Operator’s Manual

750/754 Series
Allison Off-Highway

OM1475EN
Operator’s 2006 MARCH

Manual OM1475EN

Allison Transmission
OFF-HIGHWAY TRANSMISSIONS
CBT 750, 754
CLBT 750, 754
CLBT 750, 754DB REMOTE MOUNT

Allison Transmission, Inc.

P.O. Box 894 Indianapolis, Indiana 46206-0894
www.allisontransmission.com

Printed in USA Copyright © 2007 Allison Transmission, Inc.

NOTES

2
 TABLE OF CONTENTS

INTRODUCTION
KEEPING THAT ALLISON ADVANTAGE . . . . . . . . . . . . . . . . . . . . . . . . 7
TYPICAL 750/754 SERIES OFF-HIGHWAY
TRANSMISSION MODELS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
A BRIEF DESCRIPTION OF THE ALLISON AUTOMATIC . . . . . . . . . . . . . 9
TORQUE CONVERTER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
LOCKUP CLUTCH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
POWER TAKEOFF DRIVES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
HYDRAULIC RETARDER (CBT, CLBT 750/754) . . . . . . . . . . . . . . . . . . . 10
TRANSFER GEAR HOUSING (DROPBOX) . . . . . . . . . . . . . . . . . . . . . . 10
MANUAL DISCONNECT CLUTCH . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
THROTTLE ACTUATED MODULATOR . . . . . . . . . . . . . . . . . . . . . . . . 11
COOLER, FILTER CIRCUITS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12

SHIFT SELECTORS
SHIFT SELECTORS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
RANGE SELECTION POSITIONS (FIVE-SPEED) . . . . . . . . . . . . . . . . . . 14

DRIVING TIPS
OPERATING IN COLD WEATHER . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
DOWNSHIFT CONTROL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
DOWNSHIFT OR REVERSE INHIBITOR FEATURE . . . . . . . . . . . . . . . . . 17
ACCELERATOR CONTROL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
USING THE ENGINE TO SLOW THE VEHICLE . . . . . . . . . . . . . . . . . . . 17
USING HYDRAULIC RETARDER (CBT, CLBT) . . . . . . . . . . . . . . . . . . . 17
DRIVING ON ICE AND SNOW . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
ROCKING OUT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
TOWING OR PUSHING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
PARKING BRAKE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
TEMPERATURES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19

POWER TAKEOFF OPERATION

CONVERTER-DRIVEN POWER TAKEOFF (PTO) . . . . . . . . . . . . . . . . . . 20
ENGINE-DRIVEN POWER TAKEOFF (PTO) . . . . . . . . . . . . . . . . . . . . . 20

CARE AND MAINTENANCE

PERIODIC INSPECTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
IMPORTANCE OF PROPER FLUID LEVEL . . . . . . . . . . . . . . . . . . . . . . 22
FLUID LEVEL TEST PROCEDURE . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
FLUID SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25

3
 KEEPING FLUID CLEAN . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
FLUID AND OIL FILTER CHANGE . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
HOW TO KEEP LITTLE PROBLEMS FROM
BECOMING BIG PROBLEMS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27

CUSTOMER SERVICE
OWNER ASSISTANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
SERVICE LITERATURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
ALLISON TRANSMISSION DISTRIBUTORS . . . . . . . . . . . . . . . . . . . . . 31
ALLISON TRANSMISSION REGIONAL OFFICES . . . . . . . . . . . . . . . . . . 33

4
 TRADEMARK USAGE
The following trademarks are the property of the companies indicated:
• TranSynd™ is a trademark of Castrol Ltd.
• DEXRON® is a registered trademark of the General Motors Corporation.

5
 WARNINGS, CAUTIONS, NOTES

IT IS YOUR RESPONSIBILITY to be completely familiar with the warnings

and cautions described in this handbook. It is, however, important to understand
that these warnings and cautions are not exhaustive. Allison Transmission could
not possibly know, evaluate, and advise the service trade of all conceivable ways
in which service might be done or of the possible hazardous consequences of each
way. The vehicle manufacturer is responsible for providing information related to
the operation of vehicle systems (including appropriate warnings, cautions, and
notes). Consequently, Allison Transmission has not undertaken any such broad
evaluation. Accordingly, ANYONE WHO USES A SERVICE PROCEDURE
OR TOOL WHICH IS NOT RECOMMENDED BY ALLISON
TRANSMISSION OR THE VEHICLE MANUFACTURER MUST first be
thoroughly satisfied that neither personal safety nor equipment safety will be
jeopardized by the service methods selected.
Proper service and repair is important to the safe, reliable operation of the
equipment. The service procedures recommended by Allison Transmission (or the
vehicle manufacturer) and described in this handbook are effective methods for
performing service operations. Some of these service operations require the use of
tools specially designed for the purpose. The special tools should be used when
and as recommended.
The following three types of heading are used to attract your attention to
important information:

WARNING: A warning is used when an operating procedure, practice,

etc., if not correctly followed, could result in personal injury or loss of
life.

