment safety will be jeopardized by the service methods selected. Proper service and repair are important to the safe, reliable operation af the equipment, ‘The service procedures recommended by Allison Transmission and described in this Ser- vice Manual are effective methods for performing service operations. Some of these ser vice operations require the use of taols specifically designed for the purpose. The special tools should be used when and as recommended. WARNINGS, CAUTIONS, AND NOTES Three types of headings are used in this manual to attract your attention: WARNING! is used when an operating procedure, practice, ‘etc., which, if not correctly followed, could result in petsonal injury or lass of life, (CAUTION: is used when an operating procedure, practice, ste, which, if net strictly observed, could result image to or destruction af equipment. NOTE: isused when an operating procedure, practice, cte.. isessential to highlight, Copyright © 2007 Allison Transmission, IncLIST OF WARNINGS ‘This manual e ‘OUR RESPONSIBILITY TO BE FAMILIAR WITH ALL OF THEM. itains the following Warnings — If you leave the vehicle and the engine is running, the vehicle ean move suddenly and you or others could be injured. If you must leave the engine running, do not leave the vehi until you: + Put the transmission in N (Neutral)...and the parking brake and emergency brakes and make sure they are properly + Choek the wheels and take any other steps necessary to keep the vehicle from moving. Avoid contact with the hot fluid or the hot samp when draining transi nf contact with the hot fluid or the hot sump may result in bodily injury. DO NOT conduct a converter stall test until the following actions are taken. The parking brake and/or emergency brakes must he set and properly engaged and the wheels must be choeked. Warn personnel to keep clear of the vehicle and its travel path, Failure to do so can cause serious injury. Direct Use appropriate safety equipment such as safety glasses, safety shoes, and gloves, Do not burn discarded Teflon” seals; toxic gases are produced by burning Teflon”. Never dry bearings by spinning them with compressed air. A spinning bearing can sintegrate, allowing balls or rollers to become lethal flying projectiles. Also, spinning a bearing without lubrication can damage the bearing. DO NOT disconnect the hydraulic fluid line between the accumulator and the retarder until air and hydraulic pressure haye been bled from the retarder. PREVENT PERSONA proper tools and lifting equipment when installing or removing a transmission from the repair stand, Transmission dry weights are as follows: + 4000 and 4500 Models, Base transmis 377 kg (831 Ibs) 405 kg (893 Ibs) ALL kg (906 Ibs) With retarder and PTO provision © —439 kg (968 Ibs) + 4700 and 4800 Models Base transmission —493 kg (1087 Ibs) With PTO provision S21 kg (1149 Ibs) With retarder —529 kg (1162 Ibs) With retarder and PTO provision —SS5 kg (1224 Ibs) With retarder, PTO, and integral = —496 kg (1032 Ibs) retarder sump coolerLIST OF WARNINGS ‘This manual conta the following Warnings — IT IS YOUR RESPONSIBILITY TO BE FAMILIAR WITH ALL OF THEM. ‘Get help when lifting the control module, Assistance from a hoist or another person may be required. The control module weighs approximately 25 kg (55 Ib). ‘Get help when lifting the retarder module. Assistance from a hoist or another person may he required. The retarder module weighs approximately 34 kg (75 Ib). Get help when lifting the C6 adapter housing module. Ass person may be required. The C6 adapter housing modu (150 Ib). tance from a hoist or another weighs approximately 68 kg Carefully release spring foree, Piston springs are highly compressed, Personal injury can ‘occur if the spring foree is not controlled. Piston