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Allison Transmission AT 542N User Manual

Allison Transmission AT 542N
52 pages
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MT1321EN
MT4108EN
Mechanics Tips
AT 500 and AT 1500
Series Transmissions

Table of Contents

Other manuals for Allison Transmission AT 542N

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Allison Transmission AT 542N Specifications

General IconGeneral
BrandAllison Transmission
ModelAT 542N
CategoryMicrophone system
LanguageEnglish

Summary

Warnings, Cautions, and Notes

Understanding Warnings and Cautions

Explanation of the purpose and meaning of WARNING, CAUTION, and NOTE labels in the manual.

Preventive Maintenance

Importance of Proper Fluid Level

Explains the critical role of correct fluid level for cooling, lubrication, and hydraulic power.

Fluid Check Procedure

WARNING: Fluid Check Precautions

Essential safety warnings for performing the transmission fluid level check.

CAUTION: Preventing Fluid Contamination

Cautionary advice on preventing dirt and foreign matter from entering the transmission fluid system.

Cold Check Procedure

Steps for performing a cold fluid level check, including engine operation and temperature.

Hot Check and Fluid Cleanliness

Hot Check Procedure

Steps for performing a hot fluid level check, including operating temperature requirements.

CAUTION: Fluid Contamination from Antifreeze

Warning against using containers that held antifreeze/coolant for transmission fluid.

Transmission Fluid Recommendations and Change Intervals

Recommended Fluid and Viscosity Grade

Specifies recommended fluids (DEXRON®-III, C-4) and viscosity grades for different applications.

CAUTION: Fluid Temperature Limits

Warning about disregarding minimum fluid temperature limits and their impact on transmission.

Fluid and Filter Change Intervals

Guide for determining the frequency of fluid and filter changes based on service severity.

Fluid and Filter Change Procedure

Drain Procedure

Steps for draining transmission fluid, including examining drained fluid for contamination.

Fluid and Filter Change Procedure (Continued)

Fill Procedure

Steps for refilling the transmission after fluid and filter change.

Fluid Contamination

Metal Particles in Fluid

Interpreting metal particles in fluid as an indicator of internal transmission damage.

Coolant Leakage into Transmission

Action required for coolant leaks into the hydraulic system to prevent serious damage.

Auxiliary Filter and Fluid Analysis

CAUTION: Auxiliary Filter Location

Warning against installing an auxiliary filter in the AT 500R primary cooler circuit due to retarder effectiveness.

Breather and Stall Test

Purpose of Stall Test and Cool-Down Check

Explains the stall test for diagnosing malfunctions and the cool-down check for fluid temperature data.

Transmission Stall Test Procedure

WARNING: Stall Test Safety

Critical safety precautions for conducting the transmission stall test to prevent injury.

CAUTION: Stall Test Limits

Cautions regarding stall duration, fluid temperature, and cooling between tests.

Stall Test Results and Cool-Down Check

Interpreting Stall Test Results

Analysis of stall speed results to diagnose engine or transmission problems.

Removing Transmission

Uncoupling Engine and Driveline

Transmission Removal

CAUTION: Separating Transmission from Engine

Warning regarding careful separation of the transmission from the engine to protect the torque converter.

Preparing Transmission for Installation

Installing Parking Brake and Output Flange

CAUTION: Oil Seal Surface Care

Warning against polishing oil seal surfaces to prevent leakage; advice on lubrication and installation.

Installing Shift Selector Lever

CAUTION: Output Flange Installation Tool

Warning against using hammers for output flange installation to prevent internal damage.

WARNING: Selector Lever Compatibility

Warning about using correct selector lever types for second-neutral models to ensure proper operation.

CAUTION: Selector Lever Nut Tightening

Caution against overtightening the selector lever retaining nut to prevent shaft thread damage.

Installing Power Takeoff (PTO)

CAUTION: PTO Gasket Material

Warning against using cork or soft gaskets for PTO mounting; use manufacturer-recommended parts.

Preparing Vehicle for Transmission Installation

Installing Transmission into Vehicle

Handling the Transmission

CAUTION: Handle transmission carefully after removing torque converter strap.

Installing Transmission Mounting Components

CAUTION: Transmission Mounting Pad Bolt Penetration

Specifies required bolt penetration depth for AT 540/542/545/1500 and AT 543 series.

Connecting Shift Selector Control

Installing and Adjusting Mechanical Modulator Control

Filling the Transmission

Checks and Adjustments

Installation Checklist: Proper Torque

Comprehensive list of torque specifications for various transmission installation components.

Checks and Adjustments (Continued)

Installation Checklist: System Checks

Installation Checklist: Mounting and Road Test

Road Test: Neutral Start Checks

Verifying selector lever alignment and neutral safety switch operation during road test.

Road Test: Shift Sequence and Retarder

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