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Allison Transmission AT 545 User Manual

Allison Transmission AT 545
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 545 Specifications

General IconGeneral
BrandAllison Transmission
ModelAT 545
CategoryMicrophone system
LanguageEnglish

Summary

Warnings, Cautions, and Notes

Section I Preventive Maintenance

1-1. Periodic Inspection and Care

Inspect transmission exterior for loose bolts, leaks, linkage, etc.

1-2. Importance of Proper Fluid Level

Maintaining correct fluid level is crucial for cooling, lubrication, and power transmission.

1-4. Fluid Check Procedure

Details steps for cold and hot checks to verify transmission fluid level accurately.

1-6. Recommended Automatic Transmission Fluid and Viscosity Grade

Lists recommended DEXRON-III and C-4 fluids for different applications.

1-8. Fluid and Filter Change Procedure

Outlines the step-by-step process for draining and refilling transmission fluid and replacing filters.

1-9. Fluid Contamination

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

1-12. Transmission Stall Test and Neutral Cool-Down Check

Describes procedures for diagnosing malfunctions using stall tests and temperature checks.

Section II Removing Transmission

2-5. Removing Transmission

Outlines the procedure for safely separating the transmission from the engine.

Section III Preparing Transmission for Installation

3-2. Checking Torque Converter Position

Details measurements to ensure proper torque converter seating and clearance.

Section IV Preparing Vehicle for Transmission Installation

4-1. Checking Flexplate, Engine Features

Inspects engine-to-transmission mating components for proper tolerances and alignment.

Section V Installing Transmission into Vehicle

5-2. Coupling to Engine

Details the process of aligning and securing the transmission to the engine flywheel.

5-13. Filling the Transmission

Final step to ensure transmission hydraulic system is properly filled before starting.

Section VI Checks and Adjustments

6-1. Installation Checklist

A comprehensive checklist of installation steps and torque specifications for verification.

6-2. Road Test and Vehicle Operation Checklist

A checklist for performing road tests and verifying vehicle operation after installation.

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