springs are highly compressed, Be extremely careful during removal and installation. Personal injury can occur if the spring force is not controlled. Place the P3 planetary assembly on its side to avoid possible injury while disassembling the planetary. Copyright © 2007 Allison Transmission, IheTABLE OF CONTENTS Paragraph Section f. te. Pore GENERAL INFORMATION SCOPE OF MANUAL ‘a. Comtent And Organization... b. Mlustrations. e ¢. Maintenance Information... SUPPLEMENTARY INFORMATION , ORDERING PARTS 1. Transmission Nameplate... b. Parts Catalog GENERAL DESCRIPTION a, Major Modules... . tb. Unique Features... MAJOR COMPONENTS a. Input Module agesement b, Torque Converter... : © Power Takeoff ........ 4d. Main Housing And Gear Module Range Clutches .... f. Control System Transmission Fluid Filters. 1h. Transmission Fluid Coolers i. C6 Adapter Housing Madtle. ... J. RearCover.. K. Output Retaer And Output Flange... 1-6 4000 PRODUCT FAMILY MODEL DESIGNATION CODE . . . a EXPLODED (DISASSEMBLED) VIEWS. cc ccesecsssearseeveeevere DIAGNOSIS a. Before Starting........ b. CHECK TRANS Light ¢. Entering Diagnostic Mode 4. Diagnostic Codes... : spaying Diagnostic Codes... E._ Diagnostic Code Displays & Exiting Dingnostic Mode PRESERVATION AND STORAGE a, Storage (New Transmissions Before Installation) ......... b, Preservation Methads -.- € One Year Storage (Without Fluid). 4. One Year Storage (With Fluid) ... 18 re) Perec Pave +10, RESTORING TRANSMISSION TO SERVICE a, Transmission Exterior ........ vo bb, Sealed Breather And Openings 19 ¢. New Transmissions ..... 19 Stored Without Fluid... 1 Stored With Fluid. 1.9 Jel, ELECTROMAGNETICRADIO. FREQUENCY INTERFERENCE ...... 1-10 1-12, OPERATING INSTRUCTIONS ........ 1-13, SPECIFICATIONS AND DATA... Section 2, PREVENTIVE MAINTENANCE PERIODIC INSPECTION AND CARE, a, Exterior Cleaning And Inspeetion, . IMPORTANCE OF PROPER FLUIDLEVEL a, Transmission Fluid ............ b. Gil Level Sensor .....-+ &, Electronic Controls And Protection Circuits, anise ELECTRONIC FLUID LEVEL CHECK (WHEN AN OPTIONAL OLS 1S PRESENT—FULL-FUNCTION PUSHBUTTON OR LEVER SHIFT SELECTORS) a. Fluid Level Cheek Procedure... MANUAL FLUID LEVEL CHECK PROCEDURE a Preparation . bh. Consistency OF Readings -.. COLD CHECK PURPOSE: oe reerees b. Cold Check Procedure... HOT CHECK a Purpase........ : cite b. Cold Check Procedure. KEEPING FLUID CLEAN. FLUID RECOMMENDATIONS, a, Fluid Type... 2-6, Copyright © 2007 Allison Transmission, Ine. SCOPE. - - srrers® 0 104000 PRODUCT FAMILIES SERVICE MANUAL—ALLISON 4th GENERATION Parag Pose 2-10, FLUID AND FILTER CHANGE INTERVALS a Plaid And Filter Changes 0.0.2.0... 268 Fluid Analysis... an 2 2411, FLUID CONTAMINATION a Water cee b Engihe Coolant... . a Metal ee . 2-12, FLUID AND FILTER CHANGE, PROCEDURE Drain Fluid b. Replace Filters c. Refill Transmission 2.13, BREATHER: & Location And Purpose. . 28 b. Maintenance oo. cc cecsyseees cere e A 2-14, TRANSMISSION STALL. TEST AND NEUTRAL COOL-DOWN CHECK a PURPOSE 2. cee ee) tu Stall Testing Preparation 2... = 268 ¢. Performing a‘ransmission Stall Test . 2-10 d. Driving Transmission Stall Test... 2-10 &. Driving Transmission Stall Test Preparation... oo B10 f_Pertorning a ving Tons Stall Test .... ali i. ‘Nelural Cook-Down Procedure, aa bh, Tronsrnission Stall Test Results ...... 2411 2-15. READING CLUTCH PRESSURES PUNE csc eccecs science RAID b. ‘Transmission And Wehicle Preparation . 212 e. Reconding Data... ee 3 4. Comparing Recorded Data To Specifications. 0... eeee ce Ded 2-16. FLUID LEAK DIAGNOSIS a Fidiig Leak oo b. Powder Mattia... occ ceeee ©. Black Light and Dye Method... 4. Possible Points OF Fluid Leaks And ‘Tei Causes. : ce. Repairing Leak... cccsee ce DT Pm 2-17. OUTPUT FLANGE/YOKE AND OIL, SEAL MAINTENANCE a. Disassembly coc b, Assembly... . . 