SERVICE MANUAL Gearbox - Allison AT545 - Gearbox .
SERVICE MANUALGearbox - Allison AT545 - Gearbox InstallationAmended:Oil leveldipstickAuxiliaryoil filterGearbox oilcoolerModulatorPage 3.4Dart E3 Service Manual - Publication Number 2209 - Nov 2001
SERVICE MANUALGearbox - Allison AT545Amended:Checking Oil LevelOil and Filter ChangeThe dipstick and filler are situated to the left of the engineat the rear.1. Transmission should be at operating temperatureto assist draining.2. Remove drain plug from oil pan.COLDADDCOLD HOTHOTFULLFULLADD3. Remove oil pan, gasket, filter and seal ring. Cleanthe oil pan.4. Remove the screen for the governor feed line,located in the control valve body. Clean andreplace.Cold Run1. Park vehicle on level ground and apply parkingbrake.2. Run the engine for 1 minute. Select 1st thenreverse and finally neutral. Sump temperatureshould be between 60 - 120 F (16 - 49 C).3. With engine idling, check level. If the level is not inthe cold run band, add or drain as necessary.Hot Run1. Operate transmission in Drive until normaloperating temperature is reached.Sump temperature160 - 200 F (71 - 93 C)Converter-out temperature180 - 220 F (82 - 104 C)2. Park vehicle on level ground select neutral, applyparking brake and allow engine to idle.3. Check oil level. Add or drain necessary, to bringthe level to the top of the HOT run band.4. Perform final check twice. If readings areinconsistent, check gearbox breather and venthole in the dipstick.5. Replace new filter and seal ring. Fit oil pan andgasket, tightening the bolts evenly. Replace drainplug and tighten to 15 - 20 lb ft (20 - 27 Nm).6. Remove external auxiliary oil filter element andreplace.NOTEThe oil filter seal should be lightly oiledand at contact with the filter head face,tightening the element 2/3 to one full turn.7. Refill with new oil, the refill amount is less than theinitial fill because some of the oil remains in theinternal circuits and transmission cavities.8. After refill, check the oil level using the aboveprocedure.Gearbox BreatherThe breather is located at the top of the transmissionhousing. It serves to prevent pressure buildup and mustbe kept clean and the passage open.5. The above operation may be carried outimmediately after the use of the vehicle.NOTEApproximately 1 litre of oil is required toraise the level from the bottom to the topof the hot run band. (Add to full).Dart E3 Service Manual - Publication Number 2209 - Nov 2001Page 3.5
SERVICE MANUALGearbox - Allison AT545Amended:Range Selector Cable AdjustmentTo check the correct adjustment of the selector cable,carry out the following procedure: Put transmission into drive. Remove the split pin from the cable trunnion at thegearbox end of the cable. Remove the trunnion from the gearbox selectorarm. The correct adjustment is when the trunnion is asliding fit in the gearbox selector arm and thetrunnion is at the centre of it's free play in the driveposition. This step of equalising the free play of the cablebefore checking the trunnion in the selector arm ismost important, and is necessary for trouble freeoperation. Replace the split pin. Check all speed ranges (Reverse, Neutral, Drive,1, 2, and 3) for correct operation.Page 3.6Dart E3 Service Manual - Publication Number 2209 - Nov 2001
SERVICE MANUALGearbox - Allison 2000 SeriesAmended:29/09/04DescriptionThe Allison 2000 series is a fully automatic electronicallycontrolled transmission with five forward speeds. Thetransmission control module (TCM) processesinformation received from sensors on the transmissionand sends signals to activate specific solenoids on thecontrol valve module. The transmission features"adaptive shifting" which helps to optimize shift quality bymonitoring critical clutch activation characteristics andmaking adjustments to improve subsequent changes.Service IntervalsFirst. . . . . . . . . . . . . . . . . . . . . .1,000miles (1,600km)A service interval . . .6,000miles (10,000km) / 3months *B service interval . .12,000miles (20,000km) / 6months *C service interval .24,000miles (40,000km) / 12months ** whichever is soonerTorque SettingsSpecificationBolt - flexplate to crankshaft . . . . . . .137 Nm (101 lbf.ft)Type . . . . . . . . . . . . . . . . . . . . . . . . .Allison 2000 seriesBolt - flexplate to attachment ring . . .57 - 68 Nm (42-50lbf.ft)Gears . . . . . . . . . . . . . . . . . . . . . .Five-speed