HD4000 OWNERS MANUAL - Weller

REMAN CENTER Your Source for Quality Remanufactured Drivetrain Products MD3000/HD4000 OWNERS MANUAL Tag # Mileage In:...

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MD3000/HD4000 OWNERS MANUAL Tag #������������������������������������ Mileage In:����������������������� Date Installed:��������������������������

REMAN CENTER Your Source for Quality Remanufactured Drivetrain Products

WELLER REMAN The Nation’s Complete Drivetrain Program! Transmissions and Transfer Cases –

Quality Rebuilt by WELLER in Grand Rapids, MI. Light to Heavy Duty. Borg Warner • Clark • Cotta • Fuller • FWD • IHC • Isuzu • Mack/PAI • Meritor/Rockwell • New Process GMC • New Venture • Noster • Oshkosh • Spicer/TTC • ZF A complete line of Auxiliaries and Transfer Cases.

Allison Transmissions –

Quality Rebuilt by WELLER in Grand Rapids, MI. Light to Heavy Duty. An Authorized Allison Dealer in Grand Rapids, MI, rebuilding off-road transmissions and components for Allison • Clark • IHC • Dresser • Funk • Twin Disc • Borg Warner

Steering Gear Boxes and Pumps –

All units are tested on our state-of-the-art XLT3 Road Simulator TRW-Ross • Saginaw • Sheppard • Vickers Pumps • ZF • Eaton • Luk

Differentials –

Complete Stock for quick exchange. Clark • FWD • GMC • IHC • Industrial/Off Road • Mack/PAI • Meritor/Rockwell • Spicer/Eaton • Terex

Medium Duty Automatic Transmissions – Quality Rebuilt by WELLER in Grand Rapids, MI. All Units Dyno Tested. Aisin • Jatco • Isuzu • GMC • Ford • Mercedes

THE WELLER REMAN NETWORK 2

PROGRAM DESCRIPTION

Weller’s Unit Exchange program eliminates down time by getting you the parts you need when you need them. With over 15­,000 rebuilt transmissions and differentials ready to ship, we can help you eliminate your or your customer’s downtime. Consider becoming a key partner in the industry’s leading drivetrain program today. With no commitments and no minimums, we are the industry partner for you! Our aggressive reman program includes: • All Makes Coverage – One Call • Same Day Service • Obsolete and Discontinued Specialists • One-year Warranty • 15,000 Unit Stock – It’s Available Today!

• E  xcellent Core Policy (call for details) • ASE-certified, manufacturer-trained mechanics • Technical Support on Questions

WELLER REMAN HAS THE ADVANTAGE!

THE WELLER REMAN NETWORK 3

ALLISON TRANSMISSIONS

✔✔ 100% Genuine Allison ✔✔ Outstanding Availability ✔✔ Quality Remanufacturing ✔✔ Every unit dyno tested ✔✔ New Genuine Allison Torque Converter on all AT Units ✔✔ Quality rebuilt valve bodies matched to original unit ✔✔ Priced for the best value Two year, unlimited mile warranty on On-highway applications Six month warranty on Off-highway applications Weller Reman Center, Grand Rapids, MI is an Authorized Allison Dealer

Popular Models AT540 Series 1000/2000 Series B400, B500 HD4560,HT740/750 MD3060, MT643….. EVERYTHING!

Remanufactured by experts in Allison transmissions THE WELLER REMAN NETWORK 4

DYNO TESTING

All transmissions are dyno tested with a load to simulate real truck conditions. Every transmission is evaluated to ensure proper torque, no leakage, accurate shift points, and correct main psi and clutch pressure.

