Allison Transmission AT 1542P Service Manual Download

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Printed in the U.S.A.

Service

Manual

Allison Transmission

SM1241EN

AUTOMATIC MODELS

AT 540,
AT 542(N)(R)(NFE),
AT 543,
AT 545(N)(R),
AT 1542P,
AT 1545P(N)

FEBRUARY 1996

Revision 1, 1999 April

Division of General Motors Corporation

P.O. Box 894 Indianapolis, Indiana 46206-0894

Summary of Contents for AT 1542P

Page 1: ...ors Corp Service Manual Allison Transmission SM1241EN AUTOMATIC MODELS AT 540 AT 542 N R NFE AT 543 AT 545 N R AT 1542P AT 1545P N FEBRUARY 1996 Revision 1 1999 April Division of General Motors Corporation P O Box 894 Indianapolis Indiana 46206 0894 ...

Page 2: ...gistered trademark of the DuPont Corporation Loctite is a registered trademark of the Loctite Corporation NOTE This publication is revised periodically to include improvements new models special tools and procedures A revision is indicated by letter suffix to the publication number Check with your Allison Transmission service outlet for the currently applicable publica tion Additional copies of th...

Page 3: ... 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 possible 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...

Page 4: ...ure check procedures All personnel must stand clear of the vehicle Take precautions against movement of the vehicle Be sure that gauges vacuum pressure tachometer have extended lines so that they can be read from inside the vehicle Do not burn discarded Teflon seals toxic gases are produced by burning Never dry bearings with compressed air A spinning bearing can disintegrate allowing balls or roll...

Page 5: ... AND CENTER SUPPORT a Description 2 3 b Operation of Third Clutch 2 3 c Operation of Second Clutch 2 4 2 10 FIRST CLUTCH a Description 2 4 b Operation 2 4 2 11 PLANETARY GEAR UNIT a Description 2 4 b Operation 2 4 2 12 SPEEDOMETER DRIVE SPEED SENSOR WHEEL a Description 2 5 b Operation 2 5 2 13 GOVERNOR a Description 2 5 b Operation 2 5 2 14 MODULATOR a Vacuum Modulator 2 5 b Mechanical Modulator 2...

Page 6: ...ilter 3 4 3 10 TRANSMISSION FLUID AND FILTER CHANGE PROCEDURES a Disassembly 3 7 b Assembly 3 7 3 11 BREATHER 3 8 3 12 LINKAGE a Shift Selector Lever and Control Linkage 3 9 b Mechanical Actuator Adjustment 3 9 c Other Linkage Adjustments 3 9 3 13 ADJUSTMENT OF SHIFT POINTS a Calibrated on Test Stand or in Vehicle 3 9 b Location of Adjusting Components 3 9 c Checks Before Adjusting Shift Points 3 ...

Page 7: ...ings 4 9 d Inspecting Bearings 4 10 e Keeping Bearings Clean 4 10 f Inspecting Cast Parts Machined Surfaces 4 10 g Inspecting Bushings Thrust Washers 4 11 h Inspecting Oil Seals Gaskets 4 11 i Inspecting Gears 4 12 j Inspecting Splined Parts 4 12 k Inspecting Threaded Parts 4 12 l Inspecting Snaprings 4 12 m Inspecting Springs 4 12 n Inspecting Clutch Plates 4 12 o Inspecting Swaged Interference F...

Page 8: ... 6 2 c Replacement of Needle Bearing Assembly in Stator Assembly 6 4 d Assembly 6 4 6 5 GOVERNOR a Disassembly 6 7 b Assembly 6 8 6 6 MAIN CONTROL VALVE BODY a Disassembly 6 8 b Assembly 6 10 6 7 RETARDER CONTROL VALVE BODY a Disassembly 6 12 b Assembly 6 13 6 8 TRANSFER PLATE ASSEMBLY Retarder Models a Disassembly 6 13 b Assembly 6 14 6 9 OIL PUMP AND FRONT SUPPORT ASSEMBLY a Disassembly 6 14 b I...

Page 9: ...utch and Turbine Shaft Assembly 7 10 7 8 INSTALLATION OF OIL PUMP ASSEMBLY a Selection of Front Thrust Washer 7 11 b Pump Assembly 7 12 7 9 INSTALLATION OF OUTPUT SHAFT OIL SEAL 7 13 7 10 INSTALLATION OF MAIN CONTROL VALVE BODY OIL FILTER AND OIL PAN a Main Control Valve Body 7 13 b Filter 7 15 c Oil Pan 7 15 7 11 INSTALLATION OF GOVERNOR MODULATOR AND TORQUE CONVERTER a Governor 7 16 b Vacuum Mod...

Page 10: ...pacity 4 C Input Retarder 100 Capacity 5 AT 500 Series Transmissions 6 AT 1500 Series Transmissions EXPLODED VIEWS Foldout 7 A Torque Converter Assembly AT 543 7 B Torque Converter and Oil Pump Assemblies 8 Forward Clutch and Turbine Shaft 9 A Fourth Clutch 9 B Third Clutch Second Clutch and Center Support 10 A Planetary Gear Unit 10 B First Clutch 11 Main Control Valve Body Assembly 12 A Transmis...

Page 11: ...erform all the tasks out lined However any task outlined herein may be per formed if the following conditions are met 1 The organization or individual has the re quired knowledge of the task through Formal instruction in an Allison or Distributor training facility On the job instruction by an Allison or Distributor representative Experience in performing the task 2 The work environment is suitable...

Page 12: ...t Front View Figure 1 2 AT 545R Automatic Transmission Right Rear View SHIPPING BRACKET MODULATOR RETAINER SELECTOR SHAFT WELDED TORQUE CONVERTER ASSEMBLY NOT SEPARABLE OIL PAN GOVERNOR COVER BREATHER H01341 RETARDER CONTROL VALVE ASSEMBLY NAMEPLATE OUTPUT SHAFT BRAKE MOUNTING PAD OIL FILLER TUBE PORT DRAIN PLUG BREATHER H02874 ...

Page 13: ...on Left Front View Figure 1 4 AT 542 543 1542 Automatic Transmission Right Rear View H02875 GOVERNOR COVER TORQUE CONVERTER RETAINING STRAP SEPARABLE TORQUE CONVERTER OIL PAN MODULATOR RETAINER SELECTOR SHAFT H02876 BREATHER BRAKE MOUNTING PAD OUTPUT SHAFT DRAIN PLUG OIL FILLER PTO COVER NAMEPLATE ...

Page 14: ...om the charging pump 1 5 OPERATING INSTRUCTIONS Refer to SA1334 for operating instructions 1 6 SPECIFICATIONS AND DATA The specifications and data in Table 1 1 are applicable to AT 500 and 1500 Series transmissions E C A P S O R E A E L I B O M O TUA DETINU ACIREMA F O S R E K R O W T N E M E L P M I L A R U T L U C I R G A D N A UAW 933 DIVISION OF GENERAL MOTORS CORPORATION INDIANAPOLIS INDIANA ...

Page 15: ...in drive 500 500 500 500 500 rpm Input Power Maximum net 180 134 160 119 180 134 180 134 180 134 hp kW Input Torque Maximum net 405 549 340 461 405 549 405 549 405 549 lb ft N m Turbine Torque Maximum net 709 961 585 793 709 961 709 961 709 961 lb ft N m Gross vehicle weight GVW 24250 11000 21000 9525 24250 11000 24250 11000 24250 11000 lb kg Gross combination vehicle weight GCW 24250 11000 N A 27...

Page 16: ...rnal circuits Fill From Factory Initial Fill After Rebuild Refill After Servicing U S Qts Liters U S Qts Liters U S Qts Liters Shallow oil pan 4 0 inch 102 mm 13 12 15 14 9 8 5 Deep oil pan 5 3 inch 135 mm 20 19 22 21 16 15 Temperatures Sump max 250 F 120 C To cooler converter out max 300 F 150 C To cooler retarder out max 330 F 165 C Normal operation sump 160 200 F 71 93 C Normal operation conver...

Page 17: ... Auto 1 4 1C 2C 3C 4C AT 1500 Series Auto 1 4 1C 2C 3C 3L 4L Shift modulation Gasoline Vacuum Diesel Mechanical Electronic Neutral start and reverse signal switches Supplied by OEM Speedometer drive Type and size 13 16 20 UNEF thread for SAE regular duty thread type Drive gears 5 teeth Driven gear Supplied by customer Gearing Constant mesh spur type planetary TRANSMISSION RATIOS Mechanical Range C...

Page 19: ...nsmission input pressure pump 2 AT 1500 Series transmissions are equipped with an automotive style lockup torque con verter In addition to the pump stator and turbine as semblies a lockup clutch and damper assembly is incorporated A lockup valve located in the front sup port assembly controls flow through the torque con verter and provides operation in third and fourth ranges 3 AT 540 542 545 1542...

Page 20: ...rter turbine shaft and forward clutch b Operation Foldout 7 B 1 When the torque converter is rotating its rear hub drives pump drive gear 10 Gear 10 is meshed with the internal teeth of driven gear 9 2 The pump gears draw transmission fluid from the sump When the flow of fluid fills all the re quirements in the transmission pressure is developed Valve 27 in support 16 regulates the flow of fluid f...

Page 21: ... independent of housing 13 whether housing 13 is stopped or has a different speed or direc tion of rotation 2 When hydraulic pressure is directed to the piston cavity in housing 13 piston 8 compresses plates 3 and 4 against backplate 2 or against retarder housing 36 Foldout 8 This locks internal splined plates 3 Foldout 9 A to external tanged plates 4 and in turn to housing13 3 When the fourth clu...

Page 22: ...ary ring gear 5 or 53 Foldout 10 A rotate The first clutch is released during operation in all ranges except neutral first and reverse 2 When hydraulic pressure is directed to the first clutch piston cavity piston 9 Foldout 10 B compresses clutch plates 3 and 4 against backplate 2 This locks internal splined plates 3 to external tanged plates 4 which are anchored to the transmission hous ing Plate...

Page 23: ...s Governor pressure in combi nation with modulator pressure controls the automatic shifting of the transmission 2 14 MODULATOR a Vacuum Modulator Foldout 12 A 1 Vacuum modulator 26 is calibrated and sealed at the factory 2 The position of the diaphragm in the modulator varies with vehicle speed load and engine throttle opening When the diaphragm moves the modulator valve is affected increasing or ...