CAUTION: A caution is used when an operating procedure, practice,

etc., if not strictly observed, could result in damage to or destruction of
equipment.

NOTE: A note is used when an operating procedure, practice, etc., is

essential to highlight.

6
 INTRODUCTION

KEEPING THAT ALLISON ADVANTAGE

Allison transmissions provide many advantages for the driver whose vehicle may
encounter vigorous, tough use and sometimes abuse. Driving is easier, safer, and
more efficient.
These transmissions are rugged and designed to provide long, trouble-free service.
This handbook will help you gain maximum benefits from your Allison
transmission-equipped vehicle.

7
TYPICAL 750/754 SERIES OFF-HIGHWAY
TRANSMISSION MODELS

Figure 1. CLBT 750/754 Remote Mount

Figure 2. CLBT 750/754DB Remote Mount

8
 ENGINE-DRIVEN FIRST LOW
PTO GEAR – TOP THIRD
FOURTH CLUTCH CLUTCH PLANETARY
TORQUE
CONVERTER CLUTCH SECOND SPEEDOMETER
LOCKUP FORWARD CLUTCH DRIVE
CLUTCH CLUTCH
OUTPUT
SHAFT

GOVERNOR

HYDRAULIC REAR PLANETARY

RETARDER CENTER PLANETARY
ENGINE-DRIVEN
PTO GEAR – SIDE CONTROL OIL SCREEN
CONVERTER-DRIVEN VALVE FRONT PLANETARY
PTO GEAR FIFTH CLUTCH H01980

Figure 3. CLBT 750/754 Remote Mount–Cross Section

A BRIEF DESCRIPTION OF THE ALLISON AUTOMATIC

• An hydraulic torque converter
• A planetary gear train
• An hydraulic control system
The torque converter multiplies engine torque during starts and acts as an
hydraulic cushion between the engine and gearing. The clutches and gear sets
provide multiple forward ranges and one reverse range. The torque converter
lockup clutch engages automatically after the vehicle is moving, for maximum
fuel economy. The hydraulic control system automatically selects the most
efficient gear ratio for vehicle speed and throttle position.

TORQUE CONVERTER
The torque converter (refer to Figure 3) consists of three elements:
• The pump is the input element and is driven by the engine.
• The turbine is the output element and is hydraulically driven by the pump.
• The stator is the reaction (torque multiplying) element.
When the pump (input) rotates at a higher speed than the turbine (output) speed,
the torque converter multiplies the torque. When the turbine speed approaches the

9
pump speed, torque multiplication stops and the torque converter functions as a
fluid coupling. With a fixed-capacity stator, engine power is always directed to the
vehicle power train.

LOCKUP CLUTCH
The lockup clutch (refer to Figure 3) is designed to hydraulically engage and
disengage at predetermined turbine speeds. When turbine speed approaches the
pump speed, hydraulic pressure automatically engages the lockup clutch. The
function of the lockup clutch is to lock the input element (pump) and the output
element (turbine) together. With the lockup clutch engaged, the engine output is
directed to the transmission gearing at 1:1 speed ratio. Reduction in the turbine
speed (output speed) automatically disengages the lockup clutch. When the lockup
clutch is disengaged, the converter acts as a torque multiplier or a fluid coupling.
The lockup clutch is momentarily disengaged during upshifting and downshifting

POWER TAKEOFF DRIVES

The CBT, CLBT 750/754 Series off-highway transmission (refer to Figure 1) has
provisions for three power takeoff (PTO) drives—two engine-driven PTO drives,
and one converter-driven PTO drive. Engine-driven PTOs may be mounted at top
and/or lower-left side of the torque converter housing. A converter-driven PTO
may be mounted at the upper-left side of the transmission main housing.

HYDRAULIC RETARDER (CBT, CLBT 750/754)

A vaned rotor and two vaned stators are the basic components of the retarder. A
manually-controlled valve fills the cavity around the rotor with fluid when the
vehicle must be slowed on steep downgrades. When the cavity is emptied, the
rotor is free of drag. Added safety and longer service brake life are the benefits
gained from a retarder.

TRANSFER GEAR HOUSING (DROPBOX)

The dropbox is a vertical transfer gear case mounted (refer to Figure 2) to the rear
of the transmission adapter housing. It can be mounted (refer to Figure 4)
vertically (Position 1) or in any of four other positions (Positions 2–5) to the left
of vertical as viewed from the rear of the dropbox. These positions are bolt hole
specific.
The dropbox provides a 1:1 gear ratio at three specific output locations. The top
rear location is in line with the input. The bottom rear and bottom front are
extensions of the drive, idler, and driven gears in the dropbox.