THE WELLER REMAN NETWORK 5

INSTALLATION GUIDE VEHICLE MAKE AND MODEL�����������������������

TRANSMISSION ASSEMBLY NO.��������������������

MECHANIC’S NAME������������������������������

VEHICLE ID NO.���������������������������������

I. PROPER TORQUE

• All control module bolts – 38-45 lb ft (51-61 N-m)^t.................................................................................................... ¨ • Speed sensor bolts – 18-21 lb ft (24-29 N-m)^t............................................................................................................ ¨ • Flexplate to crankshaft hub bolts – Consult engine manufacturer specifications............................................................. ¨ • Flexplate to flexplate adapter bolts – 38-45 lb ft (51-61 N-m)………........................................................................... ¨ • Fluid drain plug – 18-24 lb ft (25-32 N-m)^t.…............................................................................................................ ¨ • Fluid fill tube bracket – 18-21 lb ft (24-29 N-m)............................................................................................................ ¨ • Control module pressure taps – 7-10 lb ft (10-13 N-m)................................................................................................. ¨ • Cooler fittings................................................................................................................................................................ ¨ • Cooler port cover bolts – 38-45 lb ft (51-61 N-m).......................................................................................................... ¨ • Flexplate adapter to converter cover bolts – 18-21 lb ft (24-29 N-m)............................................................................. ¨ • Output flange bolts – 52-59 lb ft (70-80 N-m)................................................................................................................ ¨ • PTO cover bolts 38-45 lb ft (51-61 N-m)........................................................................................................................ ¨ • PTO mounting bolts – 38-45 lb ft (51-61 N-m)............................................................................................................... ¨ • Breather – 9-12 lb ft (12-16 N-m).................................................................................................................................. ¨ • PTO pressure hose to transmission 7-10 lb ft (10-13 N-m)............................................................................................ ¨ • 20-way transmission feedthrough connector bolt – 18-28 lb inch (2.0-3.2 N-m)............................................................ ¨ • Rear cover bolts – 66-81 lb ft (90-110 N-m).................................................................................................................. ¨ • TPS to transmission bracket (M6 bolts) – 84-120 lb inch (10-13 N-m) ¼-20 bolts – 108-132 lb inch (12-15 N-m)........ ¨

II. COOLER FLUID LINES AND AIR HOSE

• Check for leaks.............................................................................................................................................................. ¨ • Check for tightness of connections................................................................................................................................ ¨ • Check routing of lines.................................................................................................................................................... ¨

III. THROTTLE SENSOR

• Check for proper adjustment.......................................................................................................................................... ¨ • Check for proper routing of cable and harness............................................................................................................... ¨

IV. DRIVELINE

• Check for proper indexing of slip and universal joints..................................................................................................... ¨ • Determine if angles are within recommendations........................................................................................................... ¨ • Check for excessive backlash........................................................................................................................................ ¨ • Lubricate universals and slip joints................................................................................................................................ ¨

V. HYDRAULIC SYSTEM

• Recommended fluid – Allison approved TES-295 or TES-389 fluid................................................................................. ¨ • Fluid level correct for operating conditions..................................................................................................................... ¨ • Fill tube cap tight........................................................................................................................................................... ¨ • Fill tube tight.................................................................................................................................................................. ¨ • Breather clean and free of restriction............................................................................................................................. ¨ • Checked for fluid leaks during operation........................................................................................................................ ¨

VI. POWER TAKE OFF (PTO) (IF INSTALLED)

• Controls connected and operative.................................................................................................................................. ¨ • Properly coupled to driven equipment............................................................................................................................ ¨ • Lube line from transmission properly routed and connected........................................................................................... ¨

VII. INSTRUMENTS, ELECTRICAL COMPONENTS

• Wiring and electrical connections – functional .............................................................................................................. ¨ • Instruments, gauges, and lights work correctly.............................................................................................................. ¨ • Shift selector display is on and CHECK TRANS light is off............................................................................................... ¨ • Fluid temperature gauge................................................................................................................................................ ¨