Page 24: ...e AT 542 545R is shown on Foldout 3 The main retarder components internal to the transmission are front stator 1 Foldout 8 the rotor which is a part of forward clutch housing 14 and rear stator 35 3 The AT retarder has a dual torus design The retarder rotor provides high flow and torque gen eration Front stator 1 and rear stator 35 are both sta tionary 4 The rotating element rotor of the re tarder...

Page 25: ...lades The stationary blades in turn redirect the fluid back to the rotating blades The result is a very high velocity hydraulic flow around the torus and the absorption of a large amount of kinetic energy Cooler flow results from the large pressure drop that the high velocity fluids create between the inlet and outlet locations 2 17 MAIN CONTROL VALVE ASSEMBLY Main control valve body assembly 1 Fo...

Page 26: ...rd regulator pressure is di rected from the selector valve to the main pressure regulator valve when the selector valve is at any posi tion except reverse In neutral and in all forward ranges this pressure pushes downward on the main pressure regulator valve and reduces main pressure In reverse regulator pressure is absent permitting a higher main pressure g Governor Valve Governor Circuit Green a...

Page 27: ...e is a regulated reduced pressure derived from main pressure at the hold regulator valve 2 Hold regulator pressure at each shift sig nal valve will push the modulator valve upward and hold the shift valve down against governor pressure Thus when hold regulator pressure is present an up shift can occur at that shift signal valve only with ex cessive overspeed k Automatic Upshifts 1 When the transmi...

Page 28: ...ow the trimmer valve because it is acting upon a greater diameter pushes the trimmer valve to the top of the valve bore This throttles then stops the exhaust of the fluid When escape of fluid stops clutch apply pressure is at maximum value The plug remains downward against the stop until the clutch is released 4 When the transmission is shifted into re verse clutch apply pressure is directed to th...

Page 29: ... all drive situations and in neutral When the engine is idling impact of the fluid upon the turbine vanes is negligible When the engine is accelerated the impact is increased and the torque produced in the converter turbine shaft can exceed the engine torque by an amount equal to the torque ratio of the converter b Neutral Operation Figure 2 1 1 Torque produced in the torque converter is not trans...

Page 30: ...part of the carrier assembly which is splined to the transmission output shaft With the rear ring gear held stationary by the applied first clutch and the rear sun gear rotating the pinions the rear plane tary carrier rotates within the ring gear and drives the output shaft at a speed reduction of 3 45 1 2 For AT 1500 Series models the lockup clutch does not apply during first range operation Figu...

Page 31: ...haft assembly to which the front sun gear is also splined The rotating front sun gear rotates the front carrier pinions whose carrier is anchored against rota tion by the applied second clutch In turn the rotating front carrier pinions rotate the front ring gear which along with the center carrier is splined via the plane tary connecting drum and rear carrier assembly to the output shaft Due to th...

Page 32: ...gh the lockup valve to the space between the turbine and stator shafts From there fluid passes through slots in the turbine hub to an area between the torque converter cover and pis ton Converter in pressure moves the piston away from the reaction surface and provides the fluid nec essary for proper filling of the torque converter ele ments Fluid exhausts through slots in the stator and is sent to...

Page 33: ...te at turbine output speed The transmission output shaft is splined to the rear carrier and gives an output ratio of 1 00 1 i Fourth Range Lockup Operation AT 1500 Series Models Except for a momentary shift to con verter operation during the upshift the transmission shifts directly from third range lockup to fourth range lockup Figure 2 5 Fourth Range Power Flow V02881 TURBINE SHAFT SUN GEAR SHAFT...

Page 34: ... opposite direction The center carrier is splined to the planetary connecting drum which is splined to the rear carrier The reverse direction of ro tation of the center ring gear rotates the rear sun gear This causes the rear planetary pinions to drive the rear carrier in a reverse direction within the stationary ring gear This compounding action of the center and rear planetaries produces a rever...

Page 35: ...ot receive an ade quate supply of fluid If the level is too high the fluid will aerate the transmission will overheat and fluid may be expelled through the breather or dipstick tube b Foaming and Aerating 1 Transmission performance will be af fected when the fluid foams or aerates The primary cause of aeration is low fluid in the sump too much fluid in the sump or a defective or missing sealring o...

Page 36: ... the transmission because it can cause valves to stick cause undue wear of trans TRANSMISSION OIL PAN SPLITLINE FULL ADD 0 50 in 12 7 mm 1 00 in 25 4 mm V01299 C H E C K I N N E U T R A L A T I D L E TRANSMISSION OIL PAN SPLITLINE 0 50 in 12 7 mm 1 05 in 26 7 mm 1 80 in 45 7 mm 1 50 in 38 1 mm V01298 C H E C K I N N E U T R A L A T I D L E H O T R U N R E F F I L L WARNING When checking the transm...

Page 37: ... the hydraulic circuits with fluid 2 Park the vehicle on a level surface and shift to N Neutral or P Park Apply the parking brake block the wheels and allow the engine to idle 3 After wiping the dipstick clean check the fluid level The safe operating level is anywhere between the FULL and ADD lines Figure 3 1 within the HOT RUN band Figure 3 2 or below the HOT OVERFULL mark and above the COLD RUN ...

Page 38: ...d in the sump the transmission must be disassembled and closely in spected to find the source Metal contamination will require complete disassembly of the transmission and cleaning of all internal and external circuits cooler and all other areas where the particles could lodge See application of auxiliary filter Paragraph 3 9d c Coolant Leakage If engine coolant leaks into the transmission hydraul...

Page 39: ...uid change intervals thereafter Brass Screen Filter in Shallow Pan 4 0 inches or Deep Pan 5 3 inches 50 000 miles 80 000 km with no time limit AT 500 Series Off Highway 1000 hours max or 12 months Paper Filter in Shallow Pan 4 0 inches or Deep Pan 5 3 inches at each fluid change interval After first 500 hours and at normal fluid change intervals thereafter Brass Screen Filter in Shallow Pan 4 0 in...

Page 40: ...se must meet SAE 100 R5 specification with an operating range of 40 to 300 F 40 to 149 C 7 The total cooler circuit to and from the cooler pressure drop must not exceed 35 psi 241 kPa in neutral at 2400 rpm and at normal operating temperature Filter bypass opening pressure on units not equipped with a pressure indicator P switch must be 5 9 psi 34 62 kPa Filter bypass opening pressure on units equ...

Page 41: ...ilter install the 5 16 18 x 5 8 inch washer head screw If shallow pan 26 is used retain the filter with one 5 16 18 x 5 8 inch washer head screw Tighten either the screw or the bolt to 10 15 lb ft 14 20 N m 4 Place the pan gasket onto the oil pan Do not use any substance as a gasket retainer 5 Install the oil pan Guide the pan and gasket carefully into place Guard against dirt or for eign material...

Page 42: ...ing steam water or cleaning solu tion directly at the breather can force the water or solu tion into the transmission 2 Earlier model breathers should be equipped with a neoprene shroud Figure 3 7 If the breather is not so equipped or if the present shroud is damaged install a new shroud Figure 3 5 Measuring the Length of Oil Pan Boss to Identify Torque Requirements Figure 3 6 Fluid and Filter Cha...

Page 43: ...or is a service replacement assembly If the M is not in cluded the governor was installed at original factory build a Calibrated on Test Stand or in Vehicle 1 Proper timing of shift speed points is necessary for maximum transmission performance Shifts may be adjusted on the test stand when the transmission is rebuilt or overhauled or during road testing of the vehicle 2 The Kent Moore Valve and Go...

Page 44: ... point may be raised by adjust ing increasing the spring force on the 1 2 2 3 or 3 4 shift signal valve If the upshift speed exceeds the specified rpm or if upshift does not occur at all the spring force must be reduced Adjust the force on only the springs for valves that do not upshift at the proper speed 4 Refer to Sections 5 6 and 7 for proce dures covering removal and replacement of affected c...

Page 45: ...600 6836784 Yellow 36 40 248 276 3800 6836785 White 39 43 269 296 4000 6836785 White 39 43 269 296 Table 3 5 Modulator Pressure Modulator Spring Part Number Color Code and Modulator Valve Usage Pressure psi kPa 23012948 White with Orange Stripe 23013764 Modulator Valve 50 53 345 365 6880980 Solid Light Blue with Red Stripe 23013764 Modulator Valve 42 45 290 310 Table 3 6 Governor Pressure Governor...

Page 46: ...960 900 960 Full 2 3 865 1000 865 1000 955 1090 1045 1180 1130 1265 1220 1355 1310 1445 1400 1535 1490 1625 Drive 3 4 1455 1595 1455 1595 1595 1735 1735 1875 1880 2020 2020 2160 2165 2305 2305 2445 2450 2590 4 3 305 555 370 660 350 610 490 685 410 680 530 750 675 970 150 600 300 700 Closed 3 2 400 560 475 655 465 630 520 665 550 760 590 810 620 875 405 720 455 765 2 1 20 300 20 360 20 300 20 300 2...

Page 47: ...810 1880 2020 1595 1735 2020 2160 1740 1880 2165 2305 2305 2445 2450 2590 2555 2710 4 3 510 740 510 740 550 780 670 970 670 990 600 810 600 970 550 780 700 1100 500 795 850 1370 150 600 300 700 200 765 Closed 3 2 400 610 435 620 460 650 610 750 510 680 485 645 500 730 460 650 580 820 395 660 610 880 405 720 455 765 445 700 2 1 40 370 40 370 40 370 220 500 40 370 50 375 140 460 40 370 230 500 40 29...

Page 48: ...rpm at Start of Shift 1 2 580 640 595 655 595 655 595 655 710 770 980 1045 Full 2 3 865 1000 955 1090 1045 1180 955 1090 1130 1265 1600 1700 Drive 3 4 1560 1705 1700 1845 1845 1985 1700 1845 1985 2130 2680 2840 4 3 525 755 625 830 710 1135 625 830 660 990 310 885 Closed 3 2 400 610 460 650 510 680 460 650 500 730 445 700 2 1 40 370 40 370 40 370 40 370 140 460 75 460 DR3 4 3 1820 2120 1980 2280 21...

Page 49: ... Perform a hot check of the transmission fluid level and adjust as necessary 9 Turn all engine accessories OFF 10 Notify everyone to stay clear of the ve hicle NOTE For vehicles with engines not equipped with smoke controls proceed to Paragraph c For vehicles with engines equipped with smoke controls skip Paragraph c and proceed to Paragraph d c Stall Test Procedures Vehicles Without Smoke Control...

