Allison 3000 Family and 4000 Family Transmissions

sd mm 26.04.001

    Note: When the optional prognostics feature is enabled on an Allison transmission, the system monitors oil life and filter life. To reset the indicator, press the Mode button (on the electronic shift control) for 10 seconds with the ignition on but the engine not running. For more information, see the Allison Transmission website, www.allisontransmission.com.

  1. Park the vehicle on a level surface and apply the parking brakes.
  2. Operate the vehicle until the transmission reaches normal operating temperature: 160 to 200°F (71 to 93°C).

    3. Important:  When draining transmission fluid, check for evidence of dirt or water contamination. A small amount of condensation will appear in the fluid during operation.

    Water contamination is normally characterized as a milky discoloration of the transmission fluid. Obvious contamination of the transmission fluid indicates a leak between the water and fluid areas of the transmission cooler. Inspect and pressure-test the cooler to confirm the leak; replace leaking transmission coolers.

    Notice: To prevent dirt from entering the transmission, use only clean containers and fillers for the transmission fluid. Do not use fillers or containers that have been used for water or antifreeze. Dirt, water, or antifreeze could damage the transmission.

    Engine coolant in the transmission hydraulic system requires immediate action to prevent malfunction and possible serious transmission damage. For more information, see the Allison Transmission website, www.allisontransmission.com .

    Note: If only the filter is being changed, do not drain the fluid.

  3. Clean the area around the drain plug and the transmission fluid pan. Place a drain pan under the transmission and remove the drain plug. Examine the fluid as it drains.
  4. Remove the 12 mounting capscrews (six each) from the two filter covers. See Fig..

    Note: Allison 4000 Family transmission shown. Components and location are similar for Allison 3000 Family transmissions.

    1. Filter Cover

    2. Filter

    3. Filter Element O-Ring

    4. Square-Cut Seal

    Fig. 1, Allison Transmission Filter Locations and Components

    5. Note: A lot of fluid will drain when the filter covers are removed.

  5. Remove the filter covers, gaskets, O-rings, and filters from the transmission.
  6. Lubricate the new O-rings with transmission fluid, and install them on the covers.
  7. Install the filter over the gaskets.
  8. Install the fluid filters on the cover assemblies.
  9. Install the filter and cover assemblies into the filter compartment. Align each cover assembly with the holes in the channel plate sump, and push the cover assemblies in by hand to seat the seals.

    10. Notice: Do not use the capscrews to draw the filter covers to the sump. This can damage the covers, seals, or sump.

  10. Install six capscrews in each cover, and torque the bolts 38 to 44 lbf·ft (51 to 61 N·m).
  11. Install a new drain plug O-ring, and install the drain plug. Tighten the drain plug 18 to 24 lbf·ft (25 to 32 N·m).

    12. Note: Fluids meeting specification TES 295 are preferred over TES 389 fluids for use in Allison 3000 and 4000 family transmissions. See the Allison Transmission website (www.allisontransmission.com) for a list of approved transmission fluids and usage recommendations.

  12. Refill the transmission with fresh transmission fluid. Use only a fluid that meets Allison Transmission specification TES 295 or TES 389. Castrol TranSynd® is a TES 295 fluid available through Allison distributors and dealerships. See Table. for lubricant refill capacities.

    Table 1, Lubricant Refill Capacities, Allison 3000 and 4000 Family Transmissions

    Lubricant Refill Capacities, Allison 3000 and 4000 Family Transmissions1

    Family

    Sump Size

    Capacity : qt (L)

    3000

    4 Inch

    19 (18)

    2 Inch

    17 (16)

    4000

    4 Inch

    39 (37)23

    2 Inch

    31 (30)23
    1. Quantities listed are approximate. Add listed amount of fluid, then perform a "hot check" and add fluid as needed. Do not overfill.
    2. Add 3 qt (2.8 L) for transmissions with PTO.
    3. Add 3 qt (2.8 L) for transmissions with PTO.

    Table 1, Lubricant Refill Capacities, Allison 3000 and 4000 Family Transmissions

  13. Check and adjust the fluid level using the appropriate Allison Transmission procedures in Eaton Fuller.
Note:
Parent topic: Allison Transmission Fluid and Filter Change
Document Number: 0000119735
Manual Publication Date: 2024-05-23
Topic Publication Date: 2024-10-30