1 INDEX

Models FD, FE, FF and SG (ALLISON AT542, AT545 and MT643) AUTOMATIC TRANSMISSION 75-1

75-01E-12

CHAPTER 75
AUTOMATIC
TRANSMISSION
Models: FD with Allison AT542
FE and FF with Allison AT545
SG with Allison MT643

TROUBLESHOOTING ...............................................................75 - 2

SPECIAL TOOL .........................................................................75 - 3

REMOVAL AND INSTALLATION OF TRANSMISSION

For Models FD, FE and FF .......................................................75 - 4
(Allison AT542 and AT545)

REMOVAL AND INSTALLATION OF TRANSMISSION

For Model SG ............................................................................75 - 11
(Allison MT643)

SHIFT CONTROL LINKAGE .....................................................75 - 18

ADJUSTMENT AND INSPECTION ...........................................75 - 24

75
 1 page 1
75-2 AUTOMATIC TRANSMISSION Models FD, FE, FF and SG (ALLISON AT542, AT545 and MT643)

TROUBLESHOOTING

NOTE: When diagnosing transmission problem, refer

to the Allison Shop Manual or troubleshooting
procedures for detailed information on items
that could be causing the problem.
 1 page 1
Models FD, FE, FF and SG (ALLISON AT542, AT545 and MT643) AUTOMATIC TRANSMISSION 75-3

SPECIAL TOOL
Prior to removal and installing of automatic transmission, it is necessary to have this special tool.

Illustration Tool No. Tool name

09657-1370 SPACER COUPLING GUIDE

 1 page 1
75-4 AUTOMATIC TRANSMISSION Models FD, FE, FF and SG (ALLISON AT542, AT545 and MT643)

REMOVAL OF TRANSMISSION
For Models FD, FE and FF (Allison AT542 and AT545)

NOTE: Allison transmission repairs are to be per-

formed by an authorized Allison service dealer.

WARNING
Do not work on the transmission while it is still hot.
This can result in personal injury.

1. BLOCK THE WHEELS.

1. Park the vehicle on level ground.
2. Block the wheels.
NOTE: Be sure to apply wheel stoppers in the front
tires.

SMAT-040
Fig. 1
2. DRAIN THE TRANSMISSION FLUID.
1. Place the drain pan under the transmission.
2. Remove the drain plug from the transmission and
allow the fluid to drain.

SMAT-043
Fig. 2
SPEEDOMETER 3. REMOVE THE PROPELLER SHAFTS.
CABLE 1. Disconnect the yoke from the transmission flange,
PARKING BRAKE CABLE and remove the center bearing holder.
2. Move the forward end of the propeller shaft out of
the way.
4. DISCONNECT THE PARKING BRAKE CABLE FROM
THE PARKING BRAKE LEVER AND BRACKET.
PROPELLER 5. REMOVE THE SPEEDOMETER CABLE FROM THE
SHAFT REAR OF THE TRANSMISSION.
Fig. 3
 1 page 1
Models FD, FE, FF and SG (ALLISON AT542, AT545 and MT643) AUTOMATIC TRANSMISSION 75-5

6. DISCONNECT THE OIL COOLER LINES AT THE

TRANSMISSION.

OIL COOLER LINES

Fig. 4
7. REMOVE THE MODULATOR.
1. Remove the retainer bolt and retainer.
2. Remove the modulator from the case.

SMAT-046
Fig. 5
8. DISCONNECT THE SHIFT CABLE FROM THE MANUAL
LEVER AT THE TRANSMISSION.

SMAT-102
Fig. 6
9. DISCONNECT THE NEUTRAL SWITCH AND REVERSE
SWITCH.

SMAT-098 SMAT-098A
Fig. 7
10. REMOVE INSPECTION COVER FROM THE BOTTOM
FRONT SIDE OF THE FLYWHEEL HOUSING.

SMAT-048
Fig. 8
 1 page 1
75-6 AUTOMATIC TRANSMISSION Models FD, FE, FF and SG (ALLISON AT542, AT545 and MT643)

11. REMOVE THE SIX COUPLING FROM THE FLYWHEEL

ATTACHING BOLTS.
1. Turn the flywheel manually to match the attaching
bolt to the slot on the inspection opening at the bot-
tom front side of the flywheel housing.
2. Remove the coupling bolts one by one.

