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Allison Transmission AT 542 User Manual

Allison Transmission AT 542
52 pages
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MT1321EN
MT4108EN
Mechanic’s Tips
AT 500 and AT 1500
Series Transmissions

Table of Contents

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Allison Transmission AT 542 Specifications

General IconGeneral
BrandAllison Transmission
ModelAT 542
CategoryMicrophone system
LanguageEnglish

Summary

SECTION I PREVENTIVE MAINTENANCE

1-1. PERIODIC INSPECTION AND CARE

Regular inspection of transmission exterior and components for service and operating conditions.

1-2. IMPORTANCE OF PROPER FLUID LEVEL

Explains the critical role of correct transmission fluid levels for cooling and lubrication.

1-4. FLUID CHECK PROCEDURE

Step-by-step guide for performing cold and hot fluid level checks, including safety precautions.

1-8. FLUID AND FILTER CHANGE PROCEDURE

Outlines the steps for draining fluid, replacing filters, and refilling the transmission.

1-9. FLUID CONTAMINATION

Details how to identify and address fluid contamination from dirt, metal particles, or coolant.

1-12. TRANSMISSION STALL TEST AND NEUTRAL COOL-DOWN CHECK

Explains how to perform stall tests and cool-down checks for troubleshooting transmission malfunctions.

SECTION II REMOVING TRANSMISSION

2-1. DRAINING TRANSMISSION

Procedure for draining transmission fluid, including examining for contamination.

2-3. UNCOUPLING ENGINE FROM DRIVELINE

Instructions for separating the engine and driveline from the transmission output.

2-5. REMOVING TRANSMISSION

Step-by-step guide for physically separating and removing the transmission from the vehicle.

SECTION III PREPARING TRANSMISSION FOR INSTALLATION

3-2. CHECKING TORQUE CONVERTER POSITION

Verifies correct axial positioning and clearance of the torque converter against the flexplate.

SECTION V INSTALLING TRANSMISSION INTO VEHICLE

5-2. COUPLING TO ENGINE

Details aligning and bolting the transmission to the engine flywheel, including pilot tool use.

5-4. COUPLING TO DRIVELINE

Procedure for connecting the driveline companion flange or universal joint yoke to the transmission output.

5-13. FILLING THE TRANSMISSION

Ensures the transmission hydraulic system is properly filled with fluid before starting the engine.

SECTION VI CHECKS AND ADJUSTMENTS

6-1. INSTALLATION CHECKLIST

Comprehensive checklist for verifying proper torque, connections, and component installation.

6-2. ROAD TEST AND VEHICLE OPERATION CHECKLIST

Checklist for evaluating transmission performance during vehicle road testing and operation.

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