Allison Transmission Installation Instructions

1000 / 2000 Series Install Packet

CRITICAL WARNING!

Warranty will be VOID if the install process is not followed and all documentation is not returned on time!

Download the Allison Transmission 1000/2000 Series Installation Packet

Download the Allison Transmission SIL Installation Companion Packet here.

The warranty will be VOID if install process is not followed and all documentation is not returned on time!

1. Contamination from cooler will FAIL the transmission!

Cooler must be free of any debris or leaks. This includes cooler lines and fittings. Every cooler at minimum needs to be thoroughly flushed and tested. It is highly recommended to replace the transmission cooler at time of transmission replacement. Cooler failure is not covered by Reaction Force LLC warranty in any form.

* Every unit Reaction Force LLC receives is tested for glycol contamination.

2. Contamination from PTO/Pump will FAIL the transmission!

Contamination from Transmission mounted PTO/Pumps is NOT covered by Reaction Force LLC warranty in any way. Improper installation of PTO/Pump will void warranty. Please ensure all brackets and Allison Transmission Guidelines are followed. If you require information on proper installation guidelines, please email service@reactionforcellc.com.

3. Improper Adaptions, Outputs, and Controls will FAIL the transmission!

Please check all adaptions for cracks or wear. Allison Transmission SIL 60-TR-81 must be followed to keep your warranty in place. Please follow the process and fill out all sections in the Checksheet Form and return to Reaction Force LLC to process your warranty coverage.

For any questions please email service@reactionforcellc.com
Call us today at (503) 862-6322. We are happy to help!

This is only the first page of an 18-page service information letter installation packet from Allison Transmissions.

Please download the entire Allison Transmission SIL Installation Packet here.

Allison Transmission Service Information Letter October 2025
  1. Check Engine Adaption parts.
  2. Check all mounting points and bolt holes and clean if needed.
  3. Check input and output flanges and yokes for wear or damage.
  4. Driveline issues will cause failure of transmission.
  5. Check that all wire harnesses and electrical connections are clean and without damage.
  6. Check all linkages and shifting mechanisms for proper function. Worn shift linkages will fail transmissions!

IMPORTANT!

For your warranty to be intact, all documentation must be returned within 48 hours of transmission installation and back in service date. If you are uncertain about any of the installation process, please contact Reaction Force LLC at (503) 862-6322 prior to install.

We are happy to help with any of this process and we want this transmission to last the maximum life possible.

DUTY CYCLE: GENERAL

General Vocations: All vocations not classified as Severe

Allison approved fluid TES 668®/295®

Fluid Capacity: 1000/2000 Series shallow pan: 10 quarts (2.5 gallons)
Miles: 150,000 or 240,000 km
Time: 4,000 hours or 48 months

Allison approved fluid TES 389®

Fluid Capacity: 1000/2000 Series shallow pan: 10 quarts (2.5 gallons)
Miles: 50,000 or 80,000 km
Time: 2,000 hours or 24 months

DUTY CYCLE: SEVERE

Severe Vocations: On/Off highway, refuse, city transit, shuttle transit

Allison approved fluid: TES 668®/295®

Fluid Capacity: 1000/2000 Series deep pan: 12 quarts (3 gallons)
Miles: 75,000 or 120,000 km
Time: 3,000 hours or 36 months

Allison approved fluid TES 389®

Fluid Capacity: 1000/2000 Series deep pan: 12 quarts (3 gallons)
Miles: 12,000 or 20,000 km
Time: 500 hours or 6 months

DUTY CYCLE: GENERAL OR SEVERE

Fluid Capacity: 1000/2000 Series shallow pan: 10 quarts (2.5 gallons)
Fluid Capacity: 1000/2000 Series deep pan: 12 quarts (3 gallons)

Allison approved fluid TES 668/295®

Fluid Change: When indicated by controller or 48 months, whichever occurs first

Allison approved fluid TES 389®

Fluid Change: When indicated by controller or 24 months, whichever occurs first

Installation Checksheet

 