SMAT-049
Fig. 9
12. REMOVE THE LOWER CONVERTER HOUSING FROM
THE FLYWHEEL HOUSING ATTACHING BOLTS.

SMAT-050
Fig. 10
13. POSITION A TRANSMISSION JACK UNDER THE
TRANSMISSION AND SECURE THE TRANSMISSION
TO THE JACK WITH A SAFETY CHAIN OR WIRE
CABLE.
14. REMOVE THE REMAINING CONVERTER HOUSING
FROM THE FLYWHEEL HOUSING ATTACHING BOLTS.
15. PULL OUT THE TRANSMISSION BACKWARDS.

SMAT-051 WARNING
Fig. 11 Do not lower the front end of the transmission. If
lowered, the torque converter may slide out of the
transmission and you may be injured.
 1 page 1
Models FD, FE, FF and SG (ALLISON AT542, AT545 and MT643) AUTOMATIC TRANSMISSION 75-7

INSTALLATION OF TRANSMISSION
FOR MODEL FD, FE AND FF (ALLISON
AT542 AND AT545)
1. TIGHTEN THE FLEX PLATE, SPACER COUPLING AND
WEAR PLATE.
Tightening Torque: 800 - 900 kg·cm (58 - 65 lb·ft)
NOTE: Before tightening, face the chamfered outer
SMAT-052 rim of the wear plate to the flex plate. If as-
Fig. 1 sembled to the contrary, the wear plate edge
hits the flex plate and its strength is reduced.
2. TIGHTEN THE TORQUE CONVERTER AND THE FLEX
PLATE.
Tightening Torque: 520 - 622 kg·cm (38 - 44 lb·ft)
NOTE: Apply grease containing molybdenum disul-
fide to the boss at the end of the torque con-
verter before assembling. Without grease,
the flex plate will not slide well and abnor-
mal force will be generated, causing the flex
SMAT-053 plate to break.
Fig. 2

APPLY
GREASE

FLEX PLATE TORQUE

CONVERTER

Fig. 3
3. MOUNT THE TRANSMISSION ASSEMBLY ON A
TRANSMISSION JACK. THEN MOVE THE ASSEMBLY
INTO THE POSITION.

WARNING
Do not lower the front end of the transmission. If
lowered, the torque converter may slide out of the
transmission and you may be injured.
SMAT-054
Fig. 4
 1 page 1
75-8 AUTOMATIC TRANSMISSION Models FD, FE, FF and SG (ALLISON AT542, AT545 and MT643)

4. SCREW THE SPECIAL TOOL "GUIDE" BY HAND INTO

THE SPACER COUPLING OF THE TRANSMISSION
ASSEMBLY. ROTATE THE TORQUE CONVERTER SO
THAT THE GUIDE FACES DOWNWARD.
Special Tool: Spacer coupling guide (09657-1370)

SM35-038
Fig. 5
5. ROTATE THE ENGINE TO ALIGN THE FITTING HOLE
OF THE ENGINE FLYWHEEL AND SPACER COUPLING
WITH THE INSPECTION HOLE ON THE FRONT OF THE
FLYWHEEL HOUSING.
NOTE: First switch off power so that the engine will not
start.

SMAT-055
Fig. 6
6. MOVE THE TRANSMISSION JACK SLOWLY AND IN-
SERT THE GUIDE INTO THE FITTING HOLE OF THE
FLYWHEEL SPACER COUPLING.
NOTE: Do not lower the front side of the transmis-
sion. If lowered, the torque converter may
slide out of the transmission and you may be
injured.

SMAT-056
Fig. 7
7. MOVE THE TRANSMISSION JACK SLOWLY AND AD-
JUST BY BRINGING THE FITTING FACES OF THE
TORQUE CONVERTER HOUSING AND THE FLY-
WHEEL HOUSING TOGETHER.
8. TIGHTEN THE BOLTS TO JOIN THE TORQUE CON-
VERTER HOUSING AND THE FLYWHEEL HOUSING.
Tightening Torque: 522 - 622 kg·cm (38 - 44 lb·ft)

SMAT-057
Fig. 8
9. LOWER AND REMOVE THE TRANSMISSION JACK.
10. TAKE THE GUIDE OUT OF THE INSPECTION HOLE
ON THE FLYWHEEL HOUSING FRONT WITH A SCREW
DRIVER.