Page 50: ...rpm below the stall speed specified by the engine man ufacturer an engine problem is indicated such as the need for a tune up 2 If the engine stall speed is more than 150 rpm above specification a transmission problem is in dicated such as slipping clutches cavitation or torque converter failure 3 An extremely low stall speed such as 33 percent of the specified engine stall rpm during which the en...

Page 51: ...top the engine Do not exceed 225 F 107 C 7 As soon as the transmission is cool enough to touch seal all openings and the breather with moisture proof tape 8 Coat all exposed unpainted surfaces with preservative grease such as petrolatum MIL C 11796 Class 2 9 If additional storage time is required re peat steps 2 through 8 at yearly intervals except it is not necessary to drain the transmission eac...

Page 52: ... seal bore c Removal of Output Shaft Bearing Foldout 12 B 1 Remove internal snapring 5 from the rear of the transmission housing 2 To remove output shaft bearing 4 first count the number of balls in the bearing Figure 3 8 If the bearing has nine balls select J 38086 1 puller legs three required If the bearing has ten balls select J 24463 2 puller legs two required Assemble the se lected legs with ...

Page 53: ...o not operate the vehicle prior to completing the procedures described in this Paragraph Inspect for transmission fluid leakage Vi sually inspect all splitlines connections valve bodies fluid level indicator tube and plugs and hoses at the transmission and cooler Fluid leakage at splitlines may be caused by loose mounting bolts or defective gaskets Tighten all bolts plugs and connections where lea...

Page 54: ...n of Flange Retaining Bolt Source and material grade identification markings to appear on top of head in this area CONSTANT ANNULAR GROOVE Six 6 radial slots spaced sixty 60 degrees apart 3 4 in 1 2 in V01301 13 16 in 1 2 in Source and material grade identification markings to appear on top of head in this area VARYING ANNULAR GROOVE Five 5 radial slots spaced sixty 60 degrees apart EARLIER BOLT P...

Page 55: ... Hydraulic Pressure Checking Procedures 1 Table 3 10 is for checking main pressure on transmissions having demodulated main pressure 2 Table 3 11 is for checking main pressure on transmissions having modulated main pressure 3 Table 3 12 is for checking retarder pressure 4 The pressure check points are shown in Figures 3 11 3 12 and 3 13 3 19 TROUBLESHOOTING TRANSMISSION REMOVED FROM VEHICLE When t...

Page 56: ...re 3 11 Transmission Check Points Figure 3 12 Transmission Check Points Models Without Retarder H02887 MODULATOR ACCESS MECHANICAL OR VACUUM MAIN PRESSURE H02888 REVERSE SIGNAL PRESSURE LOCKUP PRESSURE AT 1500 SERIES OIL FILL TUBE DRAIN PLUG TO COOLER FROM COOLER AUXILIARY FILTER BREATHER ...

Page 57: ...ngine running at 1200 rpm brakes applied 4 Check Reverse pressure with engine running at 2500 rpm brakes applied Reconnect driveline 5 Check Lockup pressures with transmission in third and fourth range with engine at full throttle NEUTRAL 135 155 psi 931 1068 kPa FORWARD 135 155 psi 931 1068 kPa REVERSE 230 275 psi 1586 1896 kPa LOCKUP 120 psi min 827 kPa min E C A P S O R E A E L I B O M O TUA DE...

Page 58: ...0 psi 621 758 kPa Push or pull the cable to the idle position against the internal stop Main pressure should be 90 110 psi 621 758 kPa If main pressure is 135 155 psi 931 1068 kPa the transmission has demodulated main pressure Use Table 3 10 Push or pull the actuator cable to full throttle position against internal stop NEUTRAL 135 155 psi 931 1068 kPa 135 155 psi 931 1068 kPa FORWARD 135 155 psi ...

Page 59: ...s or bends and not close to exhaust components Vacuum modulation delayed Replace vacuum modulator Be sure that O ring is installed and that the modulator vacuum fitting is facing forward and positioned 10 below horizontal Refer to Paragraphs 5 3c and 7 11b Mechanical actuator cable kinked broken or not properly adjusted Replace adjust or repair cable Full actuator control cable travel must corresp...

Page 60: ...lean or replace governor screen and or governor The governor may be disassembled for cleaning and inspection only if the kit consisting of two governor weight pins and cover gasket is available Refer to Paragraphs 5 3e 5 3h 5 6 5 7 10a and 7 11a Vacuum modulator valve spring not properly adjusted vacuum hose kinked or leaking Check spring adjustment Replace hose Refer to Paragraph 3 13 Mechanical ...

Page 61: ...en and or governor The governor may be disassembled for cleaning and inspection only if the kit consisting of two governor weight pins and cover gasket is available Refer to Paragraphs 5 3e 5 3h 5 6 5 7 10a and 7 11a Specific range valves malfunction ing sticking Replace or rebuild main valve body assembly Refer to Paragraph 6 6 Shift flare during range shifts AT 545 models only Incorrect trimmer ...

Page 62: ...ild forward clutch Refer to Paragraph 6 8 Reverse warning buzzers and or vehicle backup lights come on dur ing forward operation Improper 1 2 relay valve installed Install new 1 2 relay valve Refer to Paragraph 6 6a 11 C Abnormal Stall Check Speed High stall speeds Low fluid level Add fluid to proper level Refer to Paragraphs 3 4 through 3 10 Clutch pressure low Refer to Chart E Low Pressure Forwa...

Page 63: ...fer to vehicle service manual Metal encased lip type seal at front of input charging pump leaking Replace pump seal Refer to Para graphs 6 7a 6 and 6 6d 10 or 12 Seal around OD of oil pump leaking Replace OD pump seal Refer to Paragraphs 6 7a 5 and 6 6d 13 Cracked weld in torque converter assembly leaking Replace or repair converter assem bly Refer to Paragraph 6 4 Torque converter pump hub worn a...

Page 64: ...6 Input charging pump worn or dam aged Replace or rebuild pump Refer to Paragraphs 5 3i 6 7 and 7 8b Missing priority valve Replace missing valve Refer to Paragraphs 6 6a and 6 6b Low main pressure in first range normal pressure in other forward ranges First range circuit leakage in control valve body Replace or rebuild main control valve body assembly Refer to Para graph 6 6 Excessive leakage at ...

Page 65: ... E Low Pressure Forward clutch slipping Rebuild forward clutch and replace piston seals Refer to Paragraph 6 8 Sealrings on front support hub bro ken Replace sealrings Refer to Para graphs 5 3i and 7 8b Slippage in fourth range and reverse only Fourth clutch slipping Rebuild clutch and replace piston seals Refer to Paragraph 6 11 Trimmer valve sticking Replace or rebuild main control valve body as...

Page 66: ...fer to Paragraph 8 2 Piston seals leaking or clutch plates slipping in range involved Overhaul transmission Broken hook type sealrings Replace sealrings Forward clutch piston seals leaking or clutch plates slipping all upshifts Overhaul forward clutch and piston assembly Refer to Paragraph 6 8 Sticking governor valve Clean or replace governor screen and or governor The governor may be disassembled...

Page 67: ...cessary Fluid level too high Drain to proper fluid level Refer to Paragraphs 3 4 through 3 10 Fluid level too low Fill to proper fluid level Refer to Paragraphs 3 4 through 3 10 Vacuum modulator failed Replace vacuum modulator Fill tube not vented or is plugged Check for blockage and clean if nec essary Breather stopped up clogged Clean or replace breather Refer to Paragraph 3 11 Water in transmis...

Page 68: ...o proper level Refer to Paragraphs 3 4 through 3 10 Air leak at intake tube O ring damaged Replace intake tube seal and filter Refer to Paragraphs 5 3g and 7 10b Clogged filter or element s Replace filter or element s Refer to Paragraph 3 10 Aerated fluid Improper fluid level Refer to Para graphs 3 4 through 3 10 Damaged filter or element s Replace filter or element s Refer to Paragraph 3 10 M Veh...

Page 69: ...s 4 2 through 4 4 They are identified in the ta ble following the illustrations These special tools are available from Kent Moore Tool Division 29784 Little Mack Roseville Michigan 48066 Aidco Inc 800 Liberty Street Adrian Michigan 49221 Section 4 GENERAL OVERHAUL INFORMATION Figure 4 1 Typical Work Table 48 in 120 cm 78 in 200 cm 24 in 60 cm 4 x 4 in LEGS 10 x 10 cm 2 x 6 in BOARD 5 x 15 cm FOR T...

Page 70: ...yright 1996 General Motors Corp AT 500 1500 SERIES AUTOMATIC TRANSMISSIONS Figure 4 2 Special Tools 1 thru 34 8 7 6 5 4 3 10 9 17 18 2 1 11 12 14 13 16 24 29 25 31 30 28 26 27 33 32 34 23 22 19 21 20 15 V03103 ...

Page 72: ...ight 1996 General Motors Corp AT 500 1500 SERIES AUTOMATIC TRANSMISSIONS Figure 4 4 Special Tools 46 thru 77 46 53 54 55 56 47 48 49 50 51 52 57 59 60 66 65 64 63 62 61 68 69 70 71 73 74 75 76 77 72 67 58 V03110 ...

Page 73: ...ter plate J 21359 A 4 2 2 Oil pump seal installer 6 9d J 21362 4 4 46 Forward and fourth clutch inner seal protector 6 10b 6 12b J 21369 E 4 2 22 Converter leak test fixture 6 3c J 21409 4 4 48 Seal protector tangless piston forward and fourth clutch same as J 23779 01 without tang slots NR J 21795 4 4 2 12 Thumb screw for J 24352 7 6a J 23549 4 4 65 Stator thrust bearing installer used with J 242...

Page 74: ...Shift valve adjusting ring tool 3 13b 6 6b J 24352 4 2 11 Sun gear shaft retainer assembly 7 6a b J 24420 B 4 4 59 Rear bearing puller body used with J 24463 2 or J 38086 A 3 16c J 24446 4 4 61 Rear bearing installer with or without output shaft installed 3 16f 7 6a J 24451 4 2 4 Output shaft bushing installer used with J 8092 6 14b J 24453 4 4 49 Retainer ring installer 6 13c J 24463 4 4 57 Rear ...

