Allison 3000/4000 Product Families - Preventive Maintenance

Allison 3000/4000 Fleets Training

Regular care and maintenance are key to ensuring proper Allison Transmission performance and long life.

• Current Allison On-Highway Transmissions are equipped with prognostics which indicate when service is due.
• Allison service publications, including the Service Manuals and the latest revision of Service Information Letter 10-TR-99, provide procedures and information regarding service intervals, approved fluids, refill capacities, and more.

The Allison Transmission website includes a Fluid and Filter calculator that can be used to estimate service intervals.

A). Inspection

Inspect the Transmission, mounting components, the vehicle driveline, and related vehicle systems during Preventive Maintenance.

• Inspect Transmission seal and gasket areas for leaks, including the input and output seals, the Transmission control valve module gasket, and the gaskets sealing the converter housing and rear cover to the main Transmission housing.

• Ensure the Transmission breather is unobstructed, undamaged, and not leaking. Any more than slight seepage at the breather indicates a potential issue.

• Check components and hardware securing the Transmission to the Engine and vehicle for proper installation and damage.

• Verify cooler lines are properly routed and secured. Check for leaking lines, hoses and fittings.

• Visually inspect the electrical harnesses and connectors for proper routing and secure installation.

Inspect the driveline to ensure it has been properly maintained – a damaged or improperly maintained driveline can cause drivability issues and Transmission damage.

• Check U-joints for wear, damage, and proper lubrication.
• Check carrier and support bearings for wear and damage.
• Inspect the driveshaft sections for damage, dents and missing weights.
• Verify all hardware is properly installed and undamaged.

Make note of any potential issues so they can be addressed as needed.

B). Fluid and Filter Change

The Transmission control valve module includes a fluid drain plug.

• With the Transmission at normal operating temperature (160 to 199 degrees Fahrenheit, or 71 to 93 degrees Celsius), remove the plug and allow the fluid to drain.
• The end of the drain plug is magnetic. Some metallic particles on the magnet are normal, but excessive or large pieces of metal may indicate a transmission issue.
• Clean the magnet, replace the drain plug O-ring, allow the fluid to completely drain, then install and torque the plug to specification.

• Inspect the drained fluid for discoloration and debris.

• Discolored fluid can indicate water or coolant contamination; if contamination is suspected, check the fluid using the GlyTek Test kit or a similar Allison-recommended process.
• Reference Technician’s Guide GN2055, "Automatic Transmission Fluid Understanding/Analysis" for additional technical details.

The Transmission utilizes two filters, both accessible from the bottom of the control valve module.

• Remove the filter cover bolts.

• If necessary, a screwdriver can be inserted into a cast relief to loosen the cover. Leave a couple of cover bolts loosely installed to prevent the cover from dropping out of the control valve module.
• The filters and covers are removed from their bores as an assembly.
• Pull the filters from the covers, remove the cover seal rings, and remove the cover gasket.

• Clean the covers and the control valve module where the covers seat – remove all old gasket material.

• Two filter kits are available, depending on the control valve module depth – as a general rule of thumb, control valve modules measuring approximately two and one-half inches or less in height use the two-inch filter kit. Control valve modules measuring over two and one-half inches use the four-inch filter kit.

• Install the new cover seal rings, lightly lubricate the internal filter O-ring, then assemble each filter to its cover – the filters and covers are identical and can be mixed.

• Lightly lubricate the cover seal rings, then install a new gasket on each cover.

• Insert the assemblies into the bores, then install and torque the cover bolts.

Reference Allison Technical Publications for transmission fluid recommendations and initial refill capacities.

• Service Information Letter 10-TR-99 is continually revised to include the most current information.
• The Allison Transmission website maintains an Approved Fluids list.

C). Dipstick Fluid Level

Proper fluid level is critical to Transmission life and performance.

3000/4000 Product Family Transmissions are equipped with an Oil Level Sensor, but may also include a dipstick which can be used to check Transmission fluid.

Fluid level typically rises as fluid temperature increases, so two checks are performed – a Cold Check and a Hot Check.

• A Cold Check is performed to determine if the Transmission has enough fluid to be operated safely until a Hot Check can be made.

• Both checks are performed with the vehicle parked, parking brake applied, the Transmission in Neutral, and the Engine at idle.

• Run the Engine for at least one minute, then with the service brakes applied, shift the Transmission to Drive, Neutral, Reverse, then back to Neutral.

• Keep the Engine running, remove the Transmission dipstick, wipe it clean, then reinstall the dipstick in the fill tube.

• Remove the dipstick and check the level – repeat the procedure to verify the reading.
• When the fluid in the Transmission sump is below normal operating temperature (160 to 199 degrees Fahrenheit, or 71 to 93 degrees Celsius), the fluid level should be within the Cold Run band on the dipstick.
• When the fluid in the Transmission sump is at normal operating temperature, the fluid level should be within the Hot Run band on the dipstick.

Add or drain fluid as needed, and take a moment to verify there are no Transmission fluid leaks at the filter or drain plug.

D). Oil Level Sensor

Most current 3000/4000 Transmissions include an electronic Oil Level Sensor accessed using the shift selector.

The OLS becomes accessible when the fluid temperature is above 104 degrees Fahrenheit (40 degrees Celsius) and below 220 degrees Fahrenheit (104 degrees Celsius).