SMAT-058
Fig. 9
 1 page 1
Models FD, FE, FF and SG (ALLISON AT542, AT545 and MT643) AUTOMATIC TRANSMISSION 75-9

11. LIGHTLY TIGHTEN THE BOLTS JOINING THE FLY-

WHEEL AND THE SPACER COUPLING THROUGH THE
INSPECTION HOLE. IN ORDER TO TIGHTEN THE
BOLTS, TURN THE RING GEAR WITH A SCREW
DRIVER THROUGH THE TIMING ADJUSTMENT HOLE
ON THE UPPER PART OF THE FLYWHEEL HOUSING.
NOTE: If the ring gear does not turn smoothly with
a screw driver, remove the transmission and
SMAT-055 repeat the procedure again from 6 above,
Fig. 10 because the hub ends of the flywheel and the
spacer coupling do not fit well. Tightening
bolts in such a condition will cause damage
to bolts and jamming of the engine.
12. TIGHTEN THE BOLTS PRETIGHTENED IN STEP 11.
Tightening Torque: 650 - 870 kg·cm (47 - 62 lb·ft)

13. CONNECT THE NEUTRAL SWITCH AND REVERSE

SWITCH.

SMAT-098 SMAT-098A
Fig. 11
14. ATTACH THE TRANSMISSION SHIFT LEVER TO THE
TRANSMISSION CASE AND THE SHIFT CABLE TO
THE LEVER AND BRACKET.
Tightening Torque: 207 - 276 kg·cm (15 - 19 lb·ft)
NOTE: ● Do not drive the lever onto shaft by ham-
mering or bumping.
● Move the lever to a detent position other
than reverse or 1st range and hold the
SMAT-059 lever by hand or adjustable wrench.
Fig. 12
15. MOUNT A MODULATOR ON THE TRANSMISSION AND
TIGHTEN THE MODULATOR RETAINER WITH THE
BOLT.
Tightening Torque: 180 - 221 kg·cm (14 - 15 lb·ft)

SMAT-046
Fig. 13
 1 page 1
75-10 AUTOMATIC TRANSMISSION Models FD, FE, FF and SG (ALLISON AT542, AT545 and MT643)

16. CONNECT THE OIL COOLER LINE.

1. For connecting the transmission case and joints, in-
sert O-rings in the grooves of the joints before tight-
ening.
NOTE: Apply ATF to the O-rings when inserting
them. If ATF is not applied, the O-rings will
not be inserted smoothly and will thus be
OIL COOLER LINES damaged, causing oil to leak.

Fig. 14
17. INSTALL THE SPEEDOMETER CABLE TO THE REAR
SPEEDOMETER PARKING BRAKE
CABLE CABLE PART OF THE TRANSMISSION.
18. ATTACH THE PARKING BRAKE CABLE TO THE PARK-
ING BRAKE LEVER AND TO THE BRACKET.
PROPELLER 19. INSTALL THE PROPELLER SHAFT YOKE TO THE
SHAFT TRANSMISSION FLANGE.
Tightening Torque:
FD, FE, FF: 650 - 870 kg·cm (47 - 62 lb·ft)
20. INSTALL THE CENTER BEARING HOLDER TO THE
Fig. 15
FRAME.
Tightening Torque: 380 - 500 kg·cm (28 - 36 lb·ft)

21. REMOVE THE CAP OF THE OIL FILLER TUBE AND

POUR TRANSMISSION FLUID INTO THE TUBE.
Fluid to be Used:
Atmospheric temperature
Below 30˚C (86˚F): ATF DEXRON or ATF
DEXRON II
Above 0˚C (32˚F): Type C-3, SAE30
Oil Volume: Refer to Item 4. CHECK THE TRANSMIS-
SION FLUID LEVEL on Page 75-27.
Fig. 16
NOTE: ● For further details, consult your nearest
ALLISON representative or ALLISON ser-
vice station.
● Vehicles shipped from the HINO factory
contain DEXRON or DEXRON II type fluid.
 1 page 1
Models FD, FE, FF and SG (ALLISON AT542, AT545 and MT643) AUTOMATIC TRANSMISSION 75-11

REMOVAL OF TRANSMISSION
For Model SG (Allison MT643)
NOTE: Allison transmission repairs are to be per-
formed by an authorized Allison service
dealer.