automaticRetarder . . . . . . . . . . . . . . . . . . . . . . . .External - TelmaBolt - attachment ring to torque convertor . . . . . . . . . . . .45 Nm (33 lbf ft)Oil capacity . . . . . . . . . . . . . . . . . . . . . . . . . . .18.9 litresSetscrew - gearbox to engine . .51 - 61 Nm (37-44 lbf.ft)Oil change . . . . . . . . . . . . . . . . . . . . . . . . . . .15.0 litresScrew - gearchange cable bracket . . . . . . . . . . . . . . . . .23-27 Nm (16-19 lbf.ft)Oil specification . . . . . . . . . . . . . . . . . .Castrol TransyndRecommended brand . . . . .Castrol Transynd (TES295)Bolt - Gearchange cable bracket . . . . . . . . . . . . . . . . . . .51 - 61 Nm (37-44 lbf.ft)Nut - selector lever . . . . . . . . . . .20-27 Nm (14-19 lbf.ft)MaintenancePlug - oil drain . . . . . . . . . . . . . .30-40 Nm (22-30 lbf.ft)Change control main oil filterNut - dipstick tube mounting . . . . . . . . .43 Nm (31 lbf.ft)At first 5,000 miles (8,000km) and then at every 50,000miles (80,000 km) 2 yearly.Gearbox to cooler hose - end fitting 37 deg. 7/8 JIC . . . .48-55 Nm (35-40 ibf ft)Change sump filterAt overhaulChange oil)Every 50,000 miles (80,000 km) 2 yearly.Check adjustment of shift linkageC service intervalGearbox to cooler hose - end fitting 37 deg 7/8-12 JIC . .48-55 Nm (35-40 ibf ft)Cooler to gearbox hose - end fitting 37 deg 7/8 JIC . . . . .48-55 Nm (35-40 ibf ft)Cooler to gearbox hose - end fitting 7/8-12 JIC . . . . . . . .48-55 Nm (35-40 ibf ft)Check gearbox breatherC service intervalCheck tightness of fixingsFirst, A, B & C service intervalsCheck for oil leaks and rectifyFirst, A, B & C service intervalsCheck oil levelFirst, A, B & C service intervalsDart E3 Service Manual - Publication Number 2209 - Nov 2001Page 3.7
SERVICE MANUALGearbox - Allison 2000 Series - Gearbox InstallationAmended:DipstickOil filterBreatherNeutral startbackup switchOil coolerPage 3.8Dart E3 Service Manual - Publication Number 2209 - Nov 2001
SERVICE MANUALGearbox - Allison 2000 SeriesChecking Oil LevelAmended:Oil and Filter ChangeThe dipstick and filler are situated to the left of the engineat the rear.1. Transmission should be at operating temperatureto assist draining.2. Remove drain plug from oil pan.COLDHOT3. Remove the control main filter by unscrewing itanti-clockwise using a strap type filter wrench.4. Remove the magnet from the filter or attachmenttube, clean the magnet and report any large metalparticles to the maintenance personnel.Cold Run5. Replace the magnet on the attachment tube.1. Park vehicle on level ground and apply parkingbrake.2. Run the engine for 1 minute. Select drive thenreverse and finally neutral.3. With engine idling, check level. If the level is not inthe cold run band, add or drain as necessary.6. Replace the control main filter.NOTEThe oil filter seal should be lightly oiled,and at contact with the filter head facetighten the element 2/3 to one full turn.7. Re fit the drain plug and tighten to 30-40 Nm (2230 lb ft).Hot Run1. Operate transmission in Drive until normaloperating temperature is reached.Sump temperature160 - 200 F (71 - 93 C)Converter-out temperature180 - 220 F (82 - 104 C)2. Park vehicle on level ground, select neutral, applyparking brake and allow engine to idle.3. Check oil level. Add or drain necessary, to bringthe level to within the HOT run band.4. Perform final check twice. If readings areinconsistent, check gearbox breather and venthole in the dipstick.8. Refill with new oil, the refill amount is less than theinitial fill because some of the oil remains in theinternal circuits and transmission cavities.9. After refill, check the oil level using the aboveprocedure.Gearbox BreatherThe breather is located at the top left of the transmissionmain housing. It serves to prevent pressure buildup andmust be kept clean and the passage open.5. The above operation may be carried outimmediately after use of the vehicle.NOTEThe width of the "HOT RUN" bandrepresents approx. 1 litre of fluid atnormal operating temperature.Dart E3 Service Manual - Publication Number 2209 - Nov 2001Page 3.9
