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Allison Transmission 1000/2000/3000/4000 Product Families Factory Service & Shop Manual

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Allison Transmission 1000/2000/3000/4000 Product Families Factory Service & Shop Manual

Complete workshop repair service manual with bonus troubleshooting manuals for Allison Transmission 1000/2000/3000/4000 Product Families. It's the same service manual used by dealers that guaranteed to be fully functional and intact without any missing page.

This Allison Transmission 1000/2000/3000/4000 Product Families service & repair manual (including maintenance, overhaul, disassembling & assembling, adjustment, tune-up, operation, inspecting, diagnostic & troubleshooting…) is divided into different sections. Each section covers a specific component or system with detailed illustrations. A table of contents is placed at the beginning of each section. Pages are easily found by category, and each page is expandable for great detail. The printer-ready PDF documents work like a charm on all kinds of devices.

FILE LIST:
TS3989FR - Manuel de dépannage (Groupes de produits 3000 et 4000).pdf
TS3989EN - Troubleshooting Manual (3000 & 4000 Product Families - 4th gen. Controls - Vocational Models).pdf
TS3977FR - Manuel de dépannage (Groupes de produits 1000 et 2000 - Commandes Allison 4. Génération).pdf
TS3977EN - Troubleshooting Manual (1000 & 2000 Product Families - 4th gen. Controls).pdf
TS3353EN - Troubleshooting Manual (5000, 6000, 8000, 9000 Series Transmissions Commercial Electronic Controls 2 (CEC2)).pdf
TS3192EN - Troubleshooting Manual (1000 & 2000 & 2400 Product Families Electronic Controls).pdf
TS2973EN - Troubleshooting Manual (WTEC III Electronic Controls - 3000 & 4000 Product Families - Vocational Models).pdf
TS2712EN - Troubleshooting Manual (Allison Transmission Electronic Controls).pdf
TS2470EN - Troubleshooting Manual (WTEC II Electronic Controls).pdf
SM4014EN - Service Manual (4000 Product Family - 4th gen. Controls - Vocational Models).pdf
SM4013EN - Service Manual (3000 Product Family - 4th gen. Controls - Vocational Models).pdf
SM4006EN - Service Manual (1000 & 2000 Product Families - 4th gen. Controls - Vocational Models).pdf
SM3191EN - Service Manual (1000 & 2000 Product Families - Pre-4th gen. Controls - Vocational Models).pdf
SM2457EN - Service Manual (4000 Product Family On-Highway Transmissions - Vocational Models).pdf
SM2148EN - Service Manual (3000 Product Family - Vocational Models).pdf
SM1241EN - Service Manual (Automatic Models AT 540, AT 542(N)(R)(NFE), AT 543, AT 545(N)(R), AT 1542P, AT 1545P(N)).pdf
OM4118EN - Operator’s Manual (1000 & 2000 Product Families - International Models).pdf
OM3757EN - Operator’s Manual (1000 & 2000 Product Families - Highway Series (HS) Transmissions).pdf
OM3349EN - Operator’s Manual (3000 & 4000 Product Families - Vocational Models).pdf
MT4108EN - Mechanic’s Tips (Allison 4th gen. Controls - 3700 SP).pdf
MT4015EN - Mechanic‘s Tips (3000 & 4000 Product Families - 4th gen. Controls).pdf
MT4007EN - Mechanic's Tips (1000 & 2000 Product Families - 4th gen. Controls).pdf
MT3190EN - Mechanic's Tips (1000 & 2000 & 2400 On-Highway Transmissions).pdf
MT3004EN - Mechanic’s Tips (3000 & 4000 Product Families - WTEC III Controls).pdf
JA3664EN - In-Chassis Maintenance (1000 & 2000 Product Families - Vocational Models).pdf
JA3450EN - Quick-Tech Reference (1000 & 2000 Product Families - Pre-4th gen. Controls Data).pdf
GN4062EN - Technician's Guide (1000 & 2000 Product Families).pdf
GN4008EN - In-Chassis Maintenance (1000 & 2000 Product Families - 4th Gen. Controls).pdf
GN2055EN - Technician’s Guide (Automatic Transmission Fluid).pdf
MT1321EN - Mechanic’s Tips (AT500 & AT1500 Series Transmissions).pdf
OM1334EN - Mechanic’s Tips (MT(B)600 Series Transmissions).pdf
OM1334EN - Operator's Manual (AT, MT, HT Series ON-Highway Transmission).pdf
BONUS_MATERIAL:
CD2456EN - Parts Catalog CD-ROM (4000 Product Family Series Transmissions)
Watch374_NoMoreC4.pdf
WATCH_360_Dex6_TES389_Fliuds.pdf
tes-295_Specs.pdf
TechTip_1898A_GlycolTestKit.pdf
SIL_17_TR_96_OilAnalysisRecs.pdf
SIL_13_TR_90_Fluid Recs.pdf
J1939 - Allison Training.pdf
Gen4LogicChartRev05wPW.pdf
Fluids Technician Guide.pdf
Change_Recs_Brochure_SA5429EN.pdf
AllTranSyndColorAds.pdf
A_Filter_Is_A_Filter_SA3980EN.pdf
10-TR-99-RevH.pdf