WARNING
Do not work on the transmission while it is still hot.
This can result in personal injury.

1. BLOCK THE WHEELS.

1. Park the vehicle on level ground.
2. Block the wheels.
NOTE: Be sure to apply wheel stoppers in the front
tires.

SMAT-040
Fig. 1
2. DRAIN THE TRANSMISSION FLUID.
1. Place the drain pan under the transmission.
2. Remove the drain plug from the transmission and
allow the fluid to drain.

SMAT-045
Fig. 2
3. REMOVE THE PROPELLER SHAFTS.
1. Disconnect the yoke from the transmission flange,
and remove the center bearing holder.
2. Move the forward end of the propeller shaft out of
the way.

SMAT-075
Fig. 3
 1 page 1
75-12 AUTOMATIC TRANSMISSION Models FD, FE, FF and SG (ALLISON AT542, AT545 and MT643)

4. REMOVE THE SPEEDOMETER CABLE FROM THE

REAR OF THE TRANSMISSION.

SMAT-076
Fig. 4
5. DISCONNECT THE OIL COOLER LINES AT THE
TRANSMISSION.

SMAT-077
Fig. 5
6. REMOVE THE MODULATOR.
1. Remove the retainer bolt and retainer.
2. Remove the modulator from the case.

SMAT-036
Fig. 6
7. DISCONNECT THE SHIFT CABLE FROM THE MANUAL
LEVER AT THE TRANSMISSION.

SMAT-102
Fig. 7
8. DISCONNECT THE NEUTRAL SWITCH AND REVERSE
SWITCH.

SMAT-098 SMAT-098A
Fig. 8
 1 page 1
Models FD, FE, FF and SG (ALLISON AT542, AT545 and MT643) AUTOMATIC TRANSMISSION 75-13

9. REMOVE INSPECTION COVER FROM THE BOTTOM

FRONT SIDE OF THE FLYWHEEL HOUSING.

SMAT-048
Fig. 9
10. REMOVE THE SIX COUPLING FROM THE FLYWHEEL
ATTACHING BOLTS.
1. Turn the flywheel manually to match the attaching
bolt to the slot on the inspection opening at the bot-
tom front side of the flywheel housing.
2. Remove the coupling bolts one by one.

SMAT-049
Fig. 10
11. REMOVE THE CONVERTER HOUSING ATTACHING
BOLTS.

SMAT-065
Fig. 11
12. POSITION A TRANSMISSION JACK UNDER THE
TRANSMISSION AND SECURE THE TRANSMISSION
TO THE JACK WITH A SAFETY CHAIN OR WIRE
CABLE.
13. REMOVE THE REMAINING CONVERTER HOUSING
FROM THE FLYWHEEL HOUSING ATTACHING BOLTS.
14. PULL OUT THE TRANSMISSION BACKWARDS.

SM75-011 WARNING
Fig. 12 Do not lower the front end of the transmission. If
lowered, the torque converter may slide out of the
transmission and you may be injured.
 1 page 1
75-14 AUTOMATIC TRANSMISSION Models FD, FE, FF and SG (ALLISON AT542, AT545 and MT643)

INSTALLATION OF TRANSMISSION
For Model SG (Allison MT643)
1. TIGHTEN THE FLEX PLATE, SPACER COUPLING AND
WEAR PLATE.
Tightening Torque: 800 - 900 kg·cm (58 - 65 lb·ft)
NOTE: Before tightening, face the chamfered outer
rim of the wear plate to the flex plate. If as-
sembled to the contrary, the wear plate edge
SMAT-052
Fig. 1
hits the flex plate and its strength is reduced.
Painted surface of the wear plate should be
located facing the transmission side.
2. TIGHTEN THE TORQUE CONVERTER AND THE
ADAPTER PLATE.
Tightening Torque: 470 - 550 kg·cm (34 - 39 lb·ft)
NOTE: Apply grease containing molybdenum disul-
fide to the boss at the end of the torque con-
verter before assembling. Without grease,
SMAT-078 the flex plate will not slide well and abnor-
Fig. 2 mal force will be generated, causing the flex
plate to break.
3. INSTALL THE ASSEMBLY CONSISTING OF FLEX
APPLY PLATE, COUPLING PLATE AND WEAR PLATE TO THE
GREASE
CONVERTER. THEN TIGHTEN THE FLEX PLATE AND
ADAPTER PLATE TOGETHER.
Tightening Torque: 470 - 550 kg·cm (34 - 39 lb·ft)