THE WELLER REMAN NETWORK 6

INSTALLATION GUIDE ROAD TEST & VEHICLE OPERATION CHECKLIST MD3000 Series I. DRIVEABILITY

Drive-away checks are performed to verify proper transmission and support equipment installation and operation. The following steps outline drive-away check procedures: 1. Check fluid – fill the transmission with the appropriate fluid. 2. Start the vehicle – check for proper system response during start-up: a. Turn on the vehicle’s master/ignition switch. b. The CHECK TRANS light should come on. c. Start the engine. d. The CHECK TRANS light should go off. e. N should appear in the shift selector display. 3. Clear Trouble Codes – during installation, it is common for false codes to be stored in the electronic control’s TCM. These codes must be cleared prior to road testing the vehicle. 4. Road Test the Vehicle – allow the electronic control time to converge shifts. 5. Check for Proper Operation – check all components for proper mounting and operation, and check for transmission fluid leaks at gasket surfaces, lines and hoses. 6. Recheck for Trouble Code – use the Allison DOC® for PC-Service Tool or shift selector to determine if codes were set during the road test. 7. Troubleshoot – if codes exist after the road test, problems must be found and corrected (refer to TS3989EN, Allison 4th Generation Controls Troubleshooting Manual).

II. SERVICE & MAINTENANCE

Refer to the current issue of the 3000 and 4000 Product Family Service Manuals for detailed transmission service & maintenance installations. Refer to the latest Allison 4th Generation Controls Troubleshooting Manual for detailed electronic control system troubleshooting.

III. ROAD TEST CHECKLIST Complete the following checklist:

• Neutral Start Circuit:

- Starts only in N (Neutral...........................................................................................................................................

¨

- CHECK TRANS light and shift selector display......................................................................................................... - Transmission fluid pressure gauge – if used............................................................................................................. - Speedometer........................................................................................................................................................... - Temperature gauge – if used................................................................................................................................... - Reverse warning system – if used........................................................................................................................... • Transmission Fluid: - Fluid level meets specifications – cold, neutral, level................................................................................................ - No leaks.................................................................................................................................................................. • No-Load Governed Engine Speed: - No-load governed speed of engine........................................................................................................................... - Adjust governor as necessary – refer to manufacturer’s specifications for the engine-transmission being tested..... • Output Retarder: - Operation of the output retarder, if installed, while descending a grade or slowing on a level road............................ • PTO – if installed: - PTO operation – refer to the appropriate Operator’s Manual..................................................................................... • Shift Sequence: - Transmission upshifts and downshifts smoothly through all ranges.......................................................................... • Other Checks: - Stall test.................................................................................................................................................................. - Shift quality.............................................................................................................................................................

¨ ¨ ¨ ¨ ¨

• Instruments:

¨ ¨ ¨ ¨ ¨ ¨ ¨ ¨ ¨

Weller Reman will honor most types of automatic transmission fluids used in our automatic reman units. For specific Allison fluid information relating to current production units, please see www.Allisontransmission.com.

THE WELLER REMAN NETWORK 7

APPROVED LUBRICANTS TES295

Approved Marketer

Product Brandname

AN-011001

Castrol Heavy Duty Lubricants

TranSynd

AN-031002

BP Lubricants

Autran Syn 295

AN-031003

Cognis Corporation

Emgard 2805

AN-031004

International Truck & Engine Company

Fleetrite Synthetic ATF

AN-051005

ExxonMobil Lubricants and Petroleum Specialties Company

Mobil Delvac Synthetic AFT

AN-071006

John Deere & Company

HD SynTran

AN-1010007

Volvo Trucks North America

Bulldog Synthetic ATF

AN-121009

Case New Holland

CNH HD Synthetic ATF

AN-121008

Shell International Petroleum Co. LTD.