10
 REAR VIEW
OF DROPBOX

30°

4
45° 15°
3 30° 2

1 VERTICAL V07146

Figure 4. Dropbox Mounting Positions

MANUAL DISCONNECT CLUTCH

A manually-applied disconnect housing is available at any one or all three of the
dropbox output locations. Linkage controls the movement of the shift lever in the
disconnect housing, engaging or disengaging the clutch.

THROTTLE ACTUATED MODULATOR

Mechanical linkage between the engine throttle and the transmission moves the
control system modulator valve. This feature makes the transmission automatic
control system responsive to throttle position. Opening the throttle will raise the
speed at which upshifts occur. Timing of shifts and clutch applications are
regulated by the modulator system. Precise and smoother shifts are obtained.
Other modulator control systems may be used including air and electrically
actuated devices.

11
COOLER, FILTER CIRCUITS
A separate oil cooler or connection to the vehicle engine cooling system is used to
cool the transmission fluid. An external oil filter is placed in the
converter-to-cooler line on all models equipped with an hydraulic brake. An
auxiliary filter may be installed in the converter-to-cooler line on non-retarder
models at customer option.

12
 SHIFT SELECTORS

SHIFT SELECTORS

R R
N N
D 2-5
4
3 2-3
2 2
1 1

FIVE-SPEED FIVE-SPEED
LEVER LEVER
SELECTOR SELECTOR V07145

Figure 5. Five-Speed Lever Shift Selector Configurations

The vehicle manufacturers may choose different types of shift selectors for their
equipment. Different transmission models may also require different designations
on the shift selectors.
Some of the typical shift selectors found in Allison transmission-equipped vehicles
are shown in Figure 5. The lever shift selector in a particular vehicle may vary
from these or may have 1 (Low) at the top and R (Reverse) at the bottom.
The best performance will be obtained by using the correct range for each driving
condition.
When a vehicle is equipped with an Allison automatic transmission, it is not
necessary to select the right moment to upshift or downshift because the Allison
transmission shifts automatically during changing road and traffic conditions. A
knowledge of the ranges available at the shift selector will make control of the
vehicle and driving easier.

13
RANGE SELECTION POSITIONS (FIVE-SPEED)

WARNING: Take the following precautions so that unexpected,

possible sudden vehicle movement is avoided. Whenever it
becomes necessary to leave the vehicle, even momentarily, while
the engine is running, place the transmission shift selector in
N (Neutral), set the parking brake and/or emergency brakes, and
chock the wheels.

NOTE: The shift information below is applicable to the majority of

installations. However, some transmissions have automatic shifting
in all ranges.

R Use this to back the vehicle. Completely stop vehicle before

shifting from forward to R (Reverse) or from R (Reverse) to
forward. The reverse warning signal is activated when the shift
selector is in this position. Reverse has only one range.
WARNING: Do not allow your vehicle to coast in neutral. This
practice can result in severe transmission damage. Engine
braking and hydraulic retarder action (CBT, CLBT) are not
available during neutral coast.

N Use N (Neutral) when you start the engine. If the engine starts in
any other position, the neutral start switch is malfunctioning.
N (Neutral) is also used during stationary operation of the power
takeoff (if your vehicle is equipped with a PTO).
2–5 Use this for all normal driving conditions. The vehicle will begin to
move forward in second-range. As the accelerator is depressed, the
transmission will upshift to third, fourth, and fifth ranges
automatically. As the vehicle slows, the transmission will downshift
to the correct range automatically.
2–4 Occasionally, the road, load, or traffic conditions will make it
2–3 desirable to restrict the automatic shifting to a lower range. When
conditions improve, return the shift selector to the normal driving
position. These positions also provide progressively greater engine
braking and hydraulic retarder effect (the lower the range, the
greater the braking or retarding effect).

14
2 This is second range. Use this when pulling through mud and snow
or driving up steep grades. The vehicle will start out in
second-range if calibrated for second-range start. Otherwise it will
start in first-range and shift automatically to second-range as the
accelerator is depressed.
1 This is first-range hold (low). No upshift will occur when the shift
selector is in this position. This position provides the greatest
tractive advantage. It also provides maximum engine braking and
hydraulic retarder effect.
NOTE: All models except those for scraper applications have
lockup capability in all forward ranges. Scraper transmissions have
lockup available in all forward ranges except first-range.

15
 DRIVING TIPS

OPERATING IN COLD WEATHER

CAUTION: Disregarding minimum fluid temperature limits can result
in transmission malfunction or reduced transmission life.

Table 1 lists the minimum fluid temperatures by fluid type at which the
transmission may be safely operated in a forward or reverse range. When ambient
temperature is below the minimum fluid temperature limit and the transmission is
cold, preheat is required. If auxiliary heating equipment is not available, run the
engine to preheat the fluid to the minimum temperature limit before operating in a
forward or reverse range. Failure to observe the minimum fluid temperature limit
can result in transmission malfunction or reduced transmission life.
Transmission Fluid Operating Temperature Guide
Minimum Operating Temperature
SAE Vicosity Grade or Fluid Type
Fahrenheit Celsius
MIL-PRF-46167 –25 –32
SAE 0W*-20 or TranSynd™ –22 –30
DEXRON®-III –13 –25
SAE 10W* –4 –20
SAE 15W*-40 5 –15
SAE 30W* 32 0
SAE 40W* 50 10
* SAE “W” designation indicates winter weight based on cold temperature properties.