FLEX PLATE TORQUE

CONVERTER

Fig. 3
4. MOUNT THE TRANSMISSION ASSEMBLY ON A
TRANSMISSION JACK. THEN MOVE THE ASSEMBLY
INTO THE POSITION.

WARNING
Do not lower the front end of the transmission. If
lowered, the torque converter may slide out of the
transmission and you may be injured.
SM75-011
Fig. 4
5. SCREW THE SPECIAL TOOL "GUIDE" BY HAND INTO
THE SPACER COUPLING OF THE TRANSMISSION
ASSEMBLY. ROTATE THE TORQUE CONVERTER SO
THAT THE GUIDE FACES DOWNWARD.
Special Tool: Spacer coupling guide (09657-1370)

SM5-038
Fig. 5
 1 page 1
Models FD, FE, FF and SG (ALLISON AT542, AT545 and MT643) AUTOMATIC TRANSMISSION 75-15

6. ROTATE THE ENGINE TO ALIGN THE FITTING HOLE

OF THE ENGINE FLYWHEEL AND SPACER COUPLING
WITH THE INSPECTION HOLE ON THE FRONT OF THE
FLYWHEEL HOUSING.
FLYWHEEL NOTE: First switch off the power so that the engine
will not start.
SPACER 7. MOVE THE TRANSMISSION JACK SLOWLY AND IN-
COUPLING SERT THE GUIDE INTO THE FITTING HOLE OF THE
FLYWHEEL.
NOTE: Do not lower the front side of the transmis-
sion. If lowered, the torque converter may
slide out of the transmission and you may be
injured.
GUIDE 8. MOVE THE TRANSMISSION JACK SLOWLY AND AD-
JUST BY BRINGING THE FITTING FACES OF THE
TORQUE CONVERTER HOUSING AND THE FLY-
BOLT WHEEL HOUSING OR ADAPTER HOUSING TO-
GETHER.
FLYWHEEL 9. TIGHTEN THE BOLTS TO JOIN THE TORQUE CON-
HOUSING TORQUE CONVERTER
HOUSING VERTER HOUSING AND THE FLYWHEEL HOUSING.
ADAPTER SM75-023 Tightening Torque: 522 - 622 kg·cm (38 - 44 lb·ft)
Fig. 6

10. LOWER AND REMOVE THE TRANSMISSION JACK.

11. TAKE THE GUIDE OUT OF THE INSPECTION HOLE
ON THE FLYWHEEL HOUSING FRONT WITH A SCREW
DRIVER.

SMAT-058
Fig. 7
 1 page 1
75-16 AUTOMATIC TRANSMISSION Models FD, FE, FF and SG (ALLISON AT542, AT545 and MT643)

12. LIGHTLY TIGHTEN THE BOLTS JOINING THE FLY-

WHEEL AND THE SPACER COUPLING THROUGH THE
INSPECTION HOLE. IN ORDER TO TIGHTEN THE
BOLTS, TURN THE RING GEAR WITH A SCREW
DRIVER THROUGH THE TIMING ADJUSTMENT HOLE
ON THE UPPER PART OF THE FLYWHEEL HOUSING.
NOTE: If the ring gear does not turn smoothly with
a screw driver, remove the transmission and
repeat the procedure again from 6 above,
because the hub ends of the flywheel and the
spacer coupling do not fit well. Tightening
bolts in such a condition will cause damage
to the bolts and jamming of the engine.
13. TIGHTEN THE BOLTS PRETIGHTENED IN STEP 11.
Tightening Torque: 650 - 870 kg·cm (47 - 62 lb·ft)

SMAT-055
Fig. 8
14. INSTALL THE SPEEDOMETER CABLE TO THE REAR
PART OF THE TRANSMISSION.