2.18. ON-VEHICLE MAINTENANCE... Seetion 3, GENERAL OVERHAUL INFORMATION ORE sors ii a 3-2. TOOLS AND EQUIPMENT a. Imiptovised Equipineit...... Speci Todls : by @. Mechanie’s Tools And Shop Equipment ...... me REPLACEMENT PARTS Ordering Information... bb. Parts Normally Replaced a Overhieal a M. as CAREFUL HANDLING . CLEANING AND INSPECTION a Din Causes Malfunstion bb. Cleuning Transmission, Parts e. Cleaning Bearings... 2.0... dL Inspecting Bearitigs... we e. Keejing Bearings Cteam...... f. Inspecting Cast Parts and Machined Surfaces... . i hu Hast Songs a ai i. Inspecting Gears... Inspecting Splined Parts . Inspecting Threaded Parts... |. Inspecting Retaining Rings . im. Inspecting Springs... 7 i. Inspecting Clutch Plates... © Inspecting Swaged and Imerference-Fit Parts. ae p. Inspecting Sealing Surfaces... . Copyright © 2007 Alison Transmission, ine,TABLE OF CONTENTS Paragraph Pore 3-6. ASSEMBLY PROCEDURES a. Paris Lubrication... 1b, Grease Used For Assembly , ealing Compounds And Nomsoluble Greases... 2.00. 22000.0 369 . Clutches And Pistons... ee 3D Threaded Plugs And Hydraulic MINES «vais seoseeee eee +10 f, Coated Threaded Fasteners. 10 g. Lip-Type Oil Seats. ..... “10 4h. ButtJoint Seatrings. .. oo B10 i. Bearings... 3 pee lO je Bushings. eos cose on k. Electrical Components 3-7, REMOVING TRANSMISSION FROM VEHICLE a Drain Fluide es o.sscceeees ee b. Disconiecting Contiols...... Sl ©. Uncoupling Transmission From Vehicle And Engine Driveline........3-11 dk Removing The Tramsmis B12 3-8. WEAR LIMITS. . - 2 3-9. SPRING SP TATIONS «0.02.5 SHI 3-10. TORQUE SPECIFICATIONS ..........3+12 Section 4, TRANSMISSION DISASSEMBLY 4H el Al Mlusteations. at d. General Information. ... : a ce. Poldauis.... i . 41 4-2, DISASSEMBLY OF TRANSMISSION ‘On Repair Stand. .......- ee b. Removal Of Power Takeoff, del c. Removal OF External Parts 4 d. Removal OF Integral Oil Coole: 43 fe. Removing Integral Retarder Sump Oil COEF, eee sees severe Ad £ Removal Of Control Valve Module... 44 Removal Of Torque Converter Module, . 44 bh, Removal Of Converter Housing Module... . i, Removal OF Retarder Module \(Bxcept 4700 And 4800 Models)... 46 Paragraph Pave J. Removal Of Retarder And Output Shaft Moulule (4700 And 4804) Models}. k. Removal Of Rear Cover Module (Except 4700 Aid 4800 Models). 0.0... c206 0. AAT L Removal Of Rear Cover And Output Shaft Module (4700 And 4800 Models) 4-8 m, Removal OF C6 Adapter Housing, 47 Module (4700 And 4800. Models)... 4-8 fn. Removal Of P3 Planetary Modal (4700 And 4810) Models)........-2.6, 49 9: Remayal Of Main Shaft Module... 4-9 p. Removal Of P2 Module, C5 Clutch Plates, And P1 Modal 49 4. Retioyal OF Front Suppor ‘Charging Pump Module And Rotating Clutch Module... 4-10 Removal Of CVC Cluteh Assembly From Main Housing Module... . 4-10 Section 5, MODULE REBUILD Sel SS. SCOPE a Section... b. Procedures... ae GENERAL INFORMATION FOR MODULE REBUILD... cece Sel ‘TORQUE CONVERTER MODULE a. Disassembly... ante erntesoe dll b. Assembly... wee BD TORQUE CONVERTER HOUSING MODULE (Models Without PTO Provision) a. Disassembly... . b. Assembly... + a i TORQUE CONVERTER HOUSING MODULE (Models With PTO Provision) 4 Disassembly 'b. Disassembly Of Bearing Retainer. © Disassembly Of PTO Gear Assembly... 54 4, Assembly OF PTO Gear Assembly... ..5-4 Assembly Of Bearing Retainer Assembly. . . 5 E Assembly... - eee 55 Copyright © 2007 Allison Transmission, Ine ix4000 PRODUCT FAMILIES SERVICE MANUAL—ALLISON 4th GENERATION Prragraph Page 5.6. FRONT SUPPORT AND OIL PUMP MODULE, a Disassembly... 5. . +S b, Asseinbly OF Froat Support ..........5-7 Assembly OF Pump Housing ST 5-7. ROTATING CLUTCH MODULE a Disasseribly 2.20... ceee bh. Assembly. 5-8, CCLAND MAIN HOUSING MODULE a. Disassembly... bh Assembly... 