Page 75: ...ft seal installer 3 16a 6 15b J 26401 4 2 32 Selector shaft seal remover 3 16a 6 15a J 26417 A 4 4 69 Pressure gauge set NR J 26470 4 4 72 Governor rebuilding set 6 5 J 26520 4 4 73 Master thread repair kit NR J 26857 4 4 53 Pump gear gauge set 6 9c J 26995 4 4 70 Spring tester NR J 28501 4 2 16 Front planetary bushing installer 6 16c J 28638 B 4 4 71 Digital phototach kit NR J 28684 4 2 17 Govern...

Page 76: ...ly 6 13c J 39736 01 4 2 11 Sun gear shaft retainer AT 1500 Series only 7 6a b J 39736 02 4 2 12 Thumb screw for J 29736 01 AT 1500 Series only 7 6a J 39737 4 2 6 Sun gear shaft bushing installer AT 1500 Series only 6 14b J 39738 4 3 43 Pump support assembly remover AT 1500 Series only 5 3i J 39739 4 4 76 Oil pump bushing installer AT 1500 Series only 6 9d J 39757 4 2 2 Oil pump seal installer AT 1...

Page 77: ...s awaiting installation 4 5 CLEANING AND INSPECTION NOTE For detailed inspection criteria refer to GN1948EN AT Technician s Guide a Dirt Free Assembly All parts must be clean to permit effective inspection It is very important that no dirt or foreign material be allowed to enter the transmission Even minute particles can cause the mal function of close fit parts such as valves b Cleaning Parts 1 C...

Page 78: ...bearings on a dirty bench place them on clean lint free paper 4 If assembly is not to be completed at once wrap or cover the exposed bearings with clean paper or lint free cloth to keep out dust f Inspecting Cast Parts Machined Surfaces 1 Inspect bores for wear scratches grooves and dirt Remove scratches and burrs with crocus cloth Remove foreign matter Replace parts that have scratches or grooves...

Page 79: ...s and distortion 3 Install a new hook type sealring if the ring shows any wear on the outside diameter or if there is excessive side wear The sides of the sealring must be smooth within 0 005 inch 0 13 mm maxi mum side wear The sides of the shaft groove or the bore into which the sealring fits should be smooth 50 microinches 1 27 micrometers equivalent and square with the axis of rotation within 0...

Page 80: ...ticles severely pitted faces excessive wear cone cracks dis tortion and damaged spline teeth Remove burrs us ing a soft honing stone Replace plates which have other defects 2 Inspect steel plates external tanged plates for burrs scoring excessive wear cone distor tion imbedded metal galling cracks breaks and dam aged tangs Remove burrs and minor surface irregularities using a soft honing stone Rep...

Page 81: ...l Co or equivalent to protect the seal during shaft installation and to provide lubrication during initial operation 2 Allison seals are precoated with a dry sealant The sealant is usually colored for easy identifi cation The precoated seals do not require any addi tional sealant before installation f Interference Fit Parts Assembly of interfer ence fit parts may be accomplished by heating and chi...

Page 82: ... cover all openings to keep out dirt NOTE Position jack or joint sling to coincide with the transmission center of gravity c Remove Clean Transmission Clean the ex terior of the transmission If steam cleaning is used disassemble and dry the transmission immediately be cause condensation allowed to remain in the transmis sion could cause rust d Transmission Installation 1 Use a transmission jack to...

Page 83: ... Refer to Paragraph 6 7 for rebuild of the retarder control valve body assembly Refer to Para graph 6 8 for rebuild of the transfer plate assembly Skip Step 6 and proceed with Step 7 6 Remove PTO or six bolts 3 Foldout 12 A PTO cover 2 and gasket 1 7 Mount holding fixture J 23642 01 Fig ure 5 1 onto PTO mounting pad 8 Install fixture base J 3289 20 onto work table 9 Using hoist as shown in Figure ...

Page 84: ...move the modula tor valve actuator rod from the transmission case Fig ure 5 4 Later model transmissions have an actuating rod retained in the modulator valve body Refer to Paragraph 3 17b for vacuum modulator check d Removal of Breather NOTE Remove breather only if necessary 1 Insert the end of a flat head screwdriver between the breather flange and main housing Pry the breather up until there is ...

Page 85: ...o disengage the drive gears Refer to Paragraph 6 5 for governor assembly inspection and rebuild 3 Remove the governor cover gasket f Removal of Oil Pan 1 Remove the twenty one screws that re tain the oil pan 2 Remove the oil pan Figure 5 6 Re move the pan gasket Figure 5 5 Removing Governor Assembly Figure 5 6 Removing Oil Pan g Removal of Filter 1 Remove washer head screw 23 or 35 Foldout 12 B or...

Page 86: ... Paragraph 6 6 for rebuild of the main control valve body assembly 7 For earlier models apply a small amount of oil soluble grease to the end of a nonmagnetic rod 1 4 inch diameter Insert the rod greased end first into the valve body cavity and remove the steel check ball Figure 5 8 8 Remove the center support anchor bolt and flat washer Figure 5 8 CAUTION Do not allow selector valve 53 Foldout 11...

Page 87: ...J 6125 2 adapters NOTE The two holes where the slide hammers are shown in place in Figures 5 9 and 5 10 are threaded for the J 6125 2 adapters Figure 5 8 Removing Governor Check Ball Earlier Models 5 Install the assembled slide hammers into the pump Hammer upward with the slide hammers to loosen the pump assembly When free lift the pump as sembly out of the transmission case Remove the slide hamme...

Page 88: ...6 9 for rebuild of the forward clutch and turbine shaft assembly k Removal of Retarder Components Forward Clutch and Turbine Shaft 1 Grasp the turbine shaft 14 and lift out the forward clutch and turbine shaft assembly Figure 5 13 Figure 5 11 Removing Front Support Gasket Models Without Retarder 2 Lift the front stator from the forward clutch assembly Figure 5 13 3 Remove thrust washer 31 Foldout ...

Page 89: ...d with Step 1 For models with retarder skip Steps 1 and 2 and proceed with Step 3 1 Remove the snapring that retains the third clutch backplate Figure 5 16 2 Remove the backplate Figure 5 16 3 Remove six models without retarder or seven models with retarder third clutch plates Fig ure 5 17 n Removal of Center Support Assembly 1 Remove the snapring that retains the cen ter support assembly Figure 5...

Page 90: ...at the case slightly if necessary DO NOT USE a torch to heat the case A sun lamp or a current of warm air is sufficient If the support assembly starts upward and then binds tap it downward and lift again H02904 CENTER SUPPORT ASSEMBLY SNAPRING INTERNAL SPLINED PLATE 3 EXTERNAL TANGED PLATE 3 Figure 5 18 Removing Center Support Assembly Figure 5 19 Removing Front Sun Gear Thrust Washer NOTE It may ...

Page 91: ... backplate 2 Remove the backplate Figure 5 21 Removing Second Clutch Snapring Figure 5 22 Removing Second Clutch Backplate 2 Remove the ring gear and clutch pack as a unit from the main case On earlier models the rear ring gear is part of the rear carrier assembly and is re moved with the planetary gear unit 3 Install first clutch spring compressor as sembly J 23630 02 Figure 5 23 Tighten nut J 23...

Page 92: ... is upward Remove output seal 6 Foldout 12 B from the rear of the transmission housing 2 Clean the bore from which the seal was removed 3 Remove the snapring that retains the out put shaft bearing Figure 5 24 4 Remove the bearing from its bore 5 Remove the transmission housing with its remaining attached parts from the transmission holding fixture Refer to Paragraph 6 14 for rebuild of the transmi...

Page 93: ...2 Retain the body of the gauge in the pump hub with one hand while rotating the center screw with the other hand locking the gauge to the turbine hub Do not overtighten 3 Assemble J 5959 1 J 5959 3 J 5959 7 J 7872 2 and J 7872 3 as shown in Figure 6 1 Install the above items onto the converter pump hub as shown 4 Adjust lug attachment J 5959 7 so the dial will make firm contact with the top of end...

Page 94: ...no cracks starting at the weld area 2 In order to pass inspection the OD of the hub in the bushing wear area must be 1 872 1 875 inch 47 54 47 63 mm for AT 500 Series other than AT 543 and 1 999 2 000 inch 50 77 50 80 mm for AT 1500 Series torque converters e Preparation for Reuse of Converter If the torque converter is to be reused flush the converter to remove any foreign material 6 4 TORQUE CON...

Page 95: ...h and flush the needle bearing assem bly thoroughly with mineral spirits Dry the bearing and lubricate it with transmission fluid Install free wheel roller race 25 into stator and bearing assembly 15 Rotate the stator and bearing assembly against the freewheel race If there is no roughness or binding the needle bearing assembly may be left in the stator and cam assembly and reused Check the needle...

Page 96: ... J 24202 4 install the thrust bearing Figure 6 9 3 Drive the bearing assembly to a height of 0 025 0 035 inch 0 64 0 89 mm above the shoulder in the side plate Figure 6 10 The installing tool will seat on the stator area surrounding the bearing when the bearing is properly installed d Assembly Foldout 7 A 1 Install new gasket 31 onto converter pump 35 Install hub 30 into pump 35 Align the holes in...

Page 97: ...ssing downward until the race touches the collapsible retainer Lift up on the stator assembly and pull on the cord to remove the retainer Continue rotat ing the race while pressing downward When the race is fully seated rotate it firmly in the opposite direction to lock the stator and cam assembly Figure 6 11 Installing Freewheel Roller Race AT 543 8 Grasp the stator and cam assembly as shown in F...

Page 98: ...drive studs on the converter cover Figure 6 3 Recheck end play as outlined in Paragraph 6 3b If end play does not exceed 0 025 inch 0 64 mm repair is complete If end play exceeds this limit perform the steps in Para graph 6 4b 1 through 4 and then proceed to Para graph 6 4d 18 18 Install the rear bearing race Figure 6 5 flat side first onto the converter turbine selective spacer is omitted The rac...

Page 99: ...by following Steps 11 through 17 6 5 GOVERNOR a Disassembly Foldout 12 A 1 Governor 18 may be disassembled for cleaning and inspection Inspect governor driven gear for scuffed nicked burred or broken teeth any dam age or wear will require governor assembly replace ment Do not disassemble the governor unless the kit H02926 DEPTH MICROMETER BLOCK BLOCK CONVERTER COVER BAR 1 x 1 x 24 in H02927 DEPTH ...