DOWNSHIFT CONTROL
Downshifting is a manual shift to a lower range to match driving conditions
encountered or expect to be encountered. Learning to take advantage of manual
downshifts will give better control on slick or icy roads, and on steep downgrades.
Downshifting to lower ranges increases engine braking and hydraulic retarder
effect. The selection of a lower range often prevents cycling between a range and
the next higher range on a series of short up-and-down grades.

16
DOWNSHIFT OR REVERSE INHIBITOR FEATURE
The transmission hydraulic system will not permit a shift into any lower forward
range at a speed that will cause excessive engine overspeed. A lower forward
range may be selected at any time, but the actual shift into that range will not
occur until road speed is reduced; downshifting is progressive as road speed
decreases. The inhibitor effect will cause downshifts to occur at slightly higher
speeds than normal automatic downshifts.
Shifting into reverse cannot be accomplished accidentally while traveling forward
until vehicle speed is very low, even though the shift lever is moved into the
reverse position. A full stop is required for any shift from forward to reverse or
from reverse to forward to avoid shift shock.

ACCELERATOR CONTROL
The Allison automatic transmission can upshift or downshift under influence of
accelerator movement. The operator can get a quicker downshift or can delay the
upshift by managing the throttle to get the best performance from the
transmission.

USING THE ENGINE TO SLOW THE VEHICLE

To use the engine as a braking force, the converter must be in lockup mode. If
lockup disengages, the frictional horsepower (braking force) from the engine is
lost. Downshift the transmission to the next lower range. If excessive speed
prohibits a downshift, apply the service brake, slowing the vehicle to an
acceptable downshifting speed.

USING HYDRAULIC RETARDER (CBT, CLBT)

WARNING: Do not use the retarder on wet, icy, or slippery surfaces.
Activating the retarder while driving on a slippery surface can cause a
loss of control and an accident.

Each CBT and CLBT transmission model has an hydraulic retarder installed
between the torque converter and the transmission gearing (refer to Figure 3).
Apply the retarder to slow the vehicle on curves or downgrades. Maximum
retarder effect occurs in the lowest range. The throttle must be closed when the
retarder is used to maximize the retarder performance and prevent overheating.
Partial application is permitted when maximum retarder effect is not required.
Continuous retarder operation raises fluid temperature. Short periods of full-release
will aid cooling. Do not exceed 330°F (165°C) during intermittent retarder
operation.

17
DRIVING ON ICE AND SNOW
The Allison automatic transmission continuously provides proper balance between
required power and good traction. The operator can have better control of the
vehicle because of this smooth, constant flow of power through the drive train.
When driving on ice or snow, any acceleration or deceleration should be made
gradually.

ROCKING OUT
If the vehicle is stuck in sand, mud, or snow, it is often possible to “rock out.”
Shift to D (Drive) or second to fifth (2–5) and apply a steady, light throttle, never
full throttle. Then by moving the shift selector back and forth between D (Drive)
or second to fifth and R (Reverse), rock the vehicle. Shifts from forward range to
reverse-range and reverse-range to forward-range should be made with the
throttle backed off.
Time the shifts to take advantage of the forward and reverse momentum. If the
wheels spin, back off the throttle. Discontinue the attempt to “rock out” if the
wheels spin without moving the vehicle. Do not apply full power for more than
30 seconds if the drive wheels are not turning.

TOWING OR PUSHING
WARNING: To help avoid injury or equipment damage, DO NOT
attempt ro jump-start the equipment using an arc welder. Arc welding
equipment requires dangerously high currents and voltage which cannot
be sufficiently reduced to permit its use for jump-starting.

CAUTION: Failure to lift drive wheels off the road, disconnect the
driveline, or remove the axle shafts before pushing or towing can cause
serious transmission damage.

The engine cannot be started by pushing or towing. Disconnect the driveline or

lift the vehicle drive wheels completely off the ground before towing or pushing
any distance at any speed.

PARKING BRAKE
WARNING: Take the following precautions so that unexpected,
possible sudden vehicle movement is avoided. Whenever it becomes
necessary to leave the vehicle, even momentarily, while the engine is
running, place the transmission shift selector in N (Neutral), set the
parking brake and/or emergency brakes, and chock the wheels.

18
There is no P (Park) position on the shift selector. Therefore, always select
N (Neutral) and apply the parking brake to hold the vehicle when it is parked.