EXCERPT:
MODULE REBUILD
b. Ground Sleeve Inspection
NOTE:
• The ground sleeve bushing and bearing are re- placed with the ground sleeve installed in the front support.
— Replace the needle bearing if the bearing is damaged.
— Replace the bushing if the bushing is damaged or the ID specification is not met.
• The only time the ground sleeve is pressed from the front support is to replace the ground sleeve.
— The new ground sleeve comes with a pre-installed bushing.
— Replace the ground sleeve if the ground sleeve splines or seal-ring bore specification is not met.
• The bearing must be removed to replace the ground sleeve. If the ground sleeve and the bear- ing both need replacing, replace the ground sleeve first.
• Replace the ground sleeve if it does not meet specifications.
1. Inspect the splines of ground sleeve (1) for damage and wear. No visible wear is allowed.
2. Measure the ID of ground sleeve (2) at the turbine shaft sealring bore (Dimension A). Maximum ID is 45.450 mm (1.7894 inch).
3. Measure the ID of ground sleeve bushing (1) (Dimension B). Maximum ID is 33.820 mm (1.3315 inch).

Troubleshooting Manual
Allison Transmission
Electronic Control
DEFINITIONS AND ABBREVIATIONS .............................. v
OPERATIONAL OVERVIEW
Introduction .................................................... 1-1
Applications ................................................... 1-2
Electronic Control Unit (ECU) ............................................ 1-3
Programmable Read Only Memory (PROM) ................................. 1-4
Output Speed Sensor ................................................. 1-5
Throttle Position Sensor ............................................ 1-6
Shift Selectors ................................................ 1-8
Reverse and Forward Pressure Switches.............................. 1-9
Oil Pressure Switches/Sensors ............................................. 1-10
Temperature Sensor........................................ 1-12
Chassis Wiring Harness............................................. 1-13
Cab Wiring Harness .................................................. 1-14
Secondary Wiring Harness ........................................ 1-15
Electro-Hydraulic Valve Body ............................................. 1-16
Solenoids ............................................. 1-17
Typical On-Highway Fluid Flows........................................ 1-19
Typical Off-Highway Fluid Flows ....................................... 1-29
COMPONENT INSTALLATION AND ADJUSTMENT
Introduction .................................................... 2-1
Electronic Control Unit (ECU) ............................................ 2-2
Programmable Read Only Memory (PROM) ................................. 2-3
Output Speed Sensor ................................................. 2-4
Throttle Position Sensor ............................................ 2-5
Shift Selectors ................................................ 2-8
Wiring Harnesses ........................................... 2-11
VEHICLE INTERFACE
Introduction .................................................... 3-1
Electronic Control Inquiry System....................................... 3-1
Mandatory Vehicle Interface ..................................... 3-2
Optional Cab Harness Interface ........................................... 3-12
Optional Secondary Harness Interface................................. 3-28
SELF-DIAGNOSTICS ....................................... 4-1
TROUBLESHOOTING–TROUBLE CODES PRESENT ......................... 5-1
TROUBLESHOOTING–INTERMITTENT TROUBLE CODES ....................... 6-1
TROUBLESHOOTING–NO TROUBLE CODES PRESENT .................. 7-1
APPENDIX A–TROUBLESHOOTING STEPS–TROUBLE CODES PRESENT........ A-1
APPENDIX B–TROUBLESHOOTING STEPS–NO TROUBLE CODES PRESENT............ B-1
APPENDIX C–CONNECTOR, TERMINAL, AND WIRE REPAIR .................. C-1
APPENDIX D–ADDITIONAL TERMINAL DESIGNATIONS................ D-1
APPENDIX E–ELECTRICAL SCHEMATICS ............................... E-1
APPENDIX F–HYDRAULIC SCHEMATICS ................................. F-1
APPENDIX G–SPECIAL TOOLS............................... G-1
APPENDIX H–DIAGNOSTIC CODE BACKGROUND INFORMATION................... H-1