Shell Spirax S6 ATF A295

Approval Number

TES-389 Product Marketer

Product Brandname

NAmerica

CAmerica

Approval Number

BP Castrol

Castrol ATF Heavy Duty

Yes

Yes

AA-33182010

BP Castrol

Castrol ATF Heavy Duty

Yes

Yes

AA-33192010

BP Lubricants

Castrol Heavy Duty Multi-Purpose ATF

Yes

Yes

AA-32252007

BP Lubricants

Castrol Heavy Duty Multi-Purpose ATF

Yes

Yes

AA-32362007

Chevron Products Company

Chevron Automatic Transmission Fluid HD-389

Yes

Yes

AA-32012007

Chevron Products Company

Chevron Automatic Transmission Fluid HD-389

Yes

Yes

AA-32202007

Chevron Products Company

Chevron Automatic Transmission Fluid HD-389

Yes

Yes

AA-32242007

Chevron Products Company

Chevron Synthetic Automatic Transmission Fluid Heavy Duty

Yes

Yes

AA-31992007

Chevron Products Company

Texaco Automatic Transmission Fluid HD-389

Yes

Yes

AA-32002007

ExxonMobil Lubricants & Petroleum Specialties Co.

Mobile ATF D/M

Yes

Yes

AA-32792008

Fuchs Petrolub AG

Fuchs Titan ATF 4000

Yes

Yes

AA-32822010

Petro-Canada

Petro-Canada ATF D3M

Yes

Yes

AA-32082007

Ravensberger Schmierstoffvertrieb GMBH

Ravenol ATF III H

Yes

Yes

AA-33072010

Shell International Petroleum Co. LTD.

Spirax S2 ATF A389

Yes

Yes

AA-33242011

Shell Lubricants

Donax TA-389

Yes

Yes

AA-32212007

Shell Lubricants

Donax TX

Yes

Yes

AA-32332007

THE WELLER REMAN NETWORK 8

SERVICE INFORMATION LETTER

16-WT-96, Rev. A August, 1996 Product Code(s): Page 1 of 2 SUBJECT:  ECU Reset to Unadapted Shifts EQUIPMENT EFFECTED:  All WT Series Transmissions Introduction: This Service Information Letter is a reminder to distributors and dealer personnel. Whenever a transmission is overhauled, exchanged, or has undergone internal repairs, the Electronic Control Unit (ECU) must be “RESET TO UNADAPTED SHIFTS.” This will erase the ECU’s previous adaptive information and begin to adapt in Fast Adaptive Mode from the original base calibration. Selecting “RESET TO FAST ADAPTIVE” is not sufficient after the above-mentioned repairs. Service Procedure: Using the Pro-Link®9000 Diagnostic Reader, scroll down through the Menu and press ENTER at “ACTION REQUESTS.” Scroll through the “ACTION REQUESTS MENU” and press ENTER at “RESET TO UNADAPTED SHIFTS.” Pressing the ENTER key with [YES] selected resets the shifts to an unadapted state. Most vehicles will shift satisfactorily after “RESET TO UNADAPTED SHIFTS” is selected on the Pro-Link. If shifts are not satisfactory, drive the vehicle as described in the following procedure to properly adapt the shifts from the base calibration. NOTE: Shift concerns may indicate the transmission has never had the shifts fully adapted. • Adaptive does not function below 100 degrees Fahrenheit transmission sump temperature. Normal running hot sump temperature is recommended before this procedure is followed. • Check transmission sump level and assure it is set to “Hot Full” at normal running hot sump temperature before this procedure is followed. • All segments of this procedure are to be repeated a minimum of 5 times or until shift quality variation is indistinguishable from shift to shift.