TEMPERATURES
Look at the temperature gauge occasionally to be sure that the converter-out
temperature is in the normal range of 180–220°F (82–104°C) . If it exceeds
275°F (135°C) due to overload, shift to N (Neutral) and run the engine at
1200–1500 rpm. This should reduce the temperature in two or three minutes to the
normal level. Transmission-to-cooler fluid temperature should never be permitted
to exceed 330°F (166°C) during retarder operation.

CAUTION: The engine should NEVER be operated for more than

30 seconds at full throttle with the transmission in gear and the output
stalled. Prolonged operation of this type will cause the transmission fluid
temperature to become excessively high and will result in severe
overheating damage to the transmission.

If the transmission overheats during normal operation, determine the fluid level in
the transmission. Refer to the fluid test procedure that is described in the CARE
AND MAINTENANCE section of this handbook. If the high temperature persists,
stop the engine and have the system inspected by maintenance personnel.

19
 POWER TAKEOFF
OPERATION

CONVERTER-DRIVEN POWER TAKEOFF (PTO)

A PTO may be mounted onto the pad on the top-left side of the transmission main
housing. The PTO drive gear is converter driven and thus provides infinitely
variable speeds. The PTO can be operated when the vehicle is either moving or
stopped.
To operate the power takeoff, follow these instructions:
• Stop the vehicle, set the brakes, and idle the engine.
• Place the shift selector in a drive range.
• Engage the PTO.

CAUTION: Do not exceed the speed limits imposed on the driven

equipment during operation of the PTO.

• If the PTO will be operated while the vehicle is stopped, set the parking
brake, shift the transmission to N (Neutral), and depress the accelerator as
required.
• If the PTO will be operated while the vehicle is moving, simply select the
desired range and depress the accelerator as required. However, the speed
of the PTO during this type of operation will be affected by the ranges and
speed of the vehicle.
• To disengage the PTO, stop the vehicle, idle the engine, and set the brakes.
Place the shift selector in a drive range and disengage the PTO.

ENGINE-DRIVEN POWER TAKEOFF (PTO)

Some models provide PTO mountings on the top and side of the torque converter
housing. The type of PTO installed will determine the operating procedures.
If the PTO driven gear is in constant mesh with the drive gear in the converter
housing, and a friction clutch is used to connect the PTO load, the PTO can be
engaged or disengaged at any time (except at engine speeds that exceed drive
speed limits imposed on the driven equipment). If the PTO is engaged by either a

20
sliding gear or dog clutch, the vehicle engine must be shutoff to engage or
disengage the PTO. Do not exceed the drive speed restrictions of the driven
equipment.

21
 CARE AND MAINTENANCE

PERIODIC INSPECTIONS
The Allison automatic requires little maintenance. Careful attention to fluid
condition and level, selector linkage, and throttle (modulator) linkage is most
important.
For easier inspection, the transmission should be kept clean. Make periodic
inspections for loose bolts and leaking fluid lines. Inspect the condition and
adjustment of the control linkage regularly. Inspect the engine cooling system
occasionally for evidence of transmission fluid, which would indicate a faulty oil
cooler (if transmission is cooled by engine cooling system). Report any abnormal
conditions to your maintenance personnel.

IMPORTANCE OF PROPER FLUID LEVEL

Since the transmission fluid cools, lubricates, and transmits power, it is important
that the proper fluid level be maintained at all times. If it is too low, the converter
and clutches will not receive an adequate supply of fluid. This can result in poor
performance or transmission failure. If the level is too high, the fluid will aerate,
causing the transmission to overheat. Determine the fluid level at intervals
specified in your vehicle service instructions, or more frequently if operating
conditions indicate.

FLUID LEVEL TEST PROCEDURE

WARNING: To help avoid injury and property damage caused by
sudden and unexpected vehicle movement, DO NOT perform
maintenance or service procedures until all of the following have been
completed:
• Put the transmission in N (Neutral).
• Set the parking brake and service brakes, and make sure they are
properly engaged.
• Chock the wheels.
• Take all other steps necessary to keep the vehicle from moving.

22
Before determining the fluid level, clean around the end of the fill tube before
removing the dipstick(s). Dirt or foreign matter must not be permitted to enter the
fluid system because it can cause:
• Valves to stick
• Undue wear of transmission parts
• Passages to clog.

NOTE: Dropbox models have a dipstick or an oil filler tube for

determining the fluid level. The transmission and dropbox have separate
fluid systems. Each system may use a different grade of fluid.

Report any of the following to maintenance personnel:

• Abnormal fluid level
• Milky appearance of fluid
• Any trace of coolant in the fluid
• Persistently high operating temperature.

COLD RUN
BAND UTRAL AT
CHECK IN NE
XRON FLUID
®
IDLE - USE DE
HOT OVERFILL

RECOMMENDED DIPSTICK MARKINGS

HOT RUN
REF OR COLD BAND
FILL RUN UTRAL AT
CHECK IN NE
BAND IDLE - USE DE
XRON FLUID
®

ALTERNATE DIPSTICK MARKINGS

V01961.01

Figure 6. Typical Dipstick Markings

Cold Test.