Page 100: ...washer 6 spring 7 and modulator valve 8 6 Remove nine bolts 35 eight some mod els from trimmer cover 34 Remove trimmer cover 34 7 Remove from the bores in valve body 11 spring 14 stop 15 plug 13 and third clutch trim mer valve 12 springs 18 and 19 if present stop 20 plug 17 and first clutch trimmer valve 16 springs 23 and 24 if present stop 25 plug 22 and second CAUTION Before removing retainer pi...

Page 101: ... with a new valve at reassembly 12 Remove the other retainer pin 36 from control valve body 11 Remove stop 39 spring 38 and 2 3 relay valve 37 13 Compress adjusting ring 51 and remove retainer pin 52 Remove adjusting ring 51 washer 50 plug 49 if present valve stop 48 valve spring 47 and hold regulator valve 46 from the bore in control valve body 11 14 Compress adjusting ring 58 and remove retainer...

Page 102: ...lve stop 20 7 If removed install spring 27 into Bore P Figure 6 20 Into the same bore install stop 26 Foldout 11 and accumulator valve 28 8 Install cover 34 Hold cover against spring force and install nine or eight some mod els 1 4 20 x 3 4 inch bolts 35 Using preset torque wrench J 26912 tighten the bolts to 8 12 lb ft 11 16 N m 9 If removed install trimmer regulator valve 76 into Bore G Figure 6...

Page 104: ...o 8 12 lb ft 11 16 N m The assembled valve body is shown in Figure 6 21 19 Install selector valve 53 Foldout 11 into the assembled valve body and retain it with a rubber band tape or soft wire to prevent its dropping out dur ing handling 20 Use special tool J 24314 recheck the po sitions of all adjusting rings Figure 6 21 with the po sitions recorded before disassembly 21 For ease of handling inst...

Page 105: ...ing 25 capacity pin 26 and plug 27 5 Depress plug 27 and install pin 22 6 Install spring 21 into valve body 23 Into the same bore install priority valve 20 smaller diame ter first and plug 19 7 Depress plug 19 and install pin 22 6 8 TRANSFER PLATE ASSEMBLY Retarder Models Foldout 13 a Disassembly 1 Remove snapring 9 from feedthrough seal 10 2 Disconnect two connectors 8 from sole noids 7 3 Remove ...

Page 106: ...crimping tools J 38125 7 and squeeze the crimper enough to hold the terminal from dropping Figure 6 23 Position the wire core in the terminal and squeeze the crimper tool to complete the core crimp Position the insulation crimp of the terminal on Anvil D so that the entire insulation crimp area and a portion of the terminal between the core and insulation crimp areas are supported by the anvil Com...

Page 107: ...h Step 11 For AT 500 Series models without lockup skip Step 11 and proceed with Step 12 11 Restrain stop 32 Foldout 7 B and re move pin 33 Remove spring 31 and lockup valve 30 from the bore of front support 21 Skip Step 12 and proceed with Step 13 Figure 6 24 Removing or Installing Main Pressure Regulator Valve 12 Turn the front support over Remove pin 15 earlier models from front support 21 Remov...

Page 108: ...ator shaft in the center bore of the front support aligning the hole in the stator shaft within Angle K Figure 6 25 or 6 26 3 Press the stator shaft into the front sup port to Dimension M as measured from Surface B to the end of the stator shaft Surface L Figure 6 25 or 6 26 Axis A is established by Diameter D and Surface B When mounted on Diameter D and Sur face B features shall be within the tot...

Page 109: ...r readings 1 Position oil pump body assembly 6 flat side upward Install drive gear 10 into pump body as sembly 6 so the internal tangs of the gear are facing upward Install gear 9 into the pump body 6 so that the side of gear 9 marked with a diamond is down ward 2 Position dial indicator J 26857 on the pump body as shown in Figure 6 28 Zero the dial while the stylus plunger is contacting the pump ...

Page 110: ...tor Shaft Front Bushing AT 500 Series Models Figure 6 28 Zero Dial Indicator on Oil Pump Body Surface Figure 6 29 Dial Indicator Check of Oil Pump Driven Gear End Clearance Figure 6 30 Dial Indicator Check of Oil Pump Drive Gear End Clearance Figure 6 31 Checking Diametrical Clearance of Oil Pump Driven Gear H02934 PUMP BODY STATOR SHAFT J 23614 A J 8092 H02935 OIL PUMP DRIVE GEAR OIL PUMP DRIVEN ...

Page 111: ...aller end first into pump as sembly 16 Into the same bore install spring 31 and stop 32 Restrain stop 32 and install pin 33 through the machined side of the front support 8 If either plug 20 or 22 was removed in stall a new plug Press plug 20 into the support to a depth of flush to 0 010 inch 0 25 mm below the sur face Press plug 22 to the shoulder in the support NOTE For models without lockup pro...

Page 112: ...rd Using a screwdriver remove snapring 3 that secures PTO drive gear 4 to forward clutch housing 9 Remove gear 4 and snapring 5 Skip Steps 2 through 7 and proceed with Step 8 2 For later models with PTO gear and without retarder locate the snapring gap by looking between the tips of the PTO gear internal splines and the roots of the housing splines Light can be seen in the gap area 3 At the openin...

Page 113: ...rs should alert you to inspect the forward clutch hub for abnormal wear Although the transmission may be functioning properly prior to overhaul the clutch hub should be re placed when wear exists Reuse of a distressed hub with new washers will accelerate washer wear and will not duplicate the original durability and service life 13 Remove thrust bearing race 25 thrust needle bearing 24 and thrust ...

Page 114: ...NOT equipped with a wave plate next to piston 19 Fold out 8 The second method is by stack dimension computation Paragraph 6 16 This method may be more convenient when assembly line overhaul practices are used THE STACK DIMENSION METHOD MUST ALSO BE USED FOR CHECK ING THE FORWARD CLUTCH IN MODELS EQUIPPED WITH A WAVE PLATE NEXT TO PISTON 19 1 Install the piston without sealrings into forward clutch...

Page 115: ...LUTCH DRIVE HUB J 23619 01 c Assembly Foldout 8 1 If ball 10 or 15 was removed place the new ball into the bore Stake the bore at three equally spaced locations The bore is properly staked when the ball has the minimum axial movement specified in Figure 6 40 and when the ball is retained by the stak ing when a 30 lb 133 N load is applied against the ball 2 Install sixteen return springs 20 Foldout...

Page 116: ...orward clutch housing assembly Skip Step 8 and proceed with Step 9 Figure 6 41 Installing Forward Clutch Thrust Bearing 8 Beginning with an external tanged clutch plate install the clutch pack established in Paragraph 6 9c 6 or 6 17b 3 Figure 6 42 9 Install the fourth clutch drive hub Figure 6 39 into the housing assembly and secure the hub with snapring 30 Foldout 8 NOTE For assembly of the PTO g...

Page 117: ...parate rear stator 35 from retarder housing 36 4 Visually inspect that all fluid passage holes are clean and free of debris b Assembly 1 Place rear stator 35 in place in retarder housing 36 aligning the bolt holes Start one screw 37 to establish alignment 2 Install the remaining three screws 37 Tighten all four screws to 10 12 lb ft 14 16 N m 6 12 FOURTH CLUTCH ASSEMBLY a Disassembly Foldout 9 A 1...

Page 118: ...ottoms against the housing 2 Beginning with an external tanged plate alternately install five external tanged clutch plates 4 Foldout 9 A and five internal splined clutch plates 3 onto piston 8 3 Install clutch backplate 2 flat side first onto the last clutch plate 3 installed Install snapring 1 into housing 13 4 While holding backplate 2 firmly against snapring 1 use clutch clearance gauge J 2361...

Page 119: ...clutch pack removed in Paragraph 6 12b 6 or that which was determined in Paragraph 6 17c 6 Install backplate 2 flat side first onto the clutch plates Install snapring 1 to retain the backplate 6 13 CENTER SUPPORT ASSEMBLY a Disassembly Foldout 9 B 1 Remove pistons 9 and 18 with attached parts from center support assembly 13 2 Remove eight retainer washers 6 and 21 Figure 6 46 3 Remove spring retai...

Page 120: ...lace with the four ejector pin bosses upward Install piston return springs 8 in the twelve holes in third clutch piston 9 4 Place spring retainer 7 on piston 9 align ing the four holes in the piston Using tool J 24453 in stall four new self locking retainer washers 6 onto the eight ejector pin bosses Figure 6 50 5 Remove piston 9 from the support as sembly 6 Repeat steps 3 through 5 for piston 18 ...

Page 121: ...drum 28 Remove ring gear 18 and center planetary carrier assembly 20 from drum 28 Refer to Paragraph 6 16 for rebuild of the center planetary carrier assembly 6 Remove main shaft assembly 4 Remove snapring 29 center ring gear 30 spiral retaining ring 34 and rear sun gear 31 7 Remove snapring 43 that holds rear plan etary carrier assembly 36 to planetary connecting drum 28 8 Remove output shaft ass...

Page 122: ...hing replacement is necessary re move two bushings 2 from sun gear shaft 3 b Assembly Foldout 10 A 1 If orifice plug 49 was removed from out put shaft 48 install a new plug Press the plug clear of the chamfer 2 If bushing 47 was removed install a new bushing into output shaft 48 following the specifica tions in Figure 6 51 Bushing installer tool J 24451 can be used along with driven handle J 8092 ...

Page 123: ...output shaft 45 Install output shaft 45 snapring groove first into rear planetary car rier assembly 36 Secure it with snapring 35 12 Lubricate race 33 and bearing assembly 32 with oil soluble grease Install the race and bearing onto the output shaft adjacent to the rear sun gear 13 Install main shaft assembly 4 into rear planetary carrier 36 Index sun gear 31 with the pin ions of the rear planetar...

Page 124: ...aft out of the housing enough to re move the selector lever The selector lever may have burred the end of the selector shaft remove the burr with a small file before removing the shaft from the transmission housing 3 Do not remove snapring 9 Foldout 12 A unless replacement is necessary 4 Do not remove the breather from trans mission housing 11 unless replacement is necessary It is press fit and sh...

Page 125: ...o dimensions shown in Fig ure 6 57 6 Install 1 8 inch test plugs 8 and 13 Fold out 12 A into housing 11 Tighten the plugs to 48 60 lb in 5 5 6 7 N m 6 16 PLANETARY CARRIER ASSEMBLIES NOTE The disassembly and assembly procedures for all the planetary carrier assemblies in the AT Series transmissions differ only in the proper tool selec tion for the specific carrier assembly Refer to the tool chart ...