Allison Transmission, Inc. Indianapolis, Indiana 46206-0894

KWH/mmw Copyright 2007 Allison Transmission, Inc. All Rights Reserved Please Note: Allison Transmission Service Information Letters are intended for use by professional, trained technicians, not for the “do-it-yourselfer”. They are written to inform those technicians of conditions that may occur on some transmission models (or serial number ranges) or to provide information that could assist in the proper servicing of a specific Allison transmission. Properly trained technicians have the equipment, tools, safety instructions, and know-how to do a job properly and safely. If a condition is described, do not assume that the Service Information Letter applies to your transmission, or that your transmission has the condition described. Product evolution and information updates are inevitable. Please see your authorized Allison Transmission service dealer or distributor to understand if your particular transmission may benefit from the information contained within the Service Information Letter. P.O. Box 894   Indianapolis, Indiana 46206-0894   (317) 242-5000   www.allisontransmission.com

THE WELLER REMAN NETWORK 9

SERVICE INFORMATION LETTER

16-WT-96, Rev. A August, 1996 Product Code(s): Page 2 of 2

1.  From Neutral, with parking brake set and service brakes applied via foot pedal, select the following sequence: Drive, Neutral, Reverse, Neutral, Drive, Reverse, Drive, Neutral. Allow each shift to fully complete before selecting the next shift. 2.  Release all brakes and perform this sequence: Wide Open Throttle (WOT) 1-2; once shift is complete, release the throttle to closed and decelerate to just prior to the Closed Throttle (CT) 2-1 and perform a Step Thru (ST) 2-1 by going to WOT. 3.  Continue the process initiated in #2 above for each Upshift and Downshift combination available. Example: Wide Open Throttle (WOT) 2-3; once shift is complete, release the throttle to closed and decelerate to just prior to the Closed Throttle (CT) 3-2 and perform a Step Thru (T) 3-2 by going to WOT. Repeat for the WOT 3-4/ST 4-3, WOT 4-5/ST 5-4, WOT 5-6/ST 6-5. 4.  From a Stop, release vehicle brakes and perform a set of Part Throttle (PT ~ 50% to 60%) Upshifts to the highest attainable range for the vehicle. Release the throttle to Closed and, using Light vehicle brakes, decelerate to a stop. NOTE: If the vehicle is equipped with an output retarder or engine brake system, these systems should be turned off for this segment. 5.  From a Stop, release vehicle brakes and perform Part Throttle (PT ~ 50% to 60%) Upshifts to 3rd range. Release the throttle to Closed and, using Moderate to Heavy vehicles brakes (NOT panic or wheel lock), decelerate to a stop. NOTE: Braking should be aggressive but not to the level that would cause passenger complaints. If the vehicle is equipped with an output retarder or engine brake system, these systems should be turned off for this segment. 6.  From a Stop, release vehicle brakes and perform a set of Wide Open Throttle Upshifts to the highest attainable range for the vehicle. Release the throttle to Closed and Preselect Down to 1st Range using the shift selector. Use light vehicle brakes, decelerate to a stop. 7.  If the vehicle is equipped with a retarder or engine brake, turn that system on for this segment. From a Stop, release vehicle brakes and perform a set of Wide Open Throttle Upshifts to the highest attainable range for the vehicle. Release the throttle to Closed and, using Light vehicle brakes and the retarder or engine brake, decelerate vehicle to a stop.

NOTE: Allison Transmission does not recommend using the vehicle brakes to “force” Powered Downshifts (PD, downshifts with the throttle applied). If grades are available, these should be used to adapt in WOT and PT Powered Downshifts.

8.  Approach the grade in the highest safely attainable range and hold the throttle steady at WOT and allow the vehicle to perform the Powered Downshifts as required to ascend the grade. 9.  Approach the grade in the highest safely attainable range and hold the throttle steady at Part Throttle (PT~ 50% to 60%) and allow the vehicle to perform the Powered Downshifts as required to ascend the grade.