NOTE: The cold test procedure is primarily used to establish if the

quantity of fluid in the transmission sump is sufficient to perform a hot
run test.

23
A cold fluid test may be made when the fluid temperature is 60–120°F (15–49°C).
To perform a cold test, do the following with the engine at idle:
1. Run the engine for at least one minute to clear the fluid system of air.
2. Remove the dipstick and wipe it clean. Re-insert the dipstick, pushing
down until it stops.
3. Remove the dipstick and determine the fluid level. Any level within the
COLD RUN band (refer to Figure 6) is safe for operating the vehicle.
4. Be sure fluid level tests are consistent. Test fluid level more than once and
if readings are not consistent, inspect the transmission breather to be sure
that it is clean and not clogged. If readings are still consistent, contact your
nearest Allison dealer or distributor.
5. If the level is at or below the COLD RUN band, add fluid until the fluid
level is within the COLD RUN band.

CAUTION: DO NOT operate the transmission for extended periods of

time until a hot test has verified proper fluid level. Transmission damage
can result from extended operation at improper fluid level conditions.

6. Perform a hot test at the first opportunity after the normal operating
temperature of 160–200°F (71–93°C) is reached.

Hot Test.

NOTE: A hot test is made to determine if there is sufficient fluid for

extended operation of the transmission.

WARNING: The normal operating temperature of transmission fluid is

180–200°F (82–93°C) and it can be hotter. Hot fluid can cause severe
burns and eye injuries. To help avoid personal injury when making hot
fluid level tests:
• AVOID CONTACT WITH HOT FLUID BY WEARING HEAVY
GLOVES AND SAFETY GLASSES.
• REMOVE TEST PLUGS VERY SLOWLY.
• DO NOT STAND DIRECTLY IN FRONT OF TEST PLUGS
BEING REMOVED.

Operate the transmission in a drive range until the normal operating temperature
of 160–200°F; 71–93°C is reached.

24
 NOTE: The fluid level rises as temperature increases. The fluid must be
at operating temperature (hot) to sure of an accurate test.

To perform a hot test, do the following with the engine at idle:

1. Shift through all drive, neutral, and reverse ranges to purge the air and fill
the clutches and fluid passages with fluid.
2. Park the vehicle on a level spot, shift to N (Neutral), apply the parking
brake and service brakes, and chock the wheels. Let the engine run at idle
speed.
3. Remove the dipstick and wipe clean. Re-insert the dipstick, pushing down
until it stops.
4. Remove the dipstick and determine the fluid level. The safe operating level
is any level within the HOT RUN band (refer to Figure 6) on the dipstick.
5. If the fluid level is not within this range, add or drain fluid as necessary to
bring the fluid level within the HOT RUN band.
6. Be sure fluid level tests are consistant. Test fluid level more than once and
if readings are not consistant, inspect the transmission breather to be sure
that it is clean and not clogged. If readings are still inconsistant, contact
your nearest Allison dealer or distributor.
7. To determine the fluid level in the dropbox, turn off the engine.
8. If the dropbox has a fill tube, remove the fill tube plug. The fluid should be
at the top of the tube.
9. If the dropbox has a dipstick, remove it, wipe it clean, re-insert pushing it
down until it stops, and remove again.
10. Safe level for the dropbox is any fluid level between the ADD and FULL
marks on the dipstick.

FLUID SPECIFICATIONS
Allison approved C-4 fluid is recommended for use in transmissions in
off-highway service. Use the C-4 fluid which conforms to the minimum
temperature (refer to Table 3 in the Driving Tips section), fluid viscosity grade,
and the dealer recommended specifications for the area. Use only SAE 30 fluid in
the transfer case (dropbox).

25
KEEPING FLUID CLEAN
CAUTION: Containers or fillers that have been used for antifreeze
solution or engine coolant MUST NEVER be used for transmission
fluid. Antifreeze and coolant solutions contain ethylene glycol which, if
put into the transmission, can cause the clutch plates and some seals to
fail.

It is absolutely necessary that the fluid put into the transmission be clean. Fluid
must be handled in clean containers and fillers to prevent foreign material
entering the transmission.

FLUID AND OIL FILTER CHANGE

CAUTION: Transmission fluid and filter change frequency is
determined by the severity of transmission service. To help avoid
transmission damage, more frequent changes may be necessary than
recommended in the general guidelines when operating conditions create
high levels of contamination or overheating.

Fluid and oil filter change frequency is determined by transmission application and
severity of operating conditions. In general, the fluid should be changed after each
1000 hours of operation and the main external filter after 500 hours of operation.
Severe operating conditions may require more frequent changes.
Allison high efficiency external oil filters do not have a mileage limitation.
Allison high efficiency external oil filters, which have a change filter indicator, do
not have to be changed when the fluid is changed unless a restriction is indicated.