Torque values

  1. All oil pan bolts—24–29 N·m (18–21 lb ft)
  2. Main pressure tap—10–13 N·m (7–10 lb ft)
  3. Cooler fittings—0.750–16 (inch series), 30–36 N·m (22–27 lb ft);1.0625–12 (inch series), 56–69 N·m (41–51 lb ft)
  4. Cooler manifold bolts—24–29 N·m (18–21 lb ft)
  5. Flexplate adapter-to-converter cover bolts—57–68 N·m (42–50 lb ft)
  6. Flexplate-to-crankshaft hub bolts—consult engine manufacturer specifications
  7. Flexplate-to-flexplate adapter bolts—57–68 N·m (42–50 lb ft) 65
  8. Fluid drain plug—30–40 N·m (22–30 lb ft)
  9. Fluid fill tube bracket bolt—firmly seated against bracket
  10. Speed sensor bolts—10–13 N·m (7–10 lb ft)
  11. Output flange bolt—108–136 N·m (80–100 lb ft)
  12. PTO cover bolts—40–45 N·m (29–33 lb ft)
  13. PTO mounting bolts—57–68 N·m (42–50 lb ft)
  14. Selector lever nut (customer-supplied)—20–27 N·m (15–20 lb ft)
  15. PTO pressure hose fittuing to transmission—10–13 N·m (7–10 lb ft)
  16. Rear cover bolts—51–61 N·m (38–45 lb ft)
  17. TPS to engine bracket (M6 bolts)—10–13 N·m (7–10 lb ft) (0.250–20 bolts)—12–15 N·m (9–11 lb ft)

Cooler Fluid Lines and Air Hose for:

  1. No leaks
  2. Connection tightness
  3. Correct routing

Throttle Sensor for:

  1. Proper adjustment
  2. Correct routing of cable and harness

Driveline for:

  1. Proper indexing of universal joints
  2. Proper drive shaft angles
  3. Driveline backlash
  4. Lubricated universals and slip-joints

Hydraulic System for:

  1. Recommended fluid
  2. Correct fluid level in transmission
  3. Dipstick correctly calibrated
  4. Fill tube tight
  5. Fill tube cap tight
  6. Breather clean and free of restrictions
  7. No fluid leaks during operation

Instruments and Electrical Equipment for:

  1. Proper wiring and electrical connections
  2. Instruments, gauges, and lights work correctly
  3. Shift selector display is on and CHECK TRANS light is off
  4. Fluid temperature gauge

Power Takeoff, if installed, for:

  1. Controls connected and operative
  2. Correctly coupled to driven equipment
  3. Lubrication line correctly installed and routed, if used
  4. Clutch apply line correctly installed and routed, if used

ROAD TEST AND VEHICLE OPERATION CHECKLIST

Complete this form after the transmission installation.

Technician Signoff

3000 / 4000 Series Install Packet

CRITICAL WARNING!

Warranty will be VOID if the install process is not followed and all documentation is not returned on time!

Download the Allison Transmission 3000/4000 Series Installation Packet

Download the Allison Transmission SIL Installation Companion Packet here.

The warranty will be VOID if install process is not followed and all documentation is not returned on time!

1. Contamination from cooler will FAIL the transmission!

Cooler must be free of any debris or leaks. This includes cooler lines and fittings. Every cooler at minimum needs to be thoroughly flushed and tested. It is highly recommended to replace the transmission cooler at time of transmission replacement. Cooler failure is not covered by Reaction Force LLC warranty in any form.

* Every unit Reaction Force LLC receives is tested for glycol contamination.

2. Contamination from PTO/Pump will FAIL the transmission!

Contamination from Transmission mounted PTO/Pumps is NOT covered by Reaction Force LLC warranty in any way. Improper installation of PTO/Pump will void warranty. Please ensure all brackets and Allison Transmission Guidelines are followed. If you require information on proper installation guidelines, please email service@reactionforcellc.com.

3. Improper Adaptions, Outputs, and Controls will FAIL the transmission!

Please check all adaptions for cracks or wear. Allison Transmission SIL 60-TR-81 must be followed to keep your warranty in place. Please follow the process and fill out all sections in the Checksheet Form and return to Reaction Force LLC to process your warranty coverage.

For any questions please email service@reactionforcellc.com
Call us today at (503) 862-6322. We are happy to help!

This is only the first page of an 18-page service information letter installation packet from Allison Transmissions.

Please download the entire Allison Transmission SIL Installation Packet here.