• The vehicle must be stationary, on a level surface, with the Transmission in Neutral for approximately 2 minutes to allow the fluid to settle.

• Leave the Engine idling with the vehicle parking brake applied.
• On pushbutton selectors, press the Up and Down arrow buttons simultaneously one time.

• On lever selectors, press the Display Mode/Diagnostics button one time.

The system can immediately access the Oil Level Mode, or it may enter a countdown while various conditions are automatically monitored.

• Once accessed, the feature indicates the Transmission fluid level is OK, or that the level is high or low by a specified number of quarts.
• The system may also display a variety of messages, including indications that Engine speed may be too high or that fluid temperature is not within the acceptable range.

Exit the OLS mode on pushbutton selectors by pressing the Neutral button.

Exit the OLS mode on lever selectors by pressing the Display Mode/Diagnostics button until the Range Selected/Range Attained display appears. The number of required button pushes varies depending on the Transmission system configuration.

E). Prognostics

Allison Transmission prognostics monitor fluid and filter life.

• When prognostics are enabled for the Transmission, the Trans Service icon (wrench) in the digital display indicates Oil Life and Filter Life status.
• If the indicator illuminates or stays on for 2 minutes after the Engine is started and Drive is selected, a fluid change is needed.
• If the indicator flashes on and off for 2 minutes after Drive is selected, a filter change is needed.
• Once a prognostics warning becomes active and the Trans Service icon is illuminated, a Diagnostic Trouble Code (DTC) sets and the Check Transmission light illuminates if fluid or filter service is not performed within a specified period of time.

F). Oil Life Monitor

With the Engine OFF and ignition ON, enter the Oil Life Monitor mode on pushbutton selectors by pressing the up and down arrow buttons simultaneously twice. On lever selectors, press the Display Mode/Diagnostic button twice.

• If the Transmission does not include an Oil Level Sensor, press the buttons just once.
• The remaining oil life is displayed as a percentage between 0 and 100.
• Exit the fluid life display on pushbutton selectors by selecting Neutral. On lever selectors, move the lever to any range position.

After servicing the Transmission, the system calibration may allow the Oil Life Monitor to be reset using the shift selector.

• While in the Oil Life Monitor display mode, press and hold the Mode button for 10 seconds.
• Or, with the Engine OFF and ignition ON, shift between N-D-N-D-N-R-N, pausing no more than 3 seconds between consecutive shifts.
• The Trans Service icon illuminates briefly following a reset to indicate the reset was successful
•  If the reset cannot be performed using the shift selector, Allison DOC® may be required to reset the Oil Life Monitor.

G). Filter Life Monitor

With the Engine OFF and ignition ON, enter the Filter Life Monitor mode on pushbutton selectors by pressing the up and down arrow buttons simultaneously three times. On lever selectors, press the Display Mode/Diagnostic three times.

• If the Transmission does not include an Oil Level Sensor, press the buttons just twice.
• The display indicates whether the filters are OK or in need of replacement.
• Exit the filter life display on pushbutton selectors by selecting Neutral. On lever selectors, move the lever to any range position.

On 3000/4000 Product Family Transmissions, the Filter Life Monitor automatically resets after the filters are serviced, with no additional actions required by the servicing Technician.

H). Selecting Fluid Type

System programming may allow setting the fluid type using the shift selector.

• With the Engine OFF and ignition ON, perform the following shift sequence: N-R-N-D-N-R-N-D-N-R-N-D-N.
• The Trans Service indicator flashes if TES 389 is the current setting and illuminates solidly if TES 295 is the current setting.

To change the Transmission fluid type, wait 5 seconds after entering the Transmission fluid type feature and perform one of the following sequences:

• To select TES 295, shift N-R-N. The Trans Service indicator illuminates solidly to indicate TES 295 has been selected.
• To select TES 389, shift N-D-N. The Trans Service indicator flashes to indicate TES 389 has been selected.
• The system automatically exits the fluid type selection feature after 30 seconds, the feature can also be exit by turning the ignition OFF.

• Only one Transmission fluid type selection may be made after entering the selection feature, all other attempts will be ignored until the feature is exited and re-entered.
• The Transmission fluid selected must match what is actually in the Transmission or the Oil Life Monitor notifications will be inaccurate, causing pre-mature TES 295 fluid changes, or possibly resulting in Transmission damage from running a TES 389 fluid too long.

I). Dipstick Calibration

The fill tube and dipstick must meet Allison specifications to ensure accurate fluid level checks.

• Transmission fluid cools, lubricates and transmits hydraulic power.
• A low fluid level can cause overheating, a lack of lubrication, and can starve the Torque Converter and Clutches.
• A high fluid level can cause aerated fluid, resulting in erratic shifting, overheating, and fluid being expelled through the breather or the dipstick fill tube.

Allison Technical Publications provide specifications which can be referenced to verify the fill tube is properly designed, that the dipstick is the correct length, and that the dipstick is appropriately marked.

• Verify the dipstick calibration if the Transmission refill seems to require excessively more or less fluid than anticipated.

• Verify the dipstick calibration if excessive fluid has been expelled at the breather or through the fill tube even though the level appears to be correct.

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