WARNING: The normal operating temperature of transmission fluid is

180–200°F (82–93°C) and it can be hotter. Hot fluid can cause severe
burns and eye injuries. To help avoid personal injury when making hot
fluid level tests:
• AVOID CONTACT WITH HOT FLUID BY WEARING HEAVY
GLOVES AND SAFETY GLASSES.
• REMOVE TEST PLUGS VERY SLOWLY.
• DO NOT STAND DIRECTLY IN FRONT OF TEST PLUGS
BEING REMOVED.

To drain the transmission fluid, remove the 1/2 inch plug at the rear of the deep oil
pan. To drain the dropbox, remove the plug from the bottom of the dropbox
housing.
Fluid will drain better if the fluid is at operating temperature. Replace the plug
after the fluid is drained.

26
Remove the filter element(s) and sealrings from the external oil filters. Install new
element(s) and sealrings.
Pour 34 U.S. quarts (31 liters) (6 or 7 inch pan) or 38 U.S. quarts (36 liters)
(81/2 inch pan) of C-4 transmission fluid into the transmission. Pour 2.6 U.S.
quarts (2.5 liters) of C-4 transmission fluid, grade 30, into the dropbox.

HOW TO KEEP LITTLE PROBLEMS FROM

BECOMING BIG PROBLEMS
By observing the operation of the transmission and making periodic inspections,
minor mechanical problems can be kept from becoming major problems. Notify
maintenance personnel when one of these conditions occur:
• Overheating
• Shifting feels odd
• Unusual sounds
• Transmission automatically upshifts or downshifts at irregular intervals
• Fluid leaks from the transmission

27
 CUSTOMER SERVICE

OWNER ASSISTANCE
The satisfaction and goodwill of the owners of Allison transmissions are of
primary concern to Allison Transmission, its distributors, and their dealers.
As an owner of an Allison transmission, you have service locations throughout the
world that are eager to meet your parts and service needs with:
• Expert service by trained personnel.
• Emergency service 24 hours a day in many areas.
• Complete parts support.
• Sales teams to help determine your transmission requirements.
• Product information and literature.
Normally, any situation that arises in connection with the sale, operation, or
service of your transmission will be handled by the distributor or dealer in your
area. Consult the telephone directory for the Allison Transmission service outlet
nearest you or utilize Allison Transmission’s Sales and Service Locator tool on the
Allison Transmission web site at www.allisontransmission.com. You may also
refer to Allison Transmission’s Worldwide Sales and Service Directory
(SA2229EN).
We recognize, however, that despite the best intentions of everyone concerned,
misunderstandings may occur. To be sure of your complete satisfaction, we have
developed the following three-step procedure to be followed in the event a
problem has not been handled satisfactorily.
Step One—Discuss your problem with a member of management from the
distributorship or dealership. Frequently, complaints are the result of a
breakdown in communication and can quickly be resolved by a member of
management. If you have already discussed the problem with the Sales or Service
Manager, contact the General Manager. All Allison Transmission dealers are
associated with an Allison Transmission distributor. If the problem originates with
a dealer, explain the matter to a management member of the distributorship with
whom the dealer has his service agreement. The dealer will provide his Allison
Transmission distributor’s name, address, and telephone number on request.

28
Step Two—When it appears the problem cannot be readily resolved at the
distributor level without additional assistance, contact the Allison Technical
Assistance Center at 800-252-5283. They will place you in contact with the
Regional Customer Support Manager for your area.
For prompt assistance, please have the following information available:
• Name and location of authorized distributor or dealer.
• Type and make of vehicle/equipment.
• Transmission model number, serial number, and assembly number (if
equipped with electronic controls, also provide the TCM assembly number).
• Transmission delivery date and accumulated miles and/or hours of
operation.
• Nature of problem.
• Chronological summary of your transmission’s history.
Step Three—If you are still not satisfied after contacting the Regional Customer
Support Manager, present the entire matter to the Home Office by writing to
the following address:
Allison Transmission
Manager, Warranty Administration
PO Box 894, Mail Code 462-470-PF9
Indianapolis, IN 46206-0894
The inclusion of all pertinent information will assist the Home Office in
expediting the matter.
When contacting the Home Office, please keep in mind that ultimately the
problem will likely be resolved at the distributorship or dealership using their
facilities, equipment, and personnel. Therefore, it is suggested that Step One be
followed when experiencing a problem.
Your purchase of an Allison Transmission product is greatly appreciated, and it is
our sincere desire to be sure of your complete satisfaction.