5-9. MAIN SHAFT MODULE a. Disassembly . 4800 Models)... Assembly (4700 And 4800 Models) 5-10, PL PLANETARY MODULE a. Disassembly, b Asem S-11. P2 PLANETARY MODULE a Disassembly... ae b. Assemii 5-12, P3 PLANETARY MODULE (4700 And 4800 Models) a Disassembly... b Assembly... 5-13. C6 ADAPTER HOUSING MODULE (4700 And 4800 Models) a. Disassembly OF Ring Gear and Hub Assembly 3 b. Disassembly ....- Disassembly OF Assembly 4. Disassembly Of Remaining C6 Parts & Asembly . {Assembly OF PS Planetary Carrier Assembly des S19 sg. Assembly OF C6 Clute... 5-14, RETARDER AND P3 PLANETARY MODULE 4. Disassembly OF Retarder Valve Body... 5-20 Disassembly Of Temperature Sensor... 5~20 Disassembly OF Retarder Housing... 5-21 Disassembly Of P3 Planetary Camier Assembly... . = as - St Pomaerieh Pave ¢. Disassembly OF Retarder Stator Assembly 1. Assembly OF Retarder Stator... g. Assembly OF PS Planetary Carrier Assembly. h, Assembly OF Retarder Housing Assembly... i. Assembly OF The Retaioe Vale Body 5-15. RETARDER AND OUTPUT SHAFI MODULE (4700 And 4800 Models Equipped With Retarder) a. Disassembly Of Retarder Valve Body . 5-25 b. Disassembly Of Temperature Sensor .. 5-25 ¢. Disassembly Of Retarder Housing .... 5-25 4. Completion Of Retarder Housing Disassembly ae cede 6. ©. Assembly OF Output Shaft Assembly . 5-26 f. Disassembly Of Retarder Stator Assembly... - seven SO. g. Assembly OF Retarder Stator ........ 5-26 h, Assembly OF Retarder Housing... 5-27 Assembly Of Output Shaft Assembly. . 5-27 J. Completion Of Retarder Housing, Assembly. S27 k. Assembly OF Retarder Valve Boxy... 5-28 5.16. REAR COVER MODULE (Models Equipped With Rear Cover, Except 4700 And 4800, Models) a. Disassembly... . soeene SOB, b Disassembly Of P3- Planctary Carrier Assembly... 50.0020. +. 5-20 ¢. Completion OF Rear Cover Disassembly 5... Beginning Rear Cover Assembly &. Assembly OF P3 Planetary suvier Assembly. . 1. Completion OF Reat Cover Assembly... 531 |. REAR COVER AND OUTPUT SHAFT MODULE (4700 And 4800 Models Equipped With Rear Cover) a. Disassembly Sota pctaanenn cn bb. Disassembly Of Output Shaft Assembly wees x Copyright © 2007 Alison Transmission, In,TABLE OF CONTENTS Paragraph Pore ©. Completion Of Rear Cover Disassembly. 4. Beginning Rear Cover Assembly . fe. Assembly OF Output Shatt ‘Assembly... su wee SB £. Completion OF Rear Cover Assembly, .5-33 5-18, CONTROL VALVE MODUL a. Removal Of Filters... S34 . Removal OF Electrical Components And Sensors. a ces 3S ssembly OF Solenoid Valve Body 5-35 a. Disassembly OF C6 Control Valve BOW ac Lacig coy eenen nie nisak 11S ©. Disassembly Of Main Valve Badly. . see 5-36 Disassembly Of Channel Plate... 5-37 Assembly OF Channel Plate... Assembly Of Main Valve Body. Assembly OF C6 Conttol Valve Body ‘Assembly OF Solenoid Valve Boxy, Installation Of Electrical Components, ‘And Sensors. seas tances BB 1. Install Filters Section 6, TRANSMISSION ASSEMBLY 1. SCOPE a, Section... ea coos Gel 1b. Procedures... 4 . o1 Gc. Mlustrations 6.2... cee. 6-1 ad. General Information . 61 fe. Poklauls.... i 6-1 G2, ASSEMBLY OF TRANSMISSION a, Assembly Of Main Housing Module... 6-1 1b. Installation OF Rowting Clutch Module. .6=1 cc. Installation OF From Suppor ‘Charging Pump Module. 6-2 Installation OF PI Planetary Module... .6-2 Installation Of P2 Planetary Module... .6-2 £, Installation OF C5 Cluich Pack... 5-6-2 Installation Of Main Shaft Module (Except 4700 Anu #800 Models)... ..6-2 1. Installation Of Main Shaft Module {4700 And 4800 Models) .....2...-.-6-3 Paragraph Paxe i. Main Shaft Sélective Shim Measurement (Close Ratio Modets) J, Main Shaft Setective Shim Meastretieat (Wide Ratio Models)... 64 Installation OF P3 Planetary Module (4700 And 4800 Modeis With Retard), .6-5 1. Installation OF C6 Adapter Housing Modlule (4700 And 4800 Moule Is With Retanderp.....