Page 126: ... upon the amount of labor machining the bushing time part replacement and extent of rework complete replacement of the assembly may be more practical Planetary Carrier Assembly Rebuild Tool Chart Note All tools in this chart have a basic number J 25587 and a suffix Only the suffix is shown below The figures in parentheses are quantities required Tools in the chart above are components of Planetary...

Page 127: ... in Figure 6 60 2 Place the front carrier on a work table rear downward 3 Press the bushing from the carrier Do not scratch or score the bushing bore Refer to Para graph 4 5f 1 4 Place the carrier in a press rear down ward 5 Apply Loctite Sleeve Retainer No 601 or equivalent to the OD of the new bushing Install the bushing using tool J 28501 Press the bushing flush to 0 010 inch 0 25 mm below its ...

Page 128: ...ure using pin remover and installer adapter J 25587 2 if required 5 Select the proper pin installer and install it into the press fixture ram NOTE Pin installers are shaped to avoid interference with bosses on the carrier assemblies They must be in stalled in the ram so that the cutaway portion of the installer will clear the bosses when the pinion pin is pressed in 6 Place a pinion pin onto the p...

Page 129: ...enly distributed b Forward Clutch 1 Stack the forward clutch plates and fourth clutch hub as shown in Figure 6 62 or 6 63 2 Apply the specified load and measure Dimension X 3 From the applicable table in Figure 6 62 or 6 63 select the forward clutch piston Use the parts measured and the selected piston in the forward clutch assembly Paragraph 6 10a c Fourth Clutch 1 Stack the fourth clutch plates ...

Page 130: ...TE WITH LATER CLUTCH HOUSING WITH IDENTIFICATION GROOVE IN HOUSING REF FIGURE 6 65 USE PISTON WITH EARLIER CLUTCH HOUSING WITHOUT IDENTIFICATION GROOVE IN HOUSING REF FIGURE 6 65 USE PISTON DIMENSION X EF E DE C B A 0 9825 1 0065 in 24 956 25 565 mm 1 0065 1 0325 in 25 565 26 226 mm 1 0325 1 0585 in 26 226 26 886 mm X FOURTH CLUTCH BACKPLATE EXTERNAL TANGED CLUTCH PLATE INTERNAL SPLINED CLUTCH PLA...

Page 131: ... 50 mm 4 Use the parts measured when the trans mission is assembled Paragraph 7 5a f First Clutch 1 Stack the first clutch plates and piston as shown in Figure 6 67 2 Apply the specified load and measure Dimension X 3 From the table in Figure 6 67 select the first clutch backplate Use the parts measured and the selected backplate when the transmission is assem bled Paragraph 7 4a ...

Page 133: ...ot install a thicker backplate if excess clearance can be eliminated by installing new clutch plates 7 4 INSTALLATION OF FIRST CLUTCH AND GEARING a First Clutch Foldout 10 B 1 Place the transmission housing assembly into the holding fixture converter housing upward 2 Place inner seal protector tool J 24216 01 over the hub in the transmission housing Figure 7 1 3 Install the inner and outer lip typ...

Page 134: ...aragraph 7 4b and continue rebuild 11 After S N 5070 place ring gear 5 Fold out 10 B on a work table extended teeth downward Beginning with an internal splined plate alternately install six internal splined and six external tanged clutch plates onto the rear ring gear Figure 7 3 NOTE Assemble ring gear 5 Foldout 10 B with extended teeth upward in housing 12 Pick up the ring gear and assembled firs...

Page 135: ...nner backplate is re quired Figure 7 4 Installing First Clutch Backplate 4 Backplates are stamped with identifying numbers 1 2 3 4 5 or no mark or 6 Thicknesses are as follows Figure 7 5 Checking First Clutch Running Clearance H02975 BACKPLATE RING GEAR Identification 1 4 0 683 to 0 693 inch 17 35 to 17 60 mm 2 5 or No Stamp 0 647 to 0 657 inch Identification 16 43 to 16 69 mm Identification 3 6 0...

Page 136: ... by the main shaft and lower the unit into the transmission Figure 7 6 Mesh the in ternal teeth of the previously installed rear ring gear Paragraph 7 4a 11 through 13 with the rear plane tary carrier pinion teeth Be sure the unit bottoms 4 Install the sun gear shaft assembly long splines first and the front sun gear thrust washer Fig ure 7 7 7 5 INSTALLATION OF SECOND CLUTCH AND CENTER SUPPORT a ...

Page 137: ... Install the second clutch piston and its at tached parts in the rear bore of the center support en gaging the small lug on the second clutch spring retainer with the slot in the center support 6 Attach center support lifting bracket J 23643 to the center support and carefully lower the support into the transmission case During installation align the threaded anchor bolt hole in the support with t...

Page 138: ...ort compressor 13 Install two new hook type sealrings 12 Foldout 9 B onto the hub of center support assem bly 13 7 6 INSTALLATION OF REAR BEARING SPACER AND FOURTH CLUTCH a Selecting Installing Rear Bearing Spacer Foldout 12 B 1 Install the sun gear shaft retainer J 24352 for AT 500 Series or J 39736 01 for AT 1500 Series onto the transmission main shaft Figure 7 12 Be sure retainer sleeve is seat...

Page 139: ...Measuring For Selection of Rear Bearing Spacer 6 Remove the gauge and using a depth mi crometer measure the distance from the end of the straight member to the lip of the curved member Use this dimension to select the proper rear spacer as listed in the following chart Install the spacer Dimension in inches millimeters 7 Using bearing installer tool J 24446 in stall rear bearing 4 Foldout 12 B num...

Page 140: ...ck and all components for an accurate selective thrust washer measurement in Paragraph 7 8 b Fourth Clutch Foldout 9 A 1 Reposition the transmission front up ward Carefully remove sun gear shaft retainer J 24352 or J 39736 01 Figure 7 12 without moving the sun gear shaft 2 If the sun gear shaft assembly is properly seated there should be approximately 1 8 inch 3 18 mm distance from the end of the ...

Page 141: ...tion to paired slots and a single slot The plate will have minimal rotational movement when properly installed NOTE For models without retarder proceed with Step 2 For models with retarder skip Steps 2 through 5 and proceed with Paragraph 7 7b 2 Install the third clutch backplate align ing its tangs with those of the three clutch plates Figure 7 20 For models prior to S N 3210668026 this plate is ...

Page 142: ... 3 Rotate the forward clutch assembly one or two revolutions while pushing it downward Make sure all the fourth clutch internal splined plates are en gaged NOTE For models with retarder proceed with Step 4 For models without retarder skip Step 4 and proceed with Paragraph 7 8 4 For models with retarder install two M6 1 x 80 mm guide bolts into the retarder housing assembly Figure 7 23 Install the ...

Page 143: ... the gauge bar to the thrust surface of the clutch housing Figure 7 25 Subtract 1 00 inch 25 4 mm or the thickness of the gauge bar and record the difference Select the proper thrust washer from the following ta ble Dimension in inches millimeters Figure 7 25 Measuring For Selection of Front Thrust Washer H03019 GUIDE BOLTS 2 M 6 1 x 80 mm RETARDER HOUSING ASSEMBLY H03020 GUIDE BOLT 5 16 18 x 3 in...

Page 144: ...gure 7 27 Installing Front Support Gasket Models Without Retarder 5 Install two 5 16 18 headless guide bolts into two opposite holes in the gasket and transmission housing Figure 7 24 or 7 28 6 Grasp the oil pump assembly by the sta tor shaft and lower it into the transmission housing Figure 7 28 or 7 29 Be sure the support bottoms Remove the guide bolts 7 Install nine 5 16 18 x 13 4 inch self loc...

Page 145: ...B 1 Refer to Paragraph 4 6e Coat the lip of oil seal 6 with high temperature grease Figure 7 30 Measuring Turbine Shaft End Play 2 Start the oil seal lip first squarely into the rear bore of the transmission housing 3 Using installer tool J 23631 drive the oil seal into the housing until the installer seats against the housing Figure 7 31 The rear of the oil seal will be 0 51 0 55 inch 13 0 14 0 m...

Page 146: ...8 Lift the main control valve body and swing the three tubes into proper position to enter their holes in the transmission case 9 Lower the main control valve body onto the case while engaging the rear ends of the tubes in the case and the selector valve on the selector lever Figure 7 33 Remove valve body lifter tool J 29863 10 For later models install the long braced first clutch feed tube Figure...

Page 147: ... Install the filter onto the intake tube making sure the grommet in the filter fits the intake pipe snugly Figure 7 34 NOTE Turn the intake tube until it enters the grommet squarely 4 Retain the filter with bolt 35 Foldout 12 B or bolt 42 and washer 43 for the deep pan or bolt 23 for the shallow pan configuration Tighten the bolt to 10 15 lb ft 14 20 N m c Oil Pan 1 Position the pan gasket on the ...

Page 148: ...oluble grease to re tain it Figure 7 36 2 Install the governor assembly by pushing it inward with a slight rotation Figure 7 36 3 Install the governor cover and retain it with four 5 16 18 x 9 16 inch bolts Figure 7 37 Tighten the bolts to 15 20 lb ft 20 27 N m b Vacuum Modulator 1 For earlier models install the vacuum modulator valve actuating rod larger diameter end first Figure 7 37 On diesel u...

Page 149: ...ng Figure 7 39 Be sure the splines on the converter turbine shaft engage the splines in the converter turbine hub and the tangs on the converter pump hub engage the input pump drive gear Refer to Foldout 1 2 or 3 2 Install the torque converter retaining strap before removing the transmission from the hold ing fixture Figure 7 39 Installing Torque Converter Assembly H02895 VALVE ACTUATING ROD EARLI...

Page 150: ...dout 13 on the work table outside surface down ward 2 Put one gasket 16 separator plate 17 and a second gasket 16 in place on retarder control valve assembly 18 3 Put transfer plate assembly 6 in place on gasket 24 and carefully install four 1 4 20 x 11 4 inch bolts 4 and flat washers 5 aligning the parts Using preset torque wrench J 29612 tighten bolts 4 to 8 12 lb ft 10 16 N m 4 Through the reta...

Page 151: ... guide bolts 5 If the PTO has a manual disconnect be sure that the disconnect lever is in the disconnect posi tion When the PTO is installed on the mounting pad the PTO driven gear must be to the rear of the PTO drive gear in the transmission 6 Install the PTO on the mounting pad 7 Connect the lubrication line if used c New Installation 1 Contact Allison Transmission Division of General Motors for...

