26–04

Allison Transmission Fluid and Filter Changing

IMPORTANT: For oil and filter change intervals, see the applicable Allison Operator's Manual.

For Allison Transmission Operators Manual and Warranty Information for on-highway vehicle applications, visit www.allisontransmission.com/my-allison/customer or scan the QR code. See Fig. 3 .

Fig. 3, Allison Transmission QR Code

When draining transmission fluid, check for evidence of dirt or water contamination. A small amount of condensation will appear in the fluid during operation.

Water contamination is normally characterized as a milky discoloration of the transmission fluid. Obvious contamination of the transmission fluid indicates a leak between the water and fluid areas of the transmission cooler. Inspect and pressure-test the cooler to confirm the leak; replace leaking transmission coolers.

2100/2200/2500 Series

Park the vehicle on a level surface and apply the parking brake.

Run the engine until the transmission fluid reaches the operating temperature of 160 to 200°F (71 to 93°C). Shift the transmission to neutral (N) and shut down the engine.

To prevent dirt from entering the transmission, use only clean containers and fillers for the transmission fluid. Do not use fillers or containers that have been used for water or antifreeze. Dirt, water, or antifreeze could damage the transmission.

Clean the area around the drain plug. Place a drain pan under the transmission and remove the drain plug. Examine the fluid while it drains. If only the filter is being changed, do not drain the fluid.

NOTE: A lot of fluid will drain when the filter is removed.

Using a standard strap-type filter wrench, remove the filter by turning it counterclockwise. See Fig. 4 .

1. Magnet
2. External Filter

Fig. 4, 2100/2200/2500 Series Transmission External Filter

Remove the magnet from the filter attachment tube or from the top of the filter element.

Clean any metal debris from the magnet. Then, install the magnet on the filter attachment tube.

Using transmission fluid, lubricate the gasket on the filter.

Using your hand, install the filter by turning it clockwise until the filter gasket contacts the converter housing or cooler manifold. Then, turn the filter one more complete turn.

Install the drain plug and sealing washer. Tighten the plug 22 to 30 lbf·ft (30 to 40 N·m).

10.

Clean the area around the fill tube and remove the dipstick. Using a clean funnel in the fill tube, add transmission fluid. See Table 3 for approved transmission lubricants, and Table 4 for lubricant capacities.

11.

Check and adjust the fluid level using the procedure under "Checking the Fluid Level".

3000 Series

Park the vehicle on a level surface and apply the parking brakes.

Operate the vehicle until the transmission reaches normal operating temperature: 160 to 200°F (71 to 93°C).

Clean the area around the drain plug and the transmission fluid pan. Place a drain pan under the transmission and remove the drain plug. Examine the fluid as it drains. If only the filter is being changed, do not drain the fluid.

Remove the 12 mounting bolts (6 each) from the 2 filter covers.

NOTE: A lot of fluid will drain when the filter covers are removed.

Remove the filter covers, O-rings, and two square-cut seals from the transmission. See Fig. 5 .

Remove the filters from the bottom of the control module.

Lubricate the new O-rings with transmission fluid, and install them on the cover assemblies.

Install a new square-cut seal on each cover assembly, and install the fluid filter elements on the cover assemblies.

Install the filter and cover assemblies into the filter compartment.

10.

Align each cover assembly with the holes in the channel plate sump, and push the cover assemblies in by hand to seat the seals.

Do not use the bolts to draw the filter covers to the sump. This can damage the covers, seals, or sump.

11.

Install six bolts in each cover, and tighten the bolts 38 to 44 lbf·ft (51 to 61 N·m).

Approved Allison Transmission Lubricants^*
TES-295 Approval Number	Company	Product Brand Name
AN-051005	ExxonMobil Lubricants and Petroleum Specialties Company	Mobil Delvac Synthetic ATF
AN-011001	Castrol Heavy Duty Lubricants	TranSynd
AN-031002	BP	Autran Syn 295
AN-031003	Cognis Corporation	Emgard 2805
AN-031004	International Truck & Engine Company	Fleetrite Synthetic ATF
AN-071006	John Deere & Company	HD SynTran

^* To check the latest Allison approved fluids, go to www.allisontransmission.com/my-allison/customer . Lubricants listed in order of preference. Do not mix types of oil.