- a cee OS mm, P3 Planetary Selective Shim Measurement (4700 And 4800 Models ‘With Retarder) + we 66 3 Planetary Selective Shim ‘Measurement (4700 And 4800 Models With Rear Cover)... cee OT 6. Installation OF Remainder OF P3 Planetary Module and C6 Adapter Housing Modul (471M) And 481) Models)... 2... .6-8 p. Installation Of Tolerance Rings Module (4700 And 4800 Models With Retardery ..... ~ 69 4. Installation OF Retader Moule (ENeept 4700 And 4800 Modets) 0.02... 669 F. Installation OF Retarder and Output Shaft Module (4700 And 4800 Models With Reiarders) . . Installation Of Rear Cover Module (Escept 4700 And 4800 Models) . , Installation Of Rear Cover Module (4700 And 4800 Moitels)..0 2.2.61 Installation OF Converter Housing Motil... 225 06..teeeece cence sO \. Installation Of Torque Converter Module... ceeceeeeeee Bet w. Installation Of Control Module. ......6=16 x. Installing Integral Oil Cooler, ........6-16 y+ Installing Integral Retarder Sump Oil Cooler. ae i wie NT 2 Install Mounted Parts... cee Ooh ‘a, Installation OF Power TakeotT...-. 6-19 ab, Removal Of Transmission From Repair Stand.....2......22.2. 6519 Copyright © 2007 Allison Transmission, Ine. si4000 PRODUCT FAMILIES SERVICE MANUAL—ALLISON 4th GENERATION Paros Page Poach Powe Section 7. WEAR LIMITS AND Section 8, CUSTOMER SERVICE SPRING DATA 8-1. OWNER ASSISTANCE, . Bl Fok WEAR EANETS DATA 8-2. SERVICE LITERATURE «.....0.2..... 82 a. Maximum Variations mH , Cleaning and Inspection , vtel 7-2. SPRINGDATA, 8. Spring Replacement . sere Tl b. Inspection S Tel sii Copyright © 2007 Allison Transmission, Ine,4000 PRODUCT FAMILIES SERVICE MANUAL—ALLISON 44 GENERATIO: LIST OF FOLDOUT ILLUSTRATIONS (Back Of Service Manual) CROSS-SECTION VIEWS Fol 1 4000 Product Family Transmission (Close Ritio)—Cross Seetion 24300 Model (Wide Ratio) Transmission With PTO Provision—Cross Section 3 4000 Product Family (Close Ratio) Transmission With Retarder—Cross Section 3A 4700 and 4800 Mode! Transmission—Cross Seetion 3.B 47/00 and 4800 Model Transihission With Retander—Cross Section 3,C_4700and 4800 Model Transmission With Retarder and PTO Provision—Cross Section EXPLODED VIEWS Folin 4.4 Flexplate and Adaper 4,B Torque Converter Module .A Converter Housing Module 5.B_ Converter Housing Module With PTO Provision 6.4 Front Support and Charging Oil Pump Module 6.B Rotating Cluich Module 7 ——-Main Housing Moxtle 8 Main Shafi Module 9,4 PI Planetary Module 9.B P2 Planetary Module 9.C —P3 Planetary Module and Cé Adapter Housing Module (4700 and 4800 Models) 1OA Rear Cover and P3 Planetary Module 10.8 Rear Caver and Ouiput Shaft Module (4700 and 4800 Models) 10.C Retarder and P3 Module 10.D — Retarder and Output Shaft Module (4700 and 4800 Models) 1A. Control Module 11,8. Control Module 12,4 Ouipat Flange and Yoke 12,B Support Equipment Invegral Retarder Sump Cooker 4900 Product Family Hydraulic Schemvat Neutral Copyright © 2007 Atison Transmission, Ie ii4000 PRODUCT FAMILIES SI ERVICE MANUAL—ALLISON 4th NERATION NOTES 2007 Allison Transmission, IneCTH SCOPE OF MANUAL 4 Content and Organization, This Service Manual describes overitaul procedures for 4000 Product Family transmissions with Allison 4 ‘Generation Controls. Power takeoft (PTO) and ouput retarder options may be added fo a base transmission model. * Detailed instructions are provided for in Section 4, rebuild in Section 5, + Part inspection instructions are in Section 3 + Wear + Major transmission components and their functions are explained in 3000 and 4000 Proulict Families Principles of Operation POSOIGEN. ‘The 4000 Product Family consists of the following Aransmiission series and models (Figures 1-1 through 1-6»: Highway Series: + 4000 HS + 4500 HS its and spring