DEFINITIONS AND ABBREVIATIONS
Allison Transmission Electronic Control System — The complete electronic control system for the transmission, including all detail components.
Bi-Directional Communication Link (BDCL) — Hard wire connections which allow the Allison Electronic
Control system to communicate with other engine or transmission controls.
Check Transmission Light — Optional instrument panel warning light that alerts the operator that a problem has occurred and the vehicle should be serviced as soon as possible. Also used by the technician to read diagnostic codes when a diagnostic data reader is not used.
Detroit Diesel Electronic Controls (DDEC) — Detroit Diesel’s electronic engine control system.
Diagnostic Codes (Trouble Codes) — Two-digit codes stored in the electronic control ECU memory. These codes are set when system self-diagnostics detects problems. Technicians access codes and use them to help troubleshoot problems.
Diagnostic Data Link (DDL) — Cab harness connector which allows a diagnostic data reader to interface with the Allison Electronic Control system.
Digital Display Unit (DDU) — Optional electronic component that displays various system operating and warning information.
Digital Volt Ohmmeter (DVOM) — Electrical device used for performing voltage, continuity and resistance tests.
Do Not Shift Light — Warning lamp located on the shift selector. This indicator alerts the driver that a potentially serious problem has been detected and shift selection has been limited.
Electronic Control Inquiry System (ECIS) — On-line data base (available through Distributor Parts Departments) that indicates which options are programmed on a particular PROM.
Electronic Control Unit (ECU) — The Allison Electronic Control system onboard microcomputer. This is the electronic “brain” for the system.
Fluidic Oil Level Sensor (FOLS) — One of the three types of switches that signal the ECU when a low lube pressure or low oil level condition exists. The FOLS uses a separate housing that bolts to the bottom of the valve body. It is very similar to the Low Oil Pressure/Level Sensor, but does not use a bi-metal strip.
Infinity (∞) — An indication that circuit or component resistance is so high it can not be measured. Generally, this means continuity is not present (the circuit is open).
Jumper Wire — A short piece of wire used to connect two electrical circuits or bypass a portion of a circuit.
Low Oil Level/Pressure Sensor — One of the three types of switches that signal the ECU when a low lube pressure or low oil level condition exists. The Low Oil Level/Pressure Sensor uses a separate housing that bolts to the bottom of the valve body. It is very similar to the Fluidic Oil Level Sensor and uses a bi-metal strip to compensate for cold oil temperatures until the transmission warms up.
Lube Pressure Switch — One of the three types of switches that signal the ECU when a low lube pressure or low oil level condition exists. The Lube Pressure Switch is configured like the forward and reverse pressure switches. It plumbs directly into the lubrication oil passage.
Ohm (Ω) — A unit of electrical resistance measurement.
Options — Programmed special features. Examples — Bed Hoist Interlock, Loading Hold, Neutral-To-Range
Inhibit, etc. Options must be programmed in the PROM and properly wired.
Programmable Read Only Memory (PROM) — This is the microchip that contains all the transmission shift and control information. The PROM is located in the ECU.
Power Take-Off (PTO) — Transmission-mounted accessory drive unit. PTOs are used to operate pumps and other accessories on specialty vehicles.
Self-Diagnostics — The Allison Transmission Electronic Control’s built-in capability to recognize system problems.
Solenoid — Components in the electro-hydraulic valve body that act as switches to direct hydraulic pressure into specific passages or to exhaust.
Speed Sensor (Output Speed Sensor) — Provides the electronic control system with output speed information.
The speed sensor replaces the conventional hydraulic governor system.
Splice — A connection of two or more wires. When repairing harness wires, they are spliced using special butt connectors.
Temperature Sensor — Monitors sump oil temperature for the ECU. On-highway sensors are mounted on the solenoid control circuit (on the internal wiring harness). Off-highway sensors are mounted in the lock-up valve body.
Throttle Position Sensor (TPS) — Provides the electronic control system with throttle position information. The TPS replaces the conventional hydraulic modulator system.
Transmission Engine Communication Link (TECL) — A type of Bi-Directional Communication Link
(BDCL) that allows the Allison Transmission Electronic Control to communicate with engine controls.
Transmission Test Switch — Vehicle manufacturer-installed switch that places the electronic control system in its diagnostic mode. When the switch is on, trouble codes can be retrieved.
Transmission to Transmission Communication Link (TTCL) — A type of Bi-Directional Communication
Link (BDCL) that allows the Allison Transmission Electronic Control to communicate with other
transmission controls.
Vehicle Interface — Term describing the electrical connections between the vehicle and the Allison
Transmission Electronic Control system.
...
“GN4008EN.pdf”
Allison Transmission Allison 4th Generation Controls (1000 Product Family, 2000 Product Family) In-Chassis Maintenance; 2007 JANUARY; GN4008EN