THE WELLER REMAN NETWORK 10

CORE RETURN INSTRUCTIONS The Weller Truck Parts core return program is designed to facilitate an efficient and cost effective way of returning your cores. Following the instructions listed below will insure your core is processed quickly and correctly. 1. A  ttach the Core Return Tag provided with the remanufactured unit to core. ⦁ For warranty units, obtain a Warranty Repair Authorization (RA#) from your Weller Truck Representative. If you are not sure who your representative is call the Reman Center at 1-800-872-6697 or email [email protected] 2. P  repare the unit for shipping. ⦁ Drain oil from unit. ⦁ Band, wrap, or strap unit(s) to a pallet. ⦁ Attach a copy of the warranty invoice, core tag or RA# to the unit for identification. 3. Notify Weller Shipping Department when unit is ready for pick up. ⦁ Email [email protected] or call 1-800-872-6697 Ext. 3794 or 3759 ⦁ Provide the following: ◆ Core return tag # or Weller Truck Parts invoice # or the RA# if the unit is a possible warranty ◆ Your contact information ◆ Hours of operation ⦁ Weller will prepare the bill of lading and schedule your unit to be picked up by a Weller approved carrier. Thank you for choosing Weller Truck Parts.

Failure to follow these procedures could result in core credit delays and freight charge backs.

www.wellertruck.com

THE WELLER REMAN NETWORK 11

WELLER WARRANTY WARRANTY STATEMENT Warranty Coverage

• Nationwide

Standard Warranty Coverage Weller Reman Allison Transmissions for “on-highway” applications – Two year, unlimited mileage – parts and labor. Weller Reman Allison Transmissions for “off-highway” applications – Six months, unlimited hours – parts and labor.

• Two Year Coverage

Authorized Repair Points – Our Nationwide Warranty may be administered only by an authorized warranty repair facility. Call 1-800-872-6697 for authorization.

• Unlimited Mileage • 800-872-6697 Tech Line For Troubleshooting • Call For Authorization And Assistance • Metal tag must not be removed or warranty will be void

Exclusions – Subject to the conditions stated herein, Weller warrants to the original retail purchaser thereof that its Reman products will, when used in a motor truck for on-highway or on/off-highway applications in the United States and properly installed and assembled on vehicles approved by the O.E.M. for such purpose, be and remain under normal conditions of use and operation free from failure due to defects in materials and workmanship from the date of sale. This warranty covers parts and labor to repair or replace, at Weller’s option, the failed Weller component. Units installed as replacements under this warranty are warranted only for the remainder of the original warranty period. This warranty shall not extend to failures or damage due to improper lubrication or operation in excess of original design limitations, failure to follow normal published preventive maintenance guidelines of the O.E.M., abuse or damage by improper installation, casualty or shipment. This warranty shall not extend to repairs for noise (including idle rattle), excessive operating temperature, transmission rear seal leakage, nor does it cover failures caused by engine, clutch, driveline; including transmission synchronizer pin breakage, or other truck components or system. This warranty does not cover failures caused by a worn, damaged or defective part or component mounted to the unit by the dealer or retail purchaser, including without limitation, the transmission end yoke. All warranty claims shall be made to Weller and shall be supported by satisfactory evidence in respect of the conditions stated herein. As a condition precedent to the allowance of such claims, the component or assembly involved shall, if requested by Weller, be returned prepaid to Weller for examination. EXCEPT FOR THE EXPRESS WARRANTY STATED HEREIN, WELLER DISCLAIMS ALL WARRANTIES, EXPRESS OR IMPLIED, INCLUDING WITHOUT LIMITATION THE IMPLIED WARRANTIES OF MERCHANTABILITY AND FITNESS FOR A PARTICULAR PURPOSE. THE FOREGOING IS THE LIMIT OF THE LIABILITY OF WELLER, AND IS THE EXCLUSIVE AND SOLE REMEDY OF THE PARTY TO WHOM THIS WARRANTY IS MADE. LIABILITY ON THE PART OF WELLER FOR DAMAGES, EXPRESSLY INCLUDING CONSEQUENTIAL DAMAGES IS DISCLAIMED. This warranty may not be changed or modified in any way except in writing by Weller.

THE WELLER REMAN NETWORK 12

WELLER WARRANTY CALL WELLER FIRST! • • • •

Possible Warranty

Have the Weller Tag or Invoice Number ready when calling. Provide the Make/Model and vocation of the truck. Provide a detailed description of the problem Weller will issue a Repair Authorization #

Customer Repair

(In Place Fix) Customer to determine failure/repair cost and get Weller approval before work is started.

