CHECKING CONTROLS

Figure 5–4. HitchPin Throttle Position Sensor Installation Diagram

HitchPin Throttle Position Sensor Installation.

Install the throttle sensor body follows:

Clamp cable end using clamp and shims ( Figure 5–4

Secure the sensor body using the mounting holes provided.

Install a heat shield if any part the throttle sensor is near the exhaust manifold, turbochargers, any other heat source. Adjust the throttle sensor follows:

The engine fuel lever must the closed throttle position.

Install the hitch pin cable end the sensor the engine fuel lever with brackets that the idle position the cable end is 1 1–17 (0.44–0.67 inch) from its fully retracted position, and wide open throttle the cable end is pulled additional 15–22.9 (0.60–0.90 inch) from the idle position.

Recheck the stroke distance the throttle sensor , from closed wide open after installation is completed. Check the stroke distance the throttle sensor , from closed wide open. Stroke distance must from 15–22.9 (0.60–0.90 inch) .

Recheck for zero clearance the fuel lever . Make sure that the 15.2–22.9 (0.60–0.90 inch) dimension has not changed.

Design throttle sensor linkage brackets and levers nominal dimensions that the system stays within tolerance bands throughout its operating life.

INST ALLING TRANSMISSION INT O VEHICLE Section VI

6–1. HANDLING

Preventing Damage. Handle the transmission carefully prevent damage components in the installation path.

Control T ransmission Movements. Use a hoist transmission jack that allows precise control transmission movements during installation.

6–2. MOUNTING TO ENGINE

W ARNING: The torque converter must held the torque converter housing a retaining device such shipping brackets. Without the retaining device, the torque converter may slide forward, disengaging the oil pump, may fall completely out the transmission causing personal injury and/or property damage.

W ARNING: The 1000 and 2000 Product Families transmission dry weights are approximately 150 (330 lb). To help avoid personal injury and/or property damage: • Use caution when installing, removing, moving the transmission. • Get help when lifting the transmission. Assistance from a hoist another person may required. • Make sure that the lifting equipment can properly support the transmission.

Use the following procedure mount the transmission the engine:

Inspect the flexplate adapter , if used, for cracks other damage and replace it when these conditions are found.

Remove the torque converter retaining bracket just before the transmission is ready installed in the vehicle.

Attach the flexplate adapter the front the torque converter the flexplate using six new adhesivecoated M10 x 1.5 x bolts. Tighten each bolt 57–68 N∙m (42–50 lb ft) . Align one the flexplate’ s bolt holes with the access opening in the engine flywheel housing. Lubricate the center pilot boss with molybdenum disulfide grease (Molycote equivalent). Install M10 x 1.5 headless guide bolt into one the flexplate bolt holes in the flexplate adapter torque converter mounting lug (refer Figure 6–1 Align the guide bolt with the flexplate hole the access opening.

Figure 6–1. Pilot T ool for T ransmissionT oEngine Alignment

Push the transmission toward the engine while guiding the pilot boss the torque converter into the flexplate hub adapter flywheel, and the guide bolt into the hole the flexplate headless guide bolt in the engine flywheel housing may also aid in the transmission installation). Seat the transmission squarely against the engine flywheel housing—no force is required. interference is encountered, move the transmission away from the engine and investigate the cause. Align the bolts holes in the converter housing with those in the engine flywheel housing.

10. Install all transmissiontoengine bolts and washers finger tight minimum bolts is required and must include the top two).

CAUTION: The entire converter housing circumference must flush against the engine flywheel housing before tightening any bolts.

NOT use the bolts seat the housing.

1 Tighten four bolts equallyspaced intervals around the converter housing bolt circle. Use the torque specified the engine vehicle manufacturer . 12. Remove the flexplate guide bolt through the engine flywheel housing access opening. Replace it with a selflocking bolt. Tighten the bolt finger tight.

NOTE: NOT tighten any flexplatetoflexplate adapter bolts until all the bolts have been installed and tightened finger tight.

13. Rotate the engine crankshaft install the remaining new adhesivecoated bolts into the flexplate adapter . After all bolts have been installed finger tight, tighten the bolts 57–68 N∙m (42–50 lb ft) . 14. Install the flywheel housing access cover , if used.

6–3. INST ALLING TRANSMISSION MOUNTING COMPONENTS

CAUTION: Use the type and grade mounting bolts recommended the vehicle manufacturer .

Install all bolts, washers, spacer , isolators, supports required support the transmission in the vehicle frame. Tighten the bolts the torque values recommended the vehicle manufacturer .

6–4. COUPLING TO DRIVELINE

Couple the driveline companion flange universal joint yoke the flange yoke the transmission. Use the bolts and torque values recommended the vehicle manufacturer .

Check the universal joint angularity all Ujoints in the driveline.

Determine if they are within specification.

6–5. CONNECTING POWER T AKEOFF CONTROLS

not already mounted, mount the PT O(s) onto the transmission (refer 4– INST ALLING PT O

CAUTION: PT O units using transmission main pressure engage the PT O gear must have a positive main pressure shutof f the solenoid valve when the PT O is not engaged. Failure provide this feature may cause inadvertent clutch apply and PT O damage.

Check the PT O harness routing for kinks and sharp bends. A void routing the cable close exhaust pipes manifold. The PT O harness must not rub interfere with adjacent parts. Connect controls the PT Check for proper PT O control operation. Couple the PT O output its driven equipment. Check couplings universal joints for correct assembly and alignment. the driven component is not a direct mount arrangement, check the PT O drivelines for angularity , phasing, and fsets.

6–6. CONNECTING P ARKING BRAKE CONTROL

Connect and properly adjust the parking brake. present, adjust the brake shoetodrum clearance specified the manufacturer .

6–7. CONNECTING COOLER

Figure 6–2 shows typical cooler port locations the transmission. Consult AS64071 in Allison Sales T ech Data Book the Allison Extranet for cooler fitting torque values.