Page 152: ...sh Models Without Retarder MEASUREMENT 0 011 0 046 inch 0 27 1 16 mm 0 047 0 070 inch 1 19 1 78 mm CORRECTION One 0 030 inch Gasket One 0 76 mm Gasket Two 0 030 inch Gaskets Two 0 76 mm Gaskets Correct Height Correct Height V02394 TRANSMISSION MAIN CASE BASE PLATE GAUGE PIN PTO PAD HOLD DOWN BOLT J 34814 PTO DRIVE GEAR MEASUREMENT ...

Page 153: ...through 13 in the back of this manual NOTE Where more than one spring part number is listed for the same location refer to the Parts Catalog SA1235 or SA2126 to determine which spring is used in your specific assembly number Section 8 WEAR LIMITS AND SPRING DATA Table 8 1 Wear Limits Wear Limit Illustration Description inch mm Foldout 7 A TORQUE CONVERTER ASSEMBLY 16 Converter stator 17 22 Max ins...

Page 154: ... External tanged clutch plate Min thickness No visible wear or scoring permitted Max cone 0 004 0 10 Foldout 9 B SECOND CLUTCH THIRD CLUTCH CENTER SUPPORT 2 Third clutch backplate min thickness No visible wear or scoring permitted 3 24 Internal splined clutch plate min thickness 0 090 2 29 Min depth of oil grooves 0 008 0 21 4 23 External tanged clutch plate Min thickness No visible wear or scorin...

Page 155: ...0 165 Foldout 10 B FIRST CLUTCH 2 Backplate ident 1 2 3 4 5 6 min thickness No visible wear or scoring permitted 3 Internal splined clutch plate min thickness 0 090 2 29 Min depth of oil grooves 0 008 0 21 4 External tanged clutch plate Min thickness No visible wear or scoring permitted Max cone 0 010 0 25 Foldout 12 A TRANSMISSION HOUSING GOVERNOR 11 Transmission housing Max clearance of governor...

Page 156: ... 33 3 22 4 37 8 54 4 23045233 Solid red 10 5 0 056 0 45 1 28 0 88 10 00 12 00 1 42 11 4 32 5 22 4 44 5 53 4 29505884 Dark blue 9 5 055 0455 1 30 0 88 10 0 12 0 1 40 11 56 33 0 22 3 44 5 53 4 9 A 7 Fourth clutch piston release 8624073 Solid red 10 5 0 055 0 45 1 31 0 88 8 50 12 22 1 40 11 4 33 3 22 4 37 8 54 4 23045233 Solid red 10 5 0 056 0 45 1 28 0 88 10 00 12 00 1 42 11 4 32 5 22 4 44 5 53 4 29...

Page 157: ...lid light 7 4 0 092 0 93 2 27 1 94 9 40 11 40 blue 2 34 23 6 57 7 49 3 41 8 50 7 6880045 Solid orange 10 0 099 0 94 2 18 1 94 6 20 7 40 2 51 23 9 55 4 49 3 27 6 32 9 23012937 Solid white 9 0 099 0 95 2 27 1 10 34 80 38 80 2 51 24 1 57 7 27 9 154 8 172 6 23017086 Solid white 8 5 0 105 0 95 2 21 1 94 11 0 13 4 black stripe 2 67 24 1 56 1 49 3 48 9 59 6 23018733 One end 11 3 0 078 0 94 2 98 1 94 8 30...

Page 158: ...31 17 53 36 8 27 9 96 5 112 5 6880274 Solid yellow 9 6 0 092 0 69 1 69 1 10 32 60 39 80 blue stripe 2 34 17 5 42 9 27 9 145 0 177 0 6884701 Solid orange 9 6 0 092 0 69 1 69 1 10 32 60 39 80 2 34 17 5 42 9 27 9 145 0 177 0 6885166 Solid orange 9 6 0 091 0 72 1 69 1 10 32 60 39 80 white stripe 2 31 18 3 42 9 27 9 145 0 177 0 11 23 Second clutch trimmer 6833940 Solid orange 8 5 0 121 0 95 2 38 1 94 2...

Page 159: ... 9 145 0 177 0 6880045 Orange 10 0 099 0 94 2 18 1 94 6 20 7 40 2 51 23 88 55 4 49 3 27 6 32 9 6883300 Solid lt green 10 0 082 0 69 1 95 1 10 31 20 37 20 white stripe 2 08 17 5 49 5 27 9 138 8 165 5 6885166 Solid orange 9 6 0 091 0 72 1 69 1 10 32 60 39 80 white stripe 2 31 18 3 42 9 27 9 145 0 177 0 23013908 Solid white 10 0 080 0 69 1 80 1 10 21 50 23 70 2 03 17 53 45 7 27 9 95 5 105 5 11 27 Tri...

Page 160: ...llow stripe 1 37 9 7 29 7 23 9 36 3 40 7 11 47 Hold regulator valve 6836784 Solid yellow 13 0 041 0 40 1 90 1 15 5 93 6 17 1 04 10 2 48 3 29 2 26 4 27 4 6836785 Solid white 14 0 041 0 40 2 01 1 15 6 22 6 48 1 04 10 2 51 1 29 2 27 7 28 8 6836976 Solid white 14 0 044 0 40 1 85 1 15 6 91 7 19 yellow stripe 1 12 10 2 47 0 29 2 30 7 32 0 6836977 Orange 16 0 047 0 40 1 85 1 15 7 79 8 11 1 19 10 16 47 0 ...

Page 161: ... stripe 1 37 16 3 64 8 29 2 36 0 38 7 23012946 Solid orange 12 0 054 0 64 2 39 1 15 7 18 7 68 yellow stripe 1 37 16 3 60 7 29 2 31 9 34 2 23017028 Solid yellow 12 0 054 0 64 2 65 1 15 8 65 9 35 black stripe 1 37 16 3 67 3 29 2 38 5 41 6 23017031 Solid orange 12 0 054 0 64 2 36 1 15 6 95 7 55 black stripe 1 37 16 3 59 9 29 2 30 9 33 6 23017045 Solid light blue 12 0 054 0 64 2 40 1 15 7 20 7 80 purp...

Page 162: ...red stripe 1 37 16 3 69 9 29 2 41 1 44 3 6880992 Solid white 12 0 054 0 64 2 85 1 15 9 85 10 55 red stripe 1 37 16 3 72 4 29 2 43 8 46 9 6881061 Solid light blue 12 0 054 0 64 2 55 1 15 8 10 8 70 orange stripe 1 37 16 3 64 8 29 2 36 0 38 7 6883665 Solid white 12 0 054 0 64 2 82 1 15 9 65 10 35 green stripe 1 37 16 3 71 6 29 2 42 9 46 0 23012950 Solid white 12 0 054 0 64 2 90 1 15 10 15 10 85 blue ...

Page 163: ...1 37 16 26 63 0 29 2 35 1 36 9 11 68 3 4 shift valve 6833935 Solid blue 9 0 054 0 64 2 17 1 15 8 60 9 10 1 37 16 3 55 1 29 2 38 3 40 5 6833941 Solid blue 13 5 0 062 0 64 2 15 1 15 9 35 9 85 white stripe 1 57 16 3 54 6 29 2 41 6 43 8 6833942 Solid white 12 0 054 0 64 2 50 1 15 7 85 8 35 1 37 16 3 63 5 29 2 34 9 37 1 6834576 Solid orange 12 0 054 0 64 2 39 1 15 7 18 7 68 yellow stripe 1 37 16 3 60 7...

Page 164: ... yellow 12 0 054 0 64 2 57 1 15 8 20 8 80 1 37 16 3 65 3 29 2 36 5 39 1 23013269 Solid orange 12 0 054 0 64 2 69 1 15 8 90 9 60 1 37 16 3 68 3 29 2 39 6 42 7 23013271 Blue 12 0 054 0 64 2 36 1 15 6 95 7 55 yellow stripe 1 37 16 26 59 9 29 2 30 9 33 6 23017047 Solid orange 12 0 054 0 64 2 48 1 15 7 70 8 30 purple stripe 1 37 16 26 63 0 29 2 34 3 36 9 29503530 Gray 12 0 054 0 64 2 48 1 15 7 9 8 3 1 ...

Page 165: ...33 1 25 0 94 0 17 0 21 one end white 0 51 8 4 31 8 23 9 0 8 0 9 13 21 Retarder priority valve 29524421 Yellow end 9 0 053 0 484 1 26 0 665 11 75 12 45 1 35 12 29 32 0 16 89 52 3 55 3 13 25 Retarder regulator valve 29524379 No color 9 0 043 0 450 1 25 0 681 5 70 6 30 1 09 11 43 31 8 17 30 25 4 27 9 13 29 Retarder auto flow valve 23011981 Solid red 8 0 080 0 931 2 52 1 94 8 8 9 8 white stripe 2 03 2...

Page 167: ...e with a dealer explain the matter to a distribu torship member of management with whom the dealer has his service agreement The dealer will provide his ATD distributor s name address and telephone num ber on request Step Two If your problem cannot be readily re solved at the distributor level without additional assis tance contact the Allison Transmission Regional Office responsible for your loca...

Page 168: ...formance and service life from your transmission see your dealer or distributor for the fol lowing publications Check the telephone directory for the Allison Transmission service outlet nearest you Table 9 1 Service Literature Literature Title AT 500 1500 Series Operator s Manual OM1334EN Mechanic s Tips MT1321EN Parts Catalog PC1235EN Troubleshooting Manual TS1838EN Inspection Analysis Technician...

Page 169: ...bly AT 540 542 9 Turbine shaft 10 Oil pump assembly 11 Front support 12 PTO drive gear 13 Forward clutch 14 Third clutch 15 Fourth clutch 16 Center support 17 Second clutch 18 Main shaft 19 First clutch 20 Transmission housing 21 Governor drive gear 22 Speedometer drive gear 23 Output shaft 24 Rear planetary gear set 25 Oil pan 26 Center planetary gear set 27 Control valve body assembly 28 Front p...

Page 170: ...FOLDOUT 1 Foldout 1 Model AT 540 542 543 Transmission Cross Section View V03029 9 10 11 3 2 5 4 6 7 8 1 12 13 14 15 16 17 18 19 20 21 22 23 25 26 24 28 29 27 30 31 32 ...