“JA3664EN.pdf”
Allison Transmission VOCATIONAL MODELS In-Chassis Maintenance; 2004 APRIL 01; JA3664EN
1000 EVS, 1000 HS, 1000 MH, 1000 PTS, 1000 RDS, 1000 SP, B 210, 2100 EVS, 2100 HS, 2100 MH, 2100 PTS, 2100 RDS, 2100 SP, B 220, 2200 EVS, 2200 HS, 2200 MH, 2200 PTS, 2200 RDS, 2200 SP, 2500 EVS, 2500 HS, 2500 MH, 2500 PTS, 2500 RDS, 2500 SP
1000 Series, 2000 Series, 2000 MH Series, 2400 Series

“MT4015EN.pdf”
Allison 4th Generation Controls - 3000 Product Family (Except 3700 SP), 4000 Product Family Mechanic’s Tips; 2005 FEBRUARY, Rev. 1 2005 SEPTEMBER; MT4015EN

“OM3349EN.pdf”
Motorhome Series 3000/4000 Operator’s Manual; 2005/09
Allison Transmission VOCATIONAL MODELS Motorhome Series (MH) Transmissions
3000 and 4000 Product Families
WTEC III Controls and Allison 4th Generation Controls
3000 MH, 4000 MH

“OM4118EN.pdf”
Allison Transmission 1000 & 2000 Product Families International Models Operator’s Manual; 2005/09
Includes Allison 4th Generation Controls
1000, 1000 MH, 1000 SP, 2100, 2100 MH, 2100 SP, 2200, 2200 MH, 2200 SP 2500, 2500 MH, 2500 SP

“SM2148EN.pdf”
3000 Product Family WTEC II & III Controls Service Manual (Rev 2016/01)
Allison Transmission VOCATIONAL MODELS
3000 EVS, 3000 HS, 3000 MH, 3000 PTS, 3000 RDS, 3000 SP, 3000 TRV, MD 3060, MD 3060P, MD 3060R, MD 3060PR, MD 3066, MD 3066P, MD 3066R, MD 3066PR, MD 3070PT, 3200 SP, 3200 TRV, 3500 EVS, 3500 HS, 3500 MH, 3500 PTS, 3500 RDS, 3500 SP, MD 3560, MD 3560P, MD 3560R, MD 3560PR, 3700 SP, B 300, B 300P, B 300R, B 300PR, B 400, B 400P, B 400R, B 400PR, T 250, T 255, T 260, T 265, T 270, T 280, T 310, T 325, T 350, T 375