SERVICE MANUALGearbox - Allison 2000 SeriesAmended:20.06.05Change Speed Linkage 6 PositionClamp plate toalign with4 mark1. If fitting a new cable remove and discard cablenut. Position the setscrew in the end of the terminalas shown. (fig 1). Screw the terminal onto thethreaded end of the cable until it bottoms againstthe setscrew. Tighten the setscrew securely (do notexceed 20-25in.lbs).Earlier Typefig 3fig 12. To fit gearchange cable attach the cable to theshift selector, ensuring that it is mounted in thecorrect spigot hole. (fig 2).CAUTIONUsing the incorrect location with respect to thecable hanger position other than shown will causeimproper control operation and damage to thesystem.On later type hanger plates the cable is clampedusing the top set of holes on the hanger plate. Theseare marked 40S on the rear surface of the hangerplate. (fig 4).Clamp plateusingtop holesNUTSLater TypeCorrect spigotlocation holefig 23. There are two types of hanger bracket. Determinewhich type of hanger bracket is used.On the earlier type, centre of two serrated screws isaligned with 4 mark on front surface. Note: screwsmust be line across hanger with serrations matinginto hanger plate serrations. (fig 3).fig 4SCREWSDuring assembly ensure that the protrusion on theinside face of the clamp is correctly located in therecess on the cable ferrule. Ensure that a new cableclamp, shim and fixings are used.Fit nuts and torque tighten (8 - 12.13.Nut - selector lever (20-27 Nm)Bracket - gearchange cableShift leverScrew - self tappingShimClampScrew - M5LocknutGearchange cablePivotSplit pinSpacerBolt - M10 (51-61 Nm)fig 5Page 3.10Dart E3 Service Manual - Publication Number 2209 - Nov 2001
SERVICE MANUALGearbox - Allison 2000 SeriesAmended:23.07.044. At the gearbox end the change speed cablebracket is attached to the gearbox with self tappingscrews (4) bolts (13) and a spacer (12). The selectorlever (3) is retained by a locknut (1). Place clamp (6)ensuring engagement in recess on cable ferrule,place shim (5) between cable hub and gearchangecable bracket (2), secure with screws (7) andlocknuts (8). Fit nuts and torque tighten (8 - 10Nm).9. Centre the position of the cable at the mid point oftravel determined by the previous two stages. (fig 8).CablePivotShift leverheld in Neutralposition5. Ensure the gearchange selector in drivers cab isin the neutral position.6. Move shift lever on gearbox to neutral position.7. At the gearbox end, push the cable and note theposition of the cable end (pivot) in relation to the holein the shift lever. (fig 6).CableCentre cable to mid pointbetween pull and push positionsfig 810. Holding the cable at the position determined inthe previous step, rotate the pivot (10) on thethreaded section of the cable until it lines up with thehole in the shift lever.(3). (fig 9).CablePivotPivotShift leverheld in NeutralpositionShift leverheld in NeutralpositionPush cable to moveselector handle againstend of Neutral gatefig 68. Pull the cable and again note the position of thepivot in relation to the hole in the shift lever. (fig 7).CablePivotShift leverheld in NeutralpositionPull cable to moveselector handle againstopposite end of Neutral gatefig 7Rotate pivot on threaded endof cable until it is aligned withhole in shift lever. Fit pivot toshift lever and install split pin.Do not spread split pin at thisstage.fig 9Verify by pulling and pushing cable to establish midpoint of travel. The pivot pin should be re alignedwith hole in shift lever.11. Insert pivot (10) into shift lever (3) and fit split pin(11) do not spread split pin at this stage. Ensure thatthe attachment pin of the pivot does not bind in theshift lever hole.Move range selector through all positions to ensurethat it is synchronised with the transmission. Adjustpivot if necessary, spread split pin and tighten rodnut against pivot.Note: As the the lock nut is part of the cableassembly, its' relative position to the pivot isgoverned purely by the adjustment at installation.Therefore, providing the lock nut 'locks' its' positioncan be either side of the pivot.Dart E3 Service Manual - Publication Number 2209 - Nov 2001Page 3.11