SMAT-076
Fig. 9
15. MOUNT A MODULATOR ON THE TRANSMISSION AND
TIGHTEN THE MODULATOR RETAINER WITH TWO
BOLT.
Tightening Torque: 180 - 221 kg·cm (14 - 15 lb·ft)

SM6-036
Fig. 10
16. ATTACH THE TRANSMISSION SHIFT LEVER TO THE
TRANSMISSION CASE AND THE SHIFT CABLE TO
THE LEVER AND BRACKET.
Tightening Torque: 207 - 276 kg·cm (15 - 19 lb·ft)
NOTE: ● Do not drive the lever onto the shaft by
hammering or bumping.
● Move the lever to a detent position other
than reverse or 1st range and hold the
SMAT-059 lever by hand or adjustable wrench.
Fig. 11
 1 page 1
Models FD, FE, FF and SG (ALLISON AT542, AT545 and MT643) AUTOMATIC TRANSMISSION 75-17

17. CONNECT THE NEUTRAL SWITCH AND REVERSE

SWITCH.

SMAT-098 SMAT-098A
Fig. 12
18. INSTALL THE PROPELLER SHAFT YOKE TO THE
TRANSMISSION FLANGE.
Tightening Torque: 1,300 - 1,600 kg·cm (95 - 115 lb·ft)
19. INSTALL THE CENTER BEARING HOLDER TO THE
FRAME.
Tightening Torque: 650 - 870 kg·cm (47 - 62 lb·ft)

SMAT-080
Fig. 13
20. CONNECT THE OIL COOLER LINE.
1. For connecting the transmission case and joints, in-
sert O-rings in the grooves of the joints before tight-
ening.
NOTE: Apply ATF to the O-rings when inserting
them. If ATF is not applied, the O-rings will
not be inserted smoothly and will thus be
damaged, causing oil to leak.
SMAT-077
Fig. 14
21. REMOVE THE CAP OF THE OIL FILLER TUBE AND
POUR TRANSMISSION FLUID INTO THE TUBE.
Fluid to be Used:
Atmospheric temperature
Below 30˚C (86˚F) : ATF DEXRON or ATF
DEXRON II
Above 0˚C (32˚F) : Type C-3, SAE30
Oil Volume: Refer to Item 4. CHECK THE TRANSMIS-
SION FLUID LEVEL on Page 75-26.
NOTE: ● For further details, consult your nearest
ALLISON representative or ALLISON ser-
vice station.
● Vehicles shipped from the HINO factory
contain DEXRON or DEXRON II type fluid.
 1 page 1
75-18 AUTOMATIC TRANSMISSION Models FD, FE, FF and SG (ALLISON AT542, AT545 and MT643)

SHIFT CONTROL LINKAGE

3
4
5

1. Selector lever assembly

2. Clamp
3. Grommet
4. Shift cable assembly
5. Lock nut

Fig. 1
1. REMOVAL OF THE SELECTOR LEVER ASSEMBLY.
1. Remove the console box.
2. Disconnect the pilot lamp harness.

Fig. 2
 1 page 1
Models FD, FE, FF and SG (ALLISON AT542, AT545 and MT643) AUTOMATIC TRANSMISSION 75-19

3. Disconnect the shift cable from the selector lever

assembly.

SMAT-099
Fig. 3
4. Remove the clamp and grommet from the floor of
the cab.

SMAT-100
Fig. 4
5. Remove the selector lever assembly from the floor
of the cab.

SMAT-101
Fig. 5
2. REMOVAL OF THE SHIFT CABLE
1. Raise the cab (Refer to OWNER'S MANUAL, cab
tilt procedure).

WARNING
Secure the safety pin.
After raising the cab, completely insert the safety
pin in the safety pin hole.
Otherwise the cab might come down and cause
personal injury.

LOCKING COMPLETE LOCKING INCOMPLETE

Safety pin holder is completely in contact Safety pin is not completely inserted, or is
with the cab stopper stay, and the pin not turned in the down position.
holder is turned in the down position.
SAFETY PIN
SAFETY PIN

SM19-500 SM19-500
Fig. 6
 1 page 1
75-20 AUTOMATIC TRANSMISSION Models FD, FE, FF and SG (ALLISON AT542, AT545 and MT643)

2. Remove the pin and disconnect the manual lever at

the transmission. (Side of the transmission)

SMAT-102
Fig. 7
3. Disconnect the shift cable from the bracket.