“SM2457EN.pdf”
4000 Product Family On-Highway Transmissions WTEC II & III Controls Service Manual (Rev 2007/03)
Allison Transmission WTEC II AND WTEC III CONTROLS VOCATIONAL MODELS
4000 EVS, 4000 HS, 4000 MH, 4000 RDS, 4000 SP, 4000 TRV, HD 4060, HD 4060P, HD 4060R, HD 4060PR, HD 4070, HD 4070P, HD 4070R, HD 4070PR, HD 4076, 4500 EVS, 4500 HS, 4500 SP, 4500 TRV, HD 4560, HD 4560P, HD 4560R, HD 4560PR, 4700 EVS, 4700 RDS, 4700 SP, 4800 EVS, 4800 SP, B 500, B 500P, B 500R, B 500PR, T 425, T 450

“SM3191EN.pdf”
1000 and 2000 Product Families Pre-4th Gen Controls Service Manual (Rev 2004/12)
Allison Transmission VOCATIONAL MODELS SERVICE MANUAL; 2004 DECEMBER
1000 EVS, 1000 HS, 1000 MH, 1000 PTS, 1000 RDS, 1000 SP, 2100 EVS, 2100 HS, 2100 MH, 2100 PTS, 2100 RDS, 2100 SP, 2200 EVS, 2200 HS, 2200 MH, 2200 PTS, 2200 RDS, 2200 SP, 2500 EVS, 2500 HS, 2500 MH, 2500 PTS, 2500 RDS, 2500 SP, B 210, B 220

“SM4006EN.pdf”
1000 and 2000 Product Families Allison 4th Generation Controls Service Manual
Allison Transmission VOCATIONAL MODELS SERVICE MANUAL; 2005 MAY, Rev. 1 2005 SEPTEMBER
1000 EVS, 1000 HS, 1000 MH, 1000 PTS, 1000 RDS, 1000 SP, 2100 EVS, 2100 HS, 2100 MH, 2100 PTS, 2100 RDS, 2100 SP, 2200 EVS, 2200 HS, 2200 MH, 2200 PTS, 2200 RDS, 2200 SP, 2500 EVS, 2500 HS, 2500 MH, 2500 PTS, 2500 RDS, 2500 SP, 2300 HS, 2300 RDS, B 210, B 220

"SM4013EN.pdf"
3000 Product Family Service Manual
ALLISON 4TH GENERATION CONTROLS VOCATIONAL MODELS SERVICE MANUAL; 2005 OCTOBER
3000 EVS, 3000 HS, 3000 MH, 3000 PTS, 3000 RDS, 3000 TRV, 3200 SP, 3200 TRV, 3500 EVS, 3500 RDS, 3500 SP, 3700 SP, B 300, B 400, T 250, T 255, T 260, T 265, T 270, T 280, T 310, T 325, T 350

“SM4014EN.pdf”
4000 Product Family Service Manual
ALLISON 4TH GENERATION CONTROLS VOCATIONAL MODELS SERVICE MANUAL; 2005 OCTOBER
4000 EVS, 4000 HS, 4000 MH, 4000 RDS, 4000 SP, 4000 TRV, 4500 EVS, 4500 HS, 4500 RDS, 4500 SP, 4700 EVS, 4700 RDS, 4700 SP, 4800 EVS, 4800 SP, B 500, T 425, T 450, T 525

"TS2470EN.pdf"
WTEC II ELECTRONIC CONTROLS TROUBLESHOOTING MANUAL
1998 MAY; REV. 1 1999 OCTOBER; REV. 2 2004 JULY; REV. 3 2005 DECEMBER
MD/HD/B SERIES TRANSMISSIONS
WTEC II Controls
(Pre-TransID and TID 1)
MD 3060/MD 3066/MD 3560(P)(R)
MD 3070PT
HD 4060/HD 4560(P)(R)
B 300/B 400/ B 500(P)(R)