29
SERVICE LITERATURE
Additional service literature is available as shown in the service literature table.
This service literature provides fully illustrated instructions for the operation,
maintenance, service, overhaul, and parts support of your transmission. To be sure
that you get maximum performance and service life from your unit, you may
order publications from:
SGI, Inc.
Attn: Allison Literature Fulfillment Desk
8350 Allison Avenue
Indianapolis, IN 46268
TOLL FREE: 888-666-5799
INTERNATIONAL: 317-471-4995
Available Service Literature
Publication CBT/CLBT 750/754
Mechanic’s Tips * MT1366EN
Parts Catalog* PC1315EN
CD1315EN
Service Manual SM1314EN
Technician’s Guide ** GN2055EN
Worldwide Sales and Service Directory* SA2229EN
* Also available on the internet at www.allisontransmission.com
** Automatic Transmission Fluid, Technician’s Guide

30
ALLISON TRANSMISSION DISTRIBUTORS
EASTERN REGION
Atlantic Detroit Diesel-Allison, LLC Penn Detroit Diesel-Allison, Inc.
180 Route 17 South 8330 State Road
Lodi, NJ 07644 Philadelphia, PA 19136-2986
201-489-5800 215-335-0500
Covington Detroit Diesel-Allison Western Branch Diesel, Inc.
8015 Piedmont Triad Parkway 3504 Shipwright Street
Greensboro, NC 27409 Portsmouth, VA 23703
336-292-9240 757-673-7000
Johnson & Towers, Inc. W.W. Williams S.E., Inc.
2021 Briggs Road 2849 Moreland Avenue, S.E
Mount Laurel, NJ 08054 Atlanta, GA 30315-0037
856-234-6990 404-366-1070
New England Detroit Diesel-Allison, Inc.
90 Bay State Road
Wakefield , MA 01880-1095
781-246-1810

CENTRAL REGION
Central Power Systems & Services Inland Detroit Diesel-Allison, Inc.
9200 Liberty Drive 210 Alexandra Way
Liberty, MO 64068 Carol Stream, IL 60188
816-781-8070 630-871-1111
Clarke Power Services, Inc. Inland Diesel, Inc.
3133 East Kemper Road 13015 West Custer Avenue
Cincinnati, OH 45241 Butler, WI 53007-0916
513-771-2200 262-781-7100
Detroit Diesel-Allison Canada East Interstate Power Systems, Inc.
Div. of Integrated Power Systems Corp. 2501 American Boulevard, East
2997 Rue Watt Minneapolis, MN 55425
Ste. Foy, Quebec G1X 3W1 952-854-5511
418-651-5371
Harper Detroit Diesel Ltd. W.W. Williams M.W., Inc.
10 Diesel Drive 1176 Industrial Parkway
Toronto, Ontario M8W 2T8 North Brunswick, OH 44212-2342
416-259-3281 330-225-7751

31
 SOUTHERN REGION
Caribe Detroit Diesel-Allison Stewart & Stevenson Power, Inc.
Division of GT Corporation 5840 Dahlia Street
Ceramic Ind. Park Commerce City, CO 80022
Campo Rico Ave., Block C 303-287-7441
Carolina, Puerto Rico 00982
787-750-5000
Detroit Diesel-Allison de Mexico S.A. Stewart & Stevenson Power Products, LLC
de C.V. 2707 North Loop West
Av. Santa Rosa No. 58 Houston, TX 77008
Col. Ampliacion Norte 713-868-7700
Tlalnepantla C.P. 54160, Mexico
525-5-5333-1800
Florida Detroit Diesel-Allison, Inc. United Engines, LLC
2277 N.W. 14th Street 5555 West Reno Avenue
Miami, FL 33125-0068 Oklahoma City, OK 73127
904-737-7330 405-947-3321

WESTERN REGION
Detroit Diesel-Allison British Stewart & Stevenson
Columbia Ltd. 1755 Adams Avenue
9300 - 192nd Street San Leandro, CA 94577-1001
Surrey, British Columbia V4N 3R8 510-635-8991
604-888-1211
Midwest Detroit Diesel-Allison Ltd. Valley Power Systems, Inc.
1460 Waverly Street 425 South Hacienda Boulevard
Winnipeg , Manitoba R3T OP6 City of Industry, CA 91745-1123
204-452-8244 626-333-1243
Pacific Power Products Company Waterous Power Systems
7215 South 228th Street 10025 - 51st Avenue
Kent, WA 98032 Edmonton, Alberta T6E OA8
253-854-0505 780-437-3550
Smith Power Products, Inc. W.W. Williams S.W., Inc.
3065 West California Avenue 2602 S. 19th Avenue
Salt Lake City, UT 84104 Phoenix, AZ 85009
801-415-5000 602-257-0561

32
ALLISON TRANSMISSION REGIONAL OFFICES
EASTERN REGION SOUTHERN REGION
19 Oaklynn Drive Av. Ejercito Nacional No. 843
PO Box 400 Colonia Granada
Columbus, NJ 08022-0400 Mexico, D.F. C.P. 11520
609-298-2541 936-321-4248
CENTRAL REGION WESTERN REGION
PO Box 894, Mail Code 462-470-PF06 Suite 3510
Indianapolis, IN 46206-0894 39465 Paseo Padre Parkway
317-242-2327 Fremont, CA 94538
510-226-8037

33
OM1475EN 200603 www.allisontransmission.com Printed in USA 200605