SMAT-103
Fig. 8
4. Remove the cable.
a. Remove the cable fitting bolts.
b. Remove the cable fitting clamp.

Fig. 9
INSPECTION AND REPAIR
INSPECT THE SHIFT CABLE END.
1. Check the shift cable for wear and damage.
If necessary, replace the parts.

Fig. 10
2. Replace the bush.
a. Remove the old bushing.
b. Install the new bushing.

SMAT-104
Fig. 11
 1 page 1
Models FD, FE, FF and SG (ALLISON AT542, AT545 and MT643) AUTOMATIC TRANSMISSION 75-21

3. Replace the pilot lamp bulb, if necessary.

SMAT-105
Fig. 12
1. INSTALL THE SELECTOR LEVER ASSEMBLY.
1. Install the selector lever assembly to the floor of the
cab.

SMAT-101
Fig. 13
2. Install the shift cable fitting clamp and grommet.

SMAT-100
Fig. 14
3. Connect the shift cable to the selector lever.
NOTE: When connecting the shift cable, it must be
connected to the selector lever at the center
hole of the selector lever.
Tightening Torque: 190 - 260 kg·cm (14 - 18 lb·ft)

SMAT-099
Fig. 15
 1 page 1
75-22 AUTOMATIC TRANSMISSION Models FD, FE, FF and SG (ALLISON AT542, AT545 and MT643)

4. Install the console box.

5. Connect the pilot lamp harness.

2. INSTALL THE SHIFT CABLE.

1. Raise the cab (Refer to OWNER'S MANUAL, cab
tilt procedure).

WARNING
Secure the safety pin.
After raising the cab, completely insert the safety
pin in the safety pin hole.
Otherwise the cab might come down and cause
personal injury.

LOCKING COMPLETE LOCKING INCOMPLETE

Safety pin holder is completely in contact Safety pin is not completely inserted, or is
with the cab stopper stay, and the pin not turned in the down position.
holder is turned in the down position.
SAFETY PIN
SAFETY PIN

SM19-500 SM19-500
Fig. 16

2. Install the shift cable.

a. Install the shift cable fitting bolts.
b. Install the shift cable fitting clamp.
NOTE: The shift cable should not bent sharply. Any
looping should have a radius of more than
150 mm (5.906 in.).

RR

SMAT-102
Fig. 17
 1 page 1
Models FD, FE, FF and SG (ALLISON AT542, AT545 and MT643) AUTOMATIC TRANSMISSION 75-23

3. Connect the shift cable to the transmission lever to

align with hole in lever. Refer to section "ADJUST-
MENT AND INSPECTION" for detailed adjusting.

SMAT-102
Fig. 18
4. Connect the shift cable at the support bracket and
tighten the nuts temporaily.

SMAT-103
Fig. 19
 1 page 1
75-24 AUTOMATIC TRANSMISSION Models FD, FE, FF and SG (ALLISON AT542, AT545 and MT643)

ADJUSTMENT AND INSPECTION

1. ADJUST THE SELECTOR LEVER LINKAGE.
Proper adjustment of the manual selector lever link-
age is important because the shift lower gate posi-
tions must correspond exactly to the detents in the
transmission. Periodic checks should be made for
bent or worn parts, loose bolts or threaded connec-
tions and accumulation of grease and dirt. All mov-
ing joints should be kept clean and lubricated.
The selector lever should move easily and give a feel
of positive engagement in each position. The pin
that engages the selector lever linkage at the trans-
mission should move freely in each range. Refer to
Adjustment and Inspection in this section.

1. Position the transmission selector lever in the "N"

position.

SMAT-068A
Fig. 1
2. Disconnect the shift cable lock nut.

SMAT-103
Fig. 2
3. Shift the transmission manual lever to the "N" posi-
tion.