Page 171: ... clutch 7 Third clutch 8 Fourth clutch 9 Center support 10 Second clutch 11 Main shaft 12 First clutch 13 Transmission housing 14 Governor drive gear 15 Speedometer drive gear 16 Output shaft 17 Rear planetary gear set 18 Oil pan 19 Center planetary gear set 20 Control valve body assembly 21 Front planetary gear set 22 Sun gear shaft 23 Oil filter 24 Intake tube 25 Stator shaft 26 Torque converter...

Page 172: ...FOLDOUT 2 Foldout 2 Model AT 545 1545 Transmission Cross Section View 1 2 3 4 5 18 19 17 21 22 20 23 24 25 26 6 7 8 9 10 11 12 13 14 15 16 V01314 ...

Page 173: ...rear stator 7 Forward clutch 8 Third clutch 9 Fourth clutch 10 Center support 11 Second clutch 12 Main shaft 13 First clutch 14 Transmission housing 15 Governor drive gear 16 Speedometer drive gear 17 Output shaft 18 Rear planetary gear set 19 Oil pan 20 Center planetary gear set 21 Main control valve body assembly 22 Front planetary gear set 23 Sun gear shaft 24 Oil filter 25 Intake tube 26 Stato...

Page 174: ...S Main Pressure Regulator Valve Pump Sump ORIFICE BYPASS V03012 FROM PRIMARY COOLER TO PRIMARY COOLER TO LUBE CIRCUIT FROM RETARDER RETARDER FEED NEUTRAL FORWARD REGULATOR CIRCUIT ORIFICE ORIFICE Solenoid F De energized Solenoid H De energized Primary Cooler Priority Valve Regulator Valve Autoflow Valve RETARDER NOT APPLIED RETARDER OUT Temperature Sender or Retarder Out Pressure Tap EX EX EX Seco...

Page 175: ...DER OUT RETARDER FEED NEUTRAL FORWARD REGULATOR CIRCUIT ORIFICE ORIFICE Primary Cooler Priority Valve Regulator Valve Autoflow Valve EX EX EX MAIN PRESSURE CONVERTER IN CONVERTER OUT LUBRICATION EXHAUST OR SUMP TO PRIMARY COOLER FROM PRIMARY COOLER RETARDER IN RETARDER OUT Temperature Sender or Retarder Out Pressure Tap NEUTRAL FORWARD REGULATOR BYPASS Solenoid F De energized Secondary Cooler Lube...

Page 176: ...ETARDER FEED NEUTRAL FORWARD REGULATOR CIRCUIT ORIFICE ORIFICE Primary Cooler Priority Valve Regulator Valve Autoflow Valve EX EX EX MAIN PRESSURE CONVERTER IN CONVERTER OUT LUBRICATION EXHAUST OR SUMP TO PRIMARY COOLER FROM PRIMARY COOLER RETARDER IN NEUTRAL FORWARD REGULATOR BYPASS CONVERTER IN Solenoid F Energized Lube Filter Secondary Cooler 100 RETARDER APPLY RETARDER OUT Temperature Sender o...

Page 177: ... Valve Hold Regulator Valve Modulator Valve 0 090 ORIFICE ORIFICE FIRST TRIMMER GOVERNOR PRESSURE V03030 01 FIRST CLUTCH PRESSURE Vacuum Modulator ORIFICE TUBE CONNECTION TUBE CONNECTION FILTER SCREEN TUBE CONNECTION 2 3 Relay Valve 1 2 Relay Valve ORIFICE REVERSE FIRST FEED ORIFICE ORIFICE ORIFICE CLUTCH FEED 1st Clutch Trimmer Valve Trim Boost Accumulator ORIFICE 3rd Clutch Trimmer Valve 2nd Clu...

Page 178: ...RIFICE ORIFICE Reverse Signal Switch D1 D2 D3 D4 FILTER SUMP Oil Pump SECOND CLUTCH PRESSURE LUBRICATION THIRD CLUTCH PRESSURE MAIN PRESSURE LOCKUP PRESSURE CONVERTER OUT MAIN PRESSURE MAIN PRESSURE FORWARD REGULATOR PRESSURE DRIVE 3 PRESSURE DRIVE 2 PRESSURE FIRST TRIMMER GOVERNOR PRESSURE FIRST TRIMMER REVERSE REVERSE FORWARD CLUTCH PRESSURE FOURTH CLUTCH PRESSURE V01295 02 HOLD FEED FORWARD CLU...

Page 179: ... 7 B 1 Torque converter assembly AT 540 542 545 1542 1545 2 Oil pump and front support assembly 3 Front oil seal 4 Sealring 5 Pump body and gear assembly 6 Pump body assembly 7 Bushing prebored for service only 8 Pump body 9 Pump driven gear 10 Pump drive gear 11 Bolt 5 16 18 x 1 inch 6 8 on earlier models A 12 Rubber coated washer 6 8 on earlier models 13 Sealring 14 Valve plug earlier models 15 ...

Page 180: ...orque Converter and Oil Pump Assemblies Exploded View 4 3 7 8 6 5 9 10 13 15 14 37 1 2 38 36 33 29 34 35 39 40 19 11 12 17 16 18 20 31 30 27 28 26 25 24 21 22 32 V03023 23 A B V03024 10 11 12 13 14 16 17 34 31 30 29 35 36 28 27 26 25 18 19 20 21 22 23 24 15 32 33 11 6 4 5 3 9 8 2 1 7 ...

Page 181: ...type sealring models with retarder 17 Piston inner sealring 18 Piston outer sealring 19 Forward clutch piston selective Piston A 0 700 0 710 inch 17 78 18 03 mm Piston B 0 726 0 736 inch 18 44 18 69 mm Piston C 0 752 0 762 inch 19 10 19 36 mm Piston EF 0 984 1 010 inch 25 00 25 65 mm Piston E 1 010 1 046 inch 25 66 26 56 mm Piston DE 1 046 1 072 inch 26 57 27 22 mm earlier models later models 20 C...

Page 182: ...ch backplate Ident 4 0 416 0 426 inch 10 57 10 82 mm Ident 0 419 0 429 inch 10 64 10 90 mm 3 Internal splined clutch plate 3 4 External tanged clutch plate 3 5 Snapring Color code white 0 148 0 150 inch 3 75 3 81 mm Color code yellow 0 152 0 154 inch 3 86 3 91 mm Color code green 0 155 0 157 inch 3 93 3 98 mm Color code red 0 158 0 160 inch 4 01 4 06 mm 6 Self locking retainer washer 4 7 Spring re...

Page 183: ...ut 9 A Fourth Clutch Exploded View V03100 1 2 3 4 8 7 6 9 5 10 13 11 12 V03025 1 2 3 4 5 7 8 6 9 10 11 14 15 16 17 18 21 19 22 20 23 24 25 12 13 Foldout 9 B Third Clutch Second Clutch and Center Support Exploded View A ...

Page 184: ...ry sun gear 32 Needle thrust bearing 33 Thrust bearing race 34 Spiral retainer ring 35 Snapring 36 Rear planetary carrier assembly Legend for Foldout 10 37 Rear planetary carrier 38 Bronze thrust washer 8 39 Steel thrust washer 8 40 Pinion matched set of 4 41 Needle roller bearing 76 42 Pinion pin 4 43 Snapring 44 Ball bearing 45 Output shaft assembly 46 Shaft and bushing assembly 47 Bushing 48 Ou...

Page 185: ...View V03032 9 10 11 16 28 30 53 49 50 43 52 47 44 38 42 37 39 39 38 41 40 54 51 48 29 31 32 33 34 35 27 20 7 17 18 19 8 6 5 4 2 2 3 12 13 11 10 15 14 46 45 1 36 22 26 21 23 23 22 25 24 1 2 3 4 5 6 7 9 8 10 11 V03026 Foldout 10 B First Clutch Exploded View A ...

Page 186: ...lve after S N 3210274681 29 Fourth clutch trimmer valve 30 Trimmer plug 31 Trimmer outer spring 32 Trimmer inner spring after S N 34500 33 Valve stop 34 Trimmer cover 35 Bolt 1 4 20 x 3 4 9 8 earlier models A 36 Retainer pin 37 2 3 relay valve 38 Relay valve spring 39 Valve stop 40 1 2 relay valve 41 Relay valve spring 42 Spacer 43 Valve stop 44 Priority valve spring 45 Priority valve 46 Hold regu...

Page 187: ...orque lb ft N m A 15 20 20 27 B 5 5 6 7 C 25 45 33 60 D 10 16 14 22 Legend for Foldout 12 19 Filter kit 20 Sealring 21 Filter assembly 22 Pan gasket 23 Washer head screw 5 16 18 x 5 8 D 24 Drain plug washer 25 Drain plug E 26 Shallow oil pan and magnet assembly 27 Magnet 28 Washer head screw 5 16 18 x 5 8 21 D 29 Drain plug E 30 Drain plug washer 31 Washer head screw 5 16 18 x 5 8 21 D 32 Tube plu...

Page 188: ... 58 61 1 2 3 4 5 6 7 8 9 56 55 54 48 45 46 44 47 49 36 43 42 33 34 31 32 30 29 37 40 41 35 38 39 19 20 18 21 22 23 24 25 27 26 28 V03028 17 7 7 6 3 24 25 8 12 2 1 5 26 19 22 15 14 21 18 23 20 27 28 4 16 13 11 10 9 8 12 15 14 16 13 11 10 9 V01315 AT 1500 SERIES Foldout 12 B Oil Pan Filter Governor and Speedometer Drives Exploded View ...

Page 189: ...ing pin 2 14 Transfer plate 15 Pipe plug 1 2 14 C 16 Gasket 2 17 Separator plate 18 Retarder control valve body assembly 19 Plug 20 Retarder priority valve 21 Spring 22 Pin 2 23 Retarder control valve body 24 Retarder regulator valve 25 Spring 26 Capacity pin 27 Plug 28 Retarder autoflow valve 29 Spring 30 Plug 31 O ring 32 Snapring 33 O ring 34 To cooler adapter 35 To cooler hose assembly 36 Bolt...

Page 190: ...V03027 37 38 36 34 33 35 4 1 7 16 17 16 18 19 20 21 22 8 9 12 13 11 10 15 23 14 6 5 2 3 24 28 29 30 31 32 25 26 27 38 REF FOLDOUT 13 Foldout 13 Retarder Control Components ...

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