Allison Transmission AT 500 Series - Post-Installation Checks and Adjustments; Installation Checklist

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6–1. INSTALLATION CHECKLIST
• PROPER TORQUE
❑ Drive cover bolts (AT 540, AT 542, AT 542N, AT 545, AT 545N,
and AT 1500 Series) — 42–50 lb ft (57–68 N·m)
❑ Flexplate nuts (AT 543) — 34–40 lb ft (46–54 N·m)
❑ Transmission-to-engine bolts*
❑ Transmission-to-frame mounting bolts — 164–192 lb ft (220–260 N·m)
❑ Output flange retaining bolt — 102–121 lb ft (138–164 N·m)
❑ Companion flange or universal joints bolts*
❑ Manual selector lever nut — 15–20 lb ft (20–27 N·m)
❑ PTO mounting bolts — 26–32 lb ft (35–43 N·m)
❑ Modulator control retaining bolt — 10–16 lb ft (14–22 N·m)
❑ Parking brake mounting bolts — 81–97 lb ft (110–132 N·m)
❑ Bellcrank and cable support brackets to transmission — 42–49 lb ft
(57–67 N·m)
❑ Hydraulic line fittings in transmission housing or retarder valve
body — 15–22 lb ft (20–30 N·m)
❑ Primary cooler fittings in retarder valve body — 40–50 lb ft (54–68 N·m)
❑ Fill tube fitting — 65–75 lb ft (88–102 N·m) or 90–100 lb ft
(122–136 N·m) with 0.675 inch long oil pan boss
❑ Drain plug — 15–20 lb ft (20–27 N·m)
❑ Speedometer driven gear assembly to rear cover — 45–50 lb ft
(61–68 N·m)
* Tighten to vehicle manufacturer’s specifications.
CHECKS AND
ADJUSTMENTS
SECTION
VI