Weller Repair

(R&R) Weller to determine failure/repair cost and get customer approval before work is started.

Non-Warranty

Warranty

• Complete the work • Send the invoice to Weller. The Repair Authorization # will become the purchase order #. • Weller will pay agreed amount

Unit Replaced

(Exchange) • Weller ships replacement unit • Replacement unit is installed • Truck is up and running • Invoice your customer until warranty process is complete

• If non-warrantable failure, repair and dealers invoice your customer. • Weller will invoice for unit repaired by Weller.

Customer returns possible warranty unit to Weller for failure analysis Weller performs failure analysis and determines failure responsibility

Failure Analysis Not Complete

Failure Analysis Complete

Warranty

Dealers Invoice your Customer

• Complete the work • Send the invoice to Weller. The Repair Authorization # will become the purchase order #. • Weller will pay agreed amount

Non-Warranty

• If non-warrantable failure, repair and dealers invoice your customer. • Weller will invoice for unit repaired by Weller.

THE WELLER REMAN NETWORK 13

WARRANTY CLAIM FORM Date:���������������������

TAG #:��������������������

Claim Contact Information:

Vehicle Owner Information:

Name, Company, and Address:

Name, Company, and Address:

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����������������������������������

�����������������������������������

Phone: ���������������������������

Phone: ����������������������������

Fax: ������������������������������

Fax: �������������������������������

E-Mail: ���������������������������

E-Mail: ����������������������������

1500 Gezon Parkway SW Grand Rapids, MI 49509 616-724-2000 800-872-6697 Fax 616-365-5679

Truck Information:

Make: Model: Mileage: Vocation: Engine: VIN:

COMPLAINT Description of the Problem:

Fluid Leak:

❏ Yes  ❏ No

Shifting:

❏ Yes  ❏ No

����������������������������������������������������������������������

Noise:

❏ Yes  ❏ No

����������������������������������������������������������������������

Vibration:

❏ Yes  ❏ No

����������������������������������������������������������������������

Hard Steering:

❏ Yes  ❏ No

����������������������������������������������������������������������

Contamination:

❏ Yes  ❏ No

����������������������������������������������������������������������

Other:

❏ Yes  ❏ No

���������������������������������������������������������������������� ���������������������������������������������������������������������� ����������������������������������������������������������������������

ADDITIONAL INFO Change with Speed?

❏ Yes  ❏ No

Suspension Modified Recently?

❏ Yes  ❏ No

Change with RPM? During Acceleration?

❏ Yes  ❏ No

Driveline in Phase?

❏ Yes  ❏ No

❏ Yes  ❏ No

Engine Mounts Checked?

❏ Yes  ❏ No

During Deceleration?

❏ Yes  ❏ No

King Pin Checked?

❏ Yes  ❏ No

When Stationary?

❏ Yes  ❏ No

Hydraulic Brakes?

❏ Yes  ❏ No

Fluid at Proper Level?

❏ Yes  ❏ No

System Flushed & Filter Replaced?

❏ Yes  ❏ No

Fluid Clean?

❏ Yes  ❏ No

Is the Unit Getting Hot?

❏ Yes  ❏ No

Vehicle Towed?

❏ Yes  ❏ No

Running PTO?

❏ Yes  ❏ No

EMAIL TO: [email protected] FAX TO: 616-365-5679, WELLER TRUCK PARTS WARRANTY 14

WELLER WARRANTY Warranty

The following table shows warranty flat rates for Allison transmissions:

It is essential that Weller is contacted before the unit is removed from the vehicle for warranty. Weller’s technician will assist in troubleshooting the problem. If the unit failed, the unit will be filmed, documented, and warranty determined.

