Description
Allison 4000 Product Family Service Manual covering Allison 4th Generation Controls vocational transmissions. This factory publication provides workshop information for the EVS, HS, RDS, SP, TRV, MH, B and T variants listed below.
Intended for transmission specialists, professional workshops and fleet maintenance departments, the manual covers preventive maintenance, diagnosis, inspection, transmission disassembly and module rebuilding. Procedures are supported by safety notices, illustrations, specifications and model-specific instructions.
This October 2005 edition is identified as Allison publication SM4014EN. The supplied manual comprises 174 pages and was copyrighted by Allison Transmission in 2007.
TRANSMISSION CONSTRUCTION
The general information section identifies the principal transmission modules, product designation codes and relevant service information. Subjects include:
- Input module and torque converter
- Main housing and gear module
- Range clutches and control system
- Transmission fluid filters and coolers
- Power take-off provision
- C6 adapter housing on applicable models
- Rear cover and output flange
- Output retarder equipment
- Exploded transmission views
PREVENTIVE MAINTENANCE
Routine transmission care and fluid-system checks are presented with the procedures required to obtain consistent readings and maintain reliable operation. Coverage includes:
- Exterior cleaning and periodic inspection
- Electronic oil-level sensor checks where fitted
- Manual cold and hot fluid-level checks
- Fluid recommendations and change intervals
- Fluid contamination by water, coolant or metal
- Fluid draining, filter replacement and refilling
- Breather location and maintenance
- Output flange, yoke and oil-seal maintenance
- On-vehicle maintenance
TESTING AND DIAGNOSIS
The manual provides practical diagnostic information for evaluating transmission condition before overhaul. It explains use of the shift selector and diagnostic displays associated with Allison 4th Generation Controls.
- CHECK TRANS light diagnosis
- Entering and leaving diagnostic mode
- Displaying and interpreting diagnostic codes
- Transmission stall testing
- Driving stall-test procedures
- Neutral cool-down checks
- Clutch-pressure measurement and comparison
- Fluid-leak diagnosis using powder or dye methods
DISASSEMBLY AND OVERHAUL
General overhaul guidance covers workshop equipment, careful handling, cleaning, component inspection and assembly practices. Wear limits, spring data and torque specifications are also included.
- Removal of the transmission from the vehicle
- Mounting the unit on a repair stand
- Removal of external parts and oil coolers
- Control valve and torque converter module removal
- Main shaft and planetary module removal
- Clutch, bearing, gear and sealing-surface inspection
- Sealring, gasket, bushing and thrust-washer inspection
- Lubrication, sealing compound and fastener procedures
MODULE REBUILD
Detailed disassembly and assembly instructions are organised by transmission module, with distinctions made for applicable 4700 and 4800 configurations.
- Torque converter and converter housing modules
- PTO gear and bearing retainer assemblies
- Front support and oil-pump module
- Rotating clutch and C3/C4 clutch assemblies
- Main shaft and P1, P2, P3 and P4 planetary assemblies
- C6 adapter housing module
- Retarder valve body, stator and housing
- Rear cover and output shaft modules
ALLISON 4000 PRODUCT FAMILY SERVICE MANUAL COVERAGE
Models covered: 4000 EVS, 4500 EVS, 4700 EVS, 4800 EVS, B 500, 4000 HS, 4500 HS, 4700 RDS, 4800 SP, T 425, 4000 MH, 4500 RDS, 4700 SP, T 450, 4000 RDS, 4500 SP, T 525, 4000 SP and 4000 TRV.
Controls: Allison 4th Generation Controls
Application: Vocational models
MANUAL DETAILS
- Manufacturer: Allison Transmission
- Manual type: Service manual
- Publication number: SM4014EN
- Edition: October 2005
- Copyright: 2007
- Language: English
- Page count: 174
The Allison 4000 Product Family Service Manual is a substantial workshop reference for maintaining, diagnosing and rebuilding the listed vocational transmission models. It should be used with the transmission identification plate to confirm the exact model and configuration before beginning work.
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