SERVICE MANUALGearbox - Allison 2000 SeriesAmended:20.06.05Change Speed Linkage 3 Position1. If fitting a new cable remove and discard cablenut. Position the setscrew in the end of the terminalas shown. (fig 1). Screw the terminal onto thethreaded end of the cable until it bottoms againstthe setscrew. Tighten the setscrew securely (do notexceed 20-25in.lbs).4060fig 3fig 12. To fit gearchange cable attach the cable to theshift selector, ensuring that it is mounted in thecorrect spigot hole. (fig 2).CAUTIONUsing the incorrect location with respect to thecable hanger position other than shown will causeimproper control operation and damage to thesystem.3. The cable is clamped using the top set of holes onthe hanger plate. These are marked 40 on thesurface of the hanger plate. (fig 3).During assembly ensure that the protrusion on theinside face of the clamp is correctly located in therecess on the cable ferrule. Ensure that a new cableclamp, shim and fixings are used.Fit nuts and torque tighten (8 - 10Nm).4. At the gearbox end the change speed cablebracket is attached to the gearbox with self tappingscrews (4) bolts (12) and a spacer (11). The selectorlever (3) is retained by a locknut (1).95 fig 2Place clamp (6) ensuring engagement in recess oncable ferrule, place shim (5) between cable hub andgearchange cable bracket (2), secure with screws(7) in threaded holes marked ‘D’, torque tighten (3 ge 3.12Nut - selector lever (20-27 Nm)Bracket - gearchange cableShift leverScrew - self tappingShimClampScrew - M5Gearchange cablePivotSplit pinSpacerBolt - M10 (51-61 Nm)12fig 4Dart E3 Service Manual - Publication Number 2209 - Nov 2001
SERVICE MANUALGearbox - Allison 2000 SeriesAmended:20.06.055. Ensure the gearchange selector in drivers cab isin the neutral position.Cable6. Move shift lever on gearbox to neutral position.Pivot7. At the gearbox end, push the cable and note theposition of the cable end (pivot) in relation to the holein the shift lever. (fig 5).CableShift leverheld in NeutralpositionCentre cable to mid pointbetween pull and push positionsfig 7PivotShift leverheld in NeutralpositionPush cable to moveselector handle againstend of Neutral gate11. Insert pivot (9) into shift lever (3) and fit split pin(10) do not spread split pin at this stage. Ensure thatthe attachment pin of the pivot does not bind in theshift lever hole.fig 5Cable8. Pull the cable and again note the position of thepivot in relation to the hole in the shift lever. (fig 6).PivotShift leverheld in NeutralpositionCablePivotShift leverheld in NeutralpositionPull cable to moveselector handle againstopposite end of Neutral gatefig 69. Centre the position of the cable at the mid point oftravel determined by the previous two stages. (fig 7).10. Holding the cable at the position determined inthe previous step, rotate the pivot (9) on thethreaded section of the cable until it lines up with thehole in the shift lever.(3). (fig 8).Rotate pivot on threaded endof cable until it is aligned withhole in shift lever. Fit pivot toshift lever and install split pin.Do not spread split pin at thisstage.fig 8Move range selector through all positions to ensurethat it is synchronised with the transmission. Adjustpivot if necessary, spread split pin and tighten rodnut against pivot.Note: As the the lock nut is part of the cableassembly, its' relative position to the pivot isgoverned purely by the adjustment at installation.Therefore, providing the lock nut 'locks' its' positioncan be either side of the pivot.Verify by pulling and pushing cable to establish midpoint of travel. The pivot pin should be re alignedwith hole in shift lever.Dart E3 Service Manual - Publication Number 2209 - Nov 2001Page 3.13
SERVICE MANUALGearbox - Allison 2000 SeriesTransmission fault light (red)The electronic control system is programmed to tell theoperator when a problem has occurred with thetransmission system by means of the transmission faultlight on the instrument panel.Every time the engine is started the transmission faultlight will illuminate and then go out after a few seconds,this is a circuit check to confirm that the bulb and wiringare working correctly. If the transmission fault light comeson at any time after start up it indicates that a problemhas been detected by the transmission control module(TCM) which will register a diagnostic trouble code(DTC).When a failure condition is detected, the DTC set by theTCM remains active as long as the ignition is switchedon, when the ignition is switched off and on again theDTC is reset and the TCM checks again for the failurecondition. If the failure condition is not detected theprevious DTC will remain in history, the transmissionfault light will go out after the circuit check and thetransmission will function normally unless another faultoccurs, this enables the vehicle to be driven to a servicecentre.While the transmission fault light is illuminated, up anddown shifts may be restricted, and