Table 3, Approved Allison Transmission Lubricants

Allison Transmission Lubricant Capacities
Transmission Model	Fill Capacity:qt (L)^*
2100/2200/2500 Series (standard sump)	15 (14)
2100/2200/2500 Series (shallow sump)	13 (12)
3000 Series (4 inch sump)	29 (27)
3000 Series (2 inch sump)	26 (25)

^* Quantities listed are approximate. Add the recommended amount of fluid as listed under fill capacity. Do not overfill.

Table 4, Allison Transmission Lubricant Capacities

1. Filter Cover
2. Filter Element
3. Filter Element O-Ring
4. Square-Cut Seal

Fig. 5, Allison 3000 Series Transmission Filter Location and Components

12.

Install a new drain plug O-ring, and install the drain plug. Tighten the drain plug 18 to 24 lbf·ft (25 to 32 N·m).

13.

Fill the transmission with fresh transmission fluid and check the fluid level. See Table 3 . See Table 4 for lubricant capacities.

14.

Check and adjust the fluid level using the procedures under "Checking the Fluid Level".

Checking the Fluid Level

Operating a transmission with the fluid level higher or lower than recommended can result in transmission damage. Do not overfill the transmission. Overfilling will force fluid out of the case through the main shaft openings.

Do not mix types and brands of fluid, because of possible incompatibility. Do not use fluid additives, friction modifiers, extreme-pressure gear fluids, or multiviscosity lubricants.

Cold Check

Clean all dirt away from around the end of the fluid fill tube before removing the dipstick.

Do not allow foreign matter to enter the transmission. Dirt or foreign matter in the hydraulic system may cause undue wear of transmission parts, make valves stick, and clog passages.

After replacing the transmission fluid or changing the filter(s), it is important to check the fluid level cold to determine if the transmission has a sufficient amount of fluid to be safely operated until a hot check can be performed.

Park the vehicle on a flat, level surface.

Apply the parking brake and chock the rear tires.

Run the engine for at least one minute.

Shift from DRIVE to NEUTRAL, and then shift to REVERSE to fill the hydraulic system.

Shift to NEUTRAL and allow the engine to idle at 500 to 800 rpm.

With the engine running at idle, remove the dipstick from the tube, then wipe the dipstick clean.

Insert the dipstick into the tube and remove the dipstick.

Check the fluid level reading and repeat the check procedure to verify the reading.

If the fluid level is within the COLD RUN band, the transmission may be operated until the fluid is hot enough to perform a HOT RUN check.

If the fluid level is not within the COLD RUN band, add or drain fluid as needed to adjust the fluid level to the middle of the COLD RUN band. See Fig. 6 .

A. Cold Run Band
B. Hot Run Band

Fig. 6, Dipstick Markings

Do not fill above the COLD RUN band if the transmission fluid is below normal operating temperature. As fluid temperature increases, so does the fluid level. Filling above the COLD RUN band when the transmission is below normal operating temperature may result in an overfilled transmission, which causes fluid foaming and aeration. Fluid foaming and aeration cause transmission overheating and erratic shifting.

NOTE: Perform a hot check at the first opportunity after the normal operating temperature, 160 to 200°F (71 to 93°C) has been reached.

Hot Check

Recommended Method

With the vehicle on a level surface and the transmission in neutral at operating temperature, perform the steps below.

On the transmission shift selector, press the up and down arrow keys simultaneously. See Fig. 7 .

1. Shift Selector Display Screen

Fig. 7, Transmission Shift Selector

Release the arrow keys and wait for a two-minute countdown.

The transmission shift selector display screen will display one of the following messages.

OL - OK indicates an acceptable oil level.

OL - HI followed by a number indicates the amount that is over-filled.

OL - LO followed by a number indicates the amount that is under-filled.

OL - 70 indicates that the transmission is not up to operating temperature.

Alternate Method

Park the vehicle on a flat, level surface. Apply the parking brake and chock the rear tires.

Shift the transmission to Neutral (N).

Operate the engine at idle (500 to 800 rpm) until normal operating temperature is reached. Check that the sump temperature is 160 to 200°F (71 to 93°C).

With the engine idling, remove the dipstick from the tube and wipe it clean.

Insert the dipstick into the tube and remove it.

Check the fluid level reading and repeat the check procedure to verify the reading. Safe operating level is within the HOT RUN band on the dipstick. The HOT RUN band is between the HOT FULL and HOT ADD marks.

If the fluid level is not within the HOT RUN band, add or drain fluid as needed to bring the fluid level within the HOT RUN band. See Fig. 6 .