Copyright © 1996 General Motors Corp. 1–1
1–1. SCOPE OF MANUAL
a. Coverage
(1) This Service Manual describes the opera-
tion, maintenance, and overhaul procedures for the AT
540, AT 542(N)(R)(NFE), AT 543, AT 545(N)(R), AT
1542P, AT 1545P(N) Series automatic transmissions
(Figures 1–1 through 1–4). A description of the major
components of the transmissions, the function and op-
eration of the hydraulic system, wear limits, and in-
spection procedures are included. Torque specifica-
tions are given with each assembly step and on the
exploded view foldouts at the back of this manual.
(2) Because of similarities of all models, in-
structions apply generally to all models. Where proce-
dures vary between models, instructions identify
specific models.
b. Illustrations.
Overhaul procedures are illus-
trated mainly by photographs. Line drawings are used
to supplement detailed assembly procedures; cross
sections show torque paths and the relationship of as-
sembled parts. Cross sections, color-coded hydraulic
schematics, and parts exploded views are on foldouts
at the back of this manual. The foldouts may be
opened for reference while studying the text.
c. Maintenance Information.
Each task out-
lined in this Service Manual has been successfully ac-
complished by service organizations and individuals.
It is not expected that every service organization or in-
dividual will possess the required special tooling,
training, or experience to perform 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 to pre-
vent contamination or damage to transmission parts or
assemblies.
(3) Required tools and fixtures are available
as outlined in the Service Manual.
(4) Reasonable and prudent maintenance
practices are utilized.
NOTE:
Service organizations and individuals are encour-
aged to contact their local Allison Transmission
Distributor for information and guidance on any of
the tasks outlined herein.
1–2. SUPPLEMENTARY
INFORMATION
Supplementary information will be issued, as required,
to cover any improvements made after publication of
this manual. Check with your dealer or distributor to
ensure you have the latest information.
1–3. ORDERING PARTS
a. Transmission Nameplate.
The nameplate
(Figure 1–5) is located on the right-rear side of the
transmission. The nameplate shows the transmission
serial number, part number (assembly number), and
model designation, all three of which
must be sup-
plied
when ordering replacement parts or requesting
service information.
b. Parts Catalog.
Do not order
by illustration
item numbers on exploded views in this manual. All
replacement parts should be ordered from your distrib-
utor or dealer. Parts are listed in the current Parts Cata-
logs PC1235EN.
Section 1 – GENERAL INFORMATION
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