direction changes maynot occur.Amended:Troubleshooting when no diagnosticcodes are presentCheck the basics first.Make sure the range selector is in the appropriateposition.Check that the batteries are fully chargedBegin by checking the transmission fluid level and theignition voltage. Some problems are temperature related,so all tests should be carried out at the temperature thatthe problem occurs.Make sure that the throttle is closed and engine speed isbelow 900 RPM.Check that all electrical connections are properly made.Check all support equipment for correct installation andoperation.If the shifting process is rough, time must be allowed forthe shifts to adapt to the "converged" state beforeassuming there is a problem.Troubleshooting intermittent diagnosticcodesIntermittent codes are a result of conditions which are notalways present.When a code is logged in the memory it will remain thereRange inhibited light (red)The range inhibited light mounted on the dashboard tellsthe operator that the transmission is being inhibited andrange changes requested by the operator may not occur.When certain operating conditions are detected by theTCM the transmission will be locked in the range which isin use at that time.until it is manually cleared or the vehicle completes fortycode free warm up cycles.When an intermittent code exists check for the following:1 Dirt, damaged or corroded harness connectors orterminals.2 Terminals not fully seated in the connectors.3 Damaged harnesses (poor routing, chafing, excessiveheat, tight bends etc).4 Incorrectly mounted electronic control components.5 Poor connector seals, where fitted.Page 3.14Dart E3 Service Manual - Publication Number 2209 - Nov 2001
Dart E3 Service Manual - Publication Number 2209 - Nov 2001 SERVICE MANUAL . Operate transmission in Drive until normal operating temperature is reached. Sump temperature 160 - 200 F (71 - 93 C) Converter-out temperature 180 - 220 F (82 - 104 C) 2. Park vehicle on level ground select neutral, apply parking brake and allow engine to idle. 3. Check oil level. Add or drain necessary .
13AAA Allison MTB-653DR N/A 64R 13AAC Allison AT-545 N/A 55R 13AAD Allison AT-545 N/A 55R 13AAE Allison AT-545 N/A 55R 13AAG Allison AT-545 N/A 55R 13ADK Ford Torqshift N/A N/A 13ADL Ford Torqshift N/A N/A 13ADN Allison 3000 EVS ALL-4 68R&68L 13ADP Allison 3500 EVS ALL-4 68R&68L 13ADR Allison 3000 EVS ALL-4 68R&68L 13ADX Allison 3000 TRV ALL-4 .
Allen, Willie Lewis 1908 Allen, George W. Clayton, Claudia Allison, Effie Pearl 1912 Allison, David Vester Allen, Essie Allison, Lewis J. 1881 Allison, Marion Lashley, Mary Allison, Lillie Mae 1912 Allison, Joseph Coleman Compton, Emma Allison, Marion Watson 1901 Allison, Will Forbes, Lou Dor Allred, Alvin 1906 Allred, Frank Capps, Daisy
50472 3 T Services, Inc Tony Derrick Sioux City IA Martin L. Winebrinner (05329) Martin L. Winebrinner (05329) 06/30/2017 . 51381 Allison Plumbing, Heating & A/C, Inc Michael Allison East Moline IL Michael D Allison (06177) Michael D Allison (06177) Michael D Allison (06177) 01/08/2017 .
REDUCTION GEARBOX FINNØY REDUCTION GEARBOX The gearbox range covers input powers from 250 kW and up to 12 000 kW. They are divided into 3 model types: - SINGLE STAGE REDUCTION GEARBOX, with vertical or horizontal offset - GXU REDUCTION GEARBOX - TWIN
Field test: torque and modal characterization. Planet bearing calibration. Trunnion stiffness characterization. Phase 1. Dyno Gearbox 1: run-in and instrumentation checkout. Field Gearbox 1: loads, responses, events. Dyno Gearbox 2: run-in, limited non-torque loading. Phase 2. Dyno Gearbox 2: extensive Non-Torque Loads (NTL), dynamics, HSS .
Harmonic gearbox have smaller backlash but a very high price, while a planetary gearbox have a higher load carrying capacity, a better coefficient of efficiency and a significantly lower price, all for the same overall dimensions. Because of this, it would be reasonable to use a planetary gearbox instead of a harmonic gearbox. Figure 5.
6-speed manual gearbox 02 M is a new development. It is a compact gearbox with six forward gears for A-platform vehicles with trans-versely mounted engine. A compact 6-speed gearbox was realised by using two output shafts and one input shaft. In this booklet, we will explain to you the new gear-box and the technology used. 205_052
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