"TS2712EN.pdf"
ALLISON TRANSMISSION ELECTRONIC CONTROLS TROUBLESHOOTING MANUAL
This document covers the following on- and off-highway transmission models:
MT(B) 648; CLBT 5962 and 6062
HT(B) 741, 746 and 748; DP 8963
HT(B) 755CR and 755DR; CL(B)T 9681
V 731, V 731RH, VR 731, and VR 731RH; CLT 755 and CL(B)T 755

"TS2973EN.pdf"
WTEC III ELECTRONIC CONTROLS TROUBLESHOOTING MANUAL
2005 OCTOBER
REV. 1 OCTOBER 2006
VOCATIONAL MODELS
3000 VOCATIONAL MODELS
3000 HS 3500 RDS B 300(P)(R)
3000 RDS 3500 EVS B 400(P)(R)
3000 EVS T 200
3000 MH T 300
3000 PTS
3000 TRV
3200 SP 3500 SP 3700 SP
3200 TRV
MD 3060 MD 3560 MD 3070PT
MD 3066
4000 VOCATIONAL MODELS
4000 EVS 4500 EVS 4700 EVS 4800 EVS B 500
4000 HS 4500 HS 4700 RDS
4000 MH 4500 RDS
4000 RDS 4500 SP
4000 TRV 4500 TRV
HD 4060 HD 4560 HD 4070 HD 4076 B 500P
HD 4060P HD 4560P HD 4070P B 500R
HD 4060R HD 4560R HD 4070R B 500PR
HD 4060PR HD 4560PR HD 4070PR T 425 T 450

"TS3192EN.pdf"
ALLISON 1000/2000/2400 PRODUCT FAMILIES ELECTRONIC CONTROLS TROUBLESHOOTING MANUAL
2003 APRIL
REV. 1 2004 MAY

"TS3353EN.pdf"
5000, 6000, 8000, 9000 Series Transmissions
COMMERCIAL ELECTRONIC CONTROLS 2 (CEC2) TROUBLESHOOTING MANUAL
2005 DECEMBER
M 5610A M 5610AR
S 5610H S 5610MR S 5610M
M 6610A M 6610AR
S 6610H S 6610HR S6610M S 6610MR
M 8610A M 8610AR
S 8610H S 8610HR S 8610M S 8610MR
M 9610A M 9610AR
S 9610A S 9610AR S 9610M S 9610MR
S 9805M S 9805MR
S 9810A S 9810AR S 9810H S 9810HR
S 9810M S 9810MR

"TS3977EN.pdf"
2008 FEBRUARY
REV. 2 2008 SEPTEMBER
ALLISON 4th GENERATION CONTROLS
1000 AND 2000 PRODUCT FAMILIES TROUBLESHOOTING MANUAL

"TS3977FR.pdf"
GROUPES DE PRODUITS 1000 ET 2000 MANUEL DE DÉPANNAGE — COMMANDES ALLISON 4ème GÉNÉRATION
JANVIER 2006

"TS3989FR.pdf"
FÉVRIER 2005
GROUPES DE PRODUITS 3000 ET 4000 MANUEL DE DÉPANNAGE—COMMANDES ALLISON 4ème GÉNÉRATION
MODÈLES SPÉCIALISÉS Manuel de dépannage FÉVRIER 2005
MODÈLES 3000 SPÉCIALISÉS
3000 HS 3500 RDS B 300(P)(R)
3000 RDS 3500 EVS B 400(P)(R)
3000 EVS T 200
3000 MH T 300
3000 PTS
3000 TRV
3200 SP 3500 SP 3700 SP 3200 TRV
MODÈLES 4000 SPÉCIALISÉS
4000 EVS 4500 EVS 4700 EVS 4800 EVS B 500
4000 HS 4500 HS 4700 RDS B 500P
4000 MH 4500 RDS B 500R
4000 RDS 4500 SP B 500PR
4000 TRV 4500 TRV T 425 T 450

“CD2456EN“
4000 Product Family Series Transmissions Parts Catalog CD
...

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