Allison Model

The following are the maximum flat rates for failures due to defective products or workmanship:

• Units do not have to be installed at a Dealer to receive flat rate warranty

• Flat Rate Warranty is available on over the counter sales

Flat Rate Credit

1000 SERIES GM APPL

$500

1000 SERIES STD APPL

$500

2000 SERIES

$500

2400 SERIES

$500

AT540, 542, 542N, 545

$500

AT545N, 545R

$500

B400R

$800

B500

$800

B500R

$800

HD4060, HD4060P, HD4560

$800

HT70, HT740, HT740RS

$800

HT750, HT750CRD, HT750DRD

$800

HT754, HT754CR, HT754CRD

$800

MD3060, MD3060P, MD3066P

$700

MD3560, MD3560P

$700

MT640, MT643

$600

MT650, MT653

$600

MT654

$600

Authorized Weller Dealers call for warranty labor hours guidelines.

THE WELLER REMAN NETWORK 15

THE WELLER REMAN NETWORK 20

16

10

5 15 6

18

23

1 9 21 7

3

24 19 13 14

17 2 4 8 12 11 22

1

Reman Center

2

Atlanta, GA

1500 Gezon Pkwy S.W. Grand Rapids, MI 49509 616-724-2000 800-872-6697

5007 Clark Howell Highway, Suite A Atlanta, GA 30349 404-768-9577 877-768-9577

3

Baltimore, MD

899 Airport Park Rd., Ste. N Glen Burnie, MD 21061 410-553-0443 877-550-0443

9

Detroit, MI

29826 W. Eight Mile Road Farmington Hills, MI 48336 248-473-1900 800-473-1905

10 Gaylord, MI

353 Expressway Court Gaylord, MI 49735 989-731-6700 888-731-6700

11 Houston, TX

4549 Aldine Bender Houston, TX 77032 281-442-8855 877-677-8855

FL 12 Jacksonville, 10330 Chedoak Court

17 Nashville, TN

230 Molly Walton Drive Hendersonville, TN 37075 615-264-2750 866-426-2750

18 Omaha, NE

8623 S. 117th St. LaVista, NE 68128 402-597-9000 855-597-9001

19 St. Louis, MO

2388 Chaffee Drive Maryland Heights, MO 63146 314-692-2227 877-992-2227

20 Seattle, WA

4

Birmingham, AL



6408 South 196th Street Kent, WA 98032 253-872-0321 877-572-0321

5

Boise, ID

Las Vegas, NV 13 2985 Coleman St., Suite 14



14 Los Angeles, CA

Tampa, FL 22 217 Hobbs Street

116 Total Solutions Way Alabaster, AL 35007 205-685-0777 866-535-0777 8484 W. Victory Road Boise, ID 83709 208-331-1061 888-331-1061

6

Chicago, IL

11152 Southwest Highway Palos Hills, IL 60465 708-974-9919 888-974-9319

7

Columbus, OH

2885 International St. Columbus, OH 43228 614-771-9500 866-771-9501

8

Dallas, TX

3113 Skyway Circle N Irving, TX 75038 972-258-0460 855-258-0460

Suite 205 Jacksonville, FL 32218 904-757-0777 888-474-0777

North Las Vegas, NV 89032 702-638-8222 866-764-8222 9355 Cherry Ave. Fontana, CA 92335 909-356-8322 877-356-8322

15 Milwaukee, WI

8625 North 107th Milwaukee, WI 53224 414-354-6400 877-354-6400

16 Minneapolis, MN

3201 85th Avenue North Brooklyn Park, MN 55443 763-424-3800 877-424-3802

Bend, IN 21 South 3303 William Richardson Ct.

Suite 200 South Bend, IN 46628 574-237-1000 800-968-8860

Suite 103 Tampa, FL 33619 813-685-6100 866-685-6109

Lake City, UT 23 Salt 3450 W. California Ave.



Suite 400 Salt Lake City, UT 84104 801-886-0100 855-847-0100

CO 24 Denver, Drive Train Industries