data are in Section 7. Rugged Duty Series: » 4000 RDS » 4700 RDS Emergency Vehicle Series: * 4000 EVS * 4500 EVS + 4700 EVS 4800 EVS ‘Motorhome Se * 4000 MH ‘Truck Recreational Vehicle Series: * 4000 TRV + 4500 TRY ‘Specialty Series: + 4000 SP » 4500 SP + 4700 SP » 4800 SP Bus s » B500 |I—GENERAL INFORMATION T400 Series: + 742s + T7450 +7 by Illustrations 1 The text is supported with Tine drawings and croxs-scctionsl views. Overhaul procedures are illustrated by fine drawings. Cross-section show the relationship of assembled parts Cross-sections, exploded views, an a hydniulic schematic (transmission in. Neutral) ‘are on foldout pages in the back of the manual 2. Mlustrations show correet procedures fior all models—including models not illustrated © Maintenance Information, Each tsk described in this manual has been successfully completed by service organizations and individuals. Not every service organization or individual possesses the required special aling, training or experience 10 perm all described tasks. However, any task may be performed if the following conditions are met: 1. ‘The organization or individual has the required knowledge of the task throwgh: + Formal instruction at Allison Trarismiséion ora Distributor training facility. + On-the-job instruction by an Allison ‘Transmission or Distributor representative. + Experience in performing the task 2. The work environment is sitable to prevent comamination or damage to transmission pars or assemblies. 3. Required tools and fixtures: are available as shown iit Section 3 OF this manual, Refer 1 Figures 3-2.and 3-3 and Tables 3-1 and 3-2, 4. Reasonable and prudent maintenance practices are used. NOTE: Service organizations and individuals ure encouraged to contact their local Allison ‘Transmission Distributor for information and guidance om any task outlined in this manual, Copyright © 2007 Allison Transmission, Ine Mt4000 PRODUCT FAMILIES SERVICE MANUAL—ALLISON 4th GENERATION vemos Figure 1=1. 4000 Product Family Transmission With PTO Provision (Except 4700 and 4800 Models)—Right-Rear View Figure 1-2, 4000 Product Family Transmission With PTO Provision (Except 4700 and 4800 Models}—Lelt-Rear View ey Copyright © 2007 Allison Transmission, Ene,GENERAL INFORMATION Figure 14, 4000 Product Family With PTO Provistan and Retarder (Except 4700 and 4800 Modols)—Lofi-Flear View Copyright © 2007 Allison Transmission, Inc, 13Thank you very much for your reading. Please Click Here. Then Get COMPLETE MANUAL. NO WAITING "cuEK HERE 3X NOTE: If there is no response to click on the link above, please download the PDF document first and then click on it.4000 PRODUCT FAMILIES SERVICE MANUAL—ALLISON 4th GENERATION Figure 1-6, 4900 Product Family With PTO Provision (4700 and 4800 Models} —Right-Roar View Copyright © 2007 Allison Transmission, Ene,GENERAL INFORMATION SUPPLEMENTARY INFORMATION Supplementary information wil be issued, as required, ian er publication of this manual, Con J-3. ORDERING PARTS a. Transmission Nameplate. “The (Figure 1-7) is located on the right side of the ‘wansmicsion ‘The nameplate is imprinted with the following: © Model number Serial number Data code ‘TransID number gineering Festure Configurition Number (for Specialty Series vocation madels) Use all of these miinbers when ondering replacement parts oF requesting service information, b. Parts Catalog. Replacement parts tre listed in the current 4000 Product Family Parts Catalog PC2456EN, Do not onder by the item nurnbers used on exploded views in this manual, Use the Parts Catalog to determine the correct part number. Order all replacement parts from your distributor. Check the Yellow: Pages for your nearest authorized service outlet, Listings are under Transmission—Truck or Engines—Diese! Id. GENERAL DESCRIPTION Allison 4000 Product amily transmissions area complete transmission system that includes all hardware needed for vehicle application, . Major Modules. 