SMAT-063A SM8-050
Fig. 3
 1 page 1
Models FD, FE, FF and SG (ALLISON AT542, AT545 and MT643) AUTOMATIC TRANSMISSION 75-25

4. With the transmission manual lever in the "N" posi-

tion, adjust the shift cable by lock nut then connect
the shift cable to the manual lever and pin.
Shift cable dimension: "A" 200 mm (7.87 in.)
5. Tighten the lock nuts of the shift cable after adjust-
ment.

"A"

SMAT-103
Fig. 4
6. Place the selector lever in all positions to make cer-
tain that the manual lever at the transmission has
full detent in all gear ranges. It may be necessary to
readjust the shift cable slightly to obtain detent in all
drive ranges.

SM08-050
Fig. 5
2. ADJUST THE MODULATOR CABLE LENGTH.
1. Move the engine throttle lever to the "Full" position
by hand.
2. Draw out the modulator cable fully by hand, and
adjust the cable length so as to leave 1 to 2 mm out
A
of the throttle lever fitting.
Modulator Cable Tension Allowance (A);
1 - 2 mm (0.04 - 0.07 in.)
3. Attach the modulator cable to the throttle lever.
Lock the connector with lock nut and install the plain
washer and cotter pin and spread it.
4. Lock the cable on the bracket.

SM75-017A
Fig. 6
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75-26 AUTOMATIC TRANSMISSION Models FD, FE, FF and SG (ALLISON AT542, AT545 and MT643)

3. TRANSMISSION DRAINING AND REFILLING

1. If the fluid is cold, operate the transmission until a
normal operating temperature, 71 - 93˚C (160 -
200˚F), is reached.
2. Remove the drain plug from the transmission pan
and allow the fluid to drain.
3. When the fluid has stopped draining, replace the
drain plug.
SMAT-043
Fig. 7
4. Remove the dipstick and pour approximately ten
quarts of transmission fluid into the transmission
through the filler tube.

SMAT-061
Fig. 8
5. With the vehicle standing level, apply the parking
brake and place the selector lever in N. Operate the
engine at idling speed.
6. If the transmission fluid is cold, operate the trans-
mission until normal operating temperature is
reached.
7. When the engine and transmission have reached
their normal operating temperatures, shift the selec-
SMAT-073A tor lever through all the range positions to make sure
Fig. 9 that warm fluid is distributed throughout the trans-
mission. Return the selector lever to N.
8. Check the fluid level with the dipstick. The safe op-
erating level is between the two HOT marks on the
dipstick. If the fluid level is low, add sufficient fluid
to bring the level between two HOT mark. If the level
is too high, drain excess fluid to attain a proper level.

SMAT-074
Fig. 10
4. CHECK THE TRANSMISSION FLUID LEVEL.
With the truck standing level and the parking brake
applied, start the engine and move the transmission
shift lever through all the shift positions, allowing
sufficient time in each range to engage the transmis-
sion. After engaging each transmission range, place
the selector lever in the N (NEUTRAL) position. The
engine should be running at idling speed and the
SMAT-073A engine and transmission at operating temperature.
Fig. 11 Do not turn off the engine during the fluid level check.
 1 page 1
Models FD, FE, FF and SG (ALLISON AT542, AT545 and MT643) AUTOMATIC TRANSMISSION 75-27

1. Clean all dirt from the transmission fluid dipstick cap

before removing the dipstick from the filler tube.
2. Pull the dipstick out of the tube, wipe it clean, and
push it back into the tube. Be sure it is fully seated.
NOTE: The dipstick has two (2) hot marks and two
(2) cold marks.

SMAT-074
Fig. 12
3. Hot oil check
Engine idling and transmission normal operating tem-
perature 71 - 93˚C (160 - 200˚F) : pull the dipstick
out and check the fluid level. The level should be
between the two HOT marks. If additional fluid is
required, add enough fluid through the filler tube to
bring the level between the two HOT marks on the
dipstick. Do not overfill the transmission, as foam-
SMAT-074 ing and loss of fluid through the vent may result in
Fig. 13 transmission malfunction.
4. Cold oil check
Engine idling and transmission at 16 - 33˚C (60 -
100˚F), cool to touch: pull the dipstick out and check
the fluid level.
The level should be between the bottom two COLD
marks. If additional fluid is required, add oil to bring
the level between the two COLD marks.

SMAT-074 5. Replace the dipstick in the tube, making sure it is

Fig. 14 fully seated.