This 52-page Allison AT 500 1500 tips document (publication MT1321EN) is the official Mechanic’s Tips handbook for servicing AT 500 and AT 1500 series automatic transmissions. It covers preventive maintenance, fluid and filter service, transmission removal and installation, flexplate inspection measurements, and modulator control adjustment.
Official Allison AT 500 1500 tips document details
| Brand | Allison Transmission |
| Model coverage | AT 540, AT 542, AT 542N, AT 542R, AT 542NR, AT 542NFE, AT 543, AT 545, AT 545N, AT 545R, AT 545NR, AT 1542, AT 1542P, AT 1542NP, AT 1545, AT 1545P, AT 1545NP |
| System / Group | Automatic transmission — Mechanic’s Tips |
| Publication no. | MT1321EN / MT4108EN |
| Year / Revision | June 1996; Revision 1, April 1999 |
| Pages | 52 |
| File size | 0.5 MB |
| Format | |
| Language | English |
Document table of contents
- Section I — Preventive Maintenance: periodic inspection, fluid level importance, dipstick markings, fluid check procedure, keeping fluid clean, recommended ATF and viscosity grade, fluid and filter change intervals and procedure, fluid contamination, auxiliary filter, breather, transmission stall test and neutral cool-down check
- Section II — Removing Transmission: draining, disconnecting controls, uncoupling engine from driveline, removing mounting bolts, removing transmission, repair instructions
- Section III — Preparing Transmission for Installation: checking input components, torque converter position, installing parking brake and output flange, shift selector lever, PTO, shift modulation control, fill tube and drain plug, neutral start and reverse signal switches, retarder controls, checking breather
- Section IV — Preparing Vehicle for Transmission Installation: checking flexplate and engine features, chassis and driveline, cooler/tubes/hoses/fittings, controls
- Section V — Installing Transmission into Vehicle: handling, coupling to engine, mounting components, coupling to driveline, vacuum or air modulator control, connecting cooler and lines, retarder controls
- Section VII — Service Literature: related service manuals, parts catalogs, technician’s guides, operator’s manuals
Applicable truck models
This handbook applies to all vehicles equipped with Allison AT 500 and AT 1500 series automatic transmissions, including the AT 540, AT 542 (and N, R, NR, NFE variants), AT 543, AT 545 (and N, R, NR variants), AT 1542 (P, NP), and AT 1545 (P, NP). It provides flexplate measurement tolerances (flywheel housing bore diameter 16.125–16.130 in., bore eccentricity 0.020 in. T.I.R., converter pilot diameter 1.703–1.705 in.), pan screw torque values (10–15 lb ft), drain plug torque (15–20 lb ft), fill tube fitting torque (65–75 lb ft), and modulator cable travel specifications (1.187–1.560 in.). Related service manual SM1241EN and parts catalogs PC2126EN / PC1235EN are referenced for full overhaul procedures. For official support, visit Allison Transmission’s official website.
Who needs this Allison AT 500 1500 tips manual
Fleet mechanics, independent workshop technicians, and vocational truck operators responsible for maintaining or replacing AT 500 and AT 1500 series transmissions will find this guide essential for correct preventive maintenance intervals, proper removal and installation sequences, and critical adaptation measurements.
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