4000 Product Family transmissions contain the following major modules: + Input Module + Main Housing anid Gear Mostule + Control Module + uiqut Module + C6 Adapter Moilile (4700 anel 4800 models) b. Unique Features. Features unique to 4000 Product Family transmissions are; * Three, Four, five, six, or seven forward speed configurations + Lockup clutch with torsional damper + Invegral retarder (optional) + Iniegral oil filters, serviceable without complete loss of transmission fluid + Adaptive electronic cloxed-toop controls with self-dingnostic capabilities MODEL MOUSER FLD Figure 1-7. Transmission Nameplate Copyright © 2007 Allison Transmission, Inc, 1s4000 PRODUCT FAMILIES SERVICE MANUAL—ALLISON 4th Gi ‘NERATION 1S. MAJOR COMPONENTS 4, Inpiit Mediate, The Input Module includes: + Engine adaptation + Torque converter ‘+ Power takeoff gearing (optional) 1b, ‘Torque Converter 1. The torque converter includes 4 lockup cluteh and torsional damper for direct and smooth transfer of engine power. 2. Torque converter models available are: ‘Torque Converter Model TC s21 TC S31 TC S41 TC 551 TC 501 ¢. Power ‘Takeoff, Direct, engine-driven PTO searing is available at two positions, except im the 4000 HS. . Main Housing and Gear Module. ‘The Main Housing and Gear Module include: + Main Housing = Oil pump charging system ‘+ Three planetary gear sets (four for 4700 ant 4800 mosels) + ‘Twortating clutches ‘+ Three stationary clutches (four for 4700-and 4860 models) ¢. Range Clutches. Range cluiches are multiple dise, wel-type clutches, Exhaust backfill pressure is used to reduce fill time for quick response and smooth shifts. £ Control System. The control system is eapable of recognizing hydraulic and electronic conditions that are not within the operating Fimits of the progeammed calibration, Some out-of-fimit conditions can be ‘control. system, AL out-of-fimit codes are stored for later retrieval bby atechnician, ‘The Electronic Control System includes: + Transmission Control Module (TCM) © Control module ft selector © Sensors © Wiring hamess (customer-furmished) ‘The TCM is a high-speed digital computer that receives information from the sensors and. shift selector, This information is processed and. shift commands. are sent to the control madule for range selection. & Transmission Fluid Filters, Two disposable cess filters are part of the conti! module. in a separate cavity which permits removal and replacement without complete loss of transmission fluid h. ‘Transmission Fluid Coolers. The 4000 Product nily has provision for remote or integral transmission fluid coolers 1. C6 Adapter Housing Module. The C6 adapter housing module is unigue to the 4700 and 4800 models, It provides 4 seventh range and is located ‘between the maim housing and rear coverfretarder. J. Rear Cover. A rear cover is standard equipment ‘on the 4000 Product Family. The output shaft can be provided with a variety of companion flanges or yokes. k. Output Retarder and Output Flange. The optional output mtarder module replases the standard rear cover, An output flange or yoke is available for use with the retarder. 1-6, 4000 PRODUCT FAMILY MODEL DESIGNATION CODE BUS = _Bus Series EVS = _Eimergency Vehicle Service HS — Highway Series MH — Motorhome Series RDS ——_~_Rugeesd Duty Series sP — Specialty Series TRY = Truck Recreational Vehicle Series, Tor8 = Widest Ratio Coverage (WRC) 3 = Wide Ratio (WR) Close Ratio (CR) ‘The following table lists the standand (STD) and optional (OPT) features of each 4000 Product Family mandel code designations: 16 ‘Copyright © 2007 Allison Transsnission, Ine