Allison Transmission Service Information Letter October 2025
  1. Check Engine Adaption parts.
  2. Check all mounting points and bolt holes and clean if needed.
  3. Check input and output flanges and yokes for wear or damage.
  4. Driveline issues will cause failure of transmission.
  5. Check that all wire harnesses and electrical connections are clean and without damage.
  6. Check all linkages and shifting mechanisms for proper function. Worn shift linkages will fail transmissions!

IMPORTANT!

For your warranty to be intact, all documentation must be returned within 48 hours of transmission installation and back in service date. If you are uncertain about any of the installation process, please contact Reaction Force LLC prior to install.

We are happy to help with any of this process and we want this transmission to last the maximum life possible.

DUTY CYCLE: GENERAL

General Vocations: All vocations not classified as Severe

Allison approved fluid TES 668®/295®

World Series Transynd 668:

Fluid Capacity: 3000 Series 2″ Sump: 18 quarts (5.5 gallons). Add 2 gallons for external cooler
Fluid Capacity: 3000 Series 4″ Sump: 20 quarts (6 gallons). Add 2 gallons for external cooler
Fluid Capacity: 4000 Series 2″ Sump: 32 quarts (9 gallons). Add 2 gallons for external cooler
Fluid Capacity: 4000 Series 4″ Sump: 40 quarts (10 gallons). Add 2 gallons for external cooler

Miles: 300,000 or 480,000 km
Time: 6,000 hours or 48 months

Allison approved fluid TES 389®

Miles: 25,000 or 40,000 km
Time: 2,000 hours or 24 months

DUTY CYCLE: SEVERE

Severe Vocations: On/Off highway, refuse, city transit, shuttle transit

Allison approved fluid: TES 668®/295®

World Series Transynd 668:

Fluid Capacity: 3000 Series 2″ Sump: 18 quarts (5.5 gallons). Add 2 gallons for external cooler
Fluid Capacity: 3000 Series 4″ Sump: 20 quarts (6 gallons). Add 2 gallons for external cooler
Fluid Capacity: 4000 Series 2″ Sump: 32 quarts (9 gallons). Add 2 gallons for external cooler
Fluid Capacity: 4000 Series 4″ Sump: 40 quarts (10 gallons). Add 2 gallons for external cooler

Miles: 150,000 or 240,000 km
Time: 6,000 hours or 48 months

Allison approved fluid TES 389®

Miles: 12,000 or 20,000 km
Time: 500 hours or 6 months

DUTY CYCLE: GENERAL OR SEVERE

World Series Transynd 668:

Fluid Capacity: 3000 Series 2″ Sump: 18 quarts (5.5 gallons). Add 2 gallons for external cooler
Fluid Capacity: 3000 Series 4″ Sump: 20 quarts (6 gallons). Add 2 gallons for external cooler
Fluid Capacity: 4000 Series 2″ Sump: 32 quarts (9 gallons). Add 2 gallons for external cooler
Fluid Capacity: 4000 Series 4″ Sump: 40 quarts (10 gallons). Add 2 gallons for external cooler

Allison approved fluid TES 668/295®

Fluid Change: When indicated by controller or 60 months, whichever occurs first

Allison approved fluid TES 389®

Fluid Change: When indicated by controller or 24 months, whichever occurs first

Installation Checksheet

 

Torque values

  1. All control module bolts—51–61 N•m (38–45 lb ft)

  2. Speed sensor bolts—24–29 N•m (18–21 lb ft)

  3. Flexplate-to-crankshaft hub bolts—Consult Engine Manufacturer Specifications

  4. Flexplate-to-flexplate adapter bolts 12-bolt design— 33–39 N•m (25–29 lb ft); 6-bolt design—63–73 N•m (46–54 lb ft)

  5. Fluid drain plug—25–32 N•m (18–24 lb ft)

  6. Fluid fill tube bracket—24–29 N•m (18–21 lb ft)

  7. Control module pressure taps—10–13 N•m (7–10 lb ft)

  8. Cooler fittings

  9. #12, 34–47 N•m (25–35 lb ft)

  10. #16, 54–68 N•m (40–50 lb ft)

  11. #20, 68–81 N•m (50–60 lb ft)

  12. Cooler port cover bolts—51–61 N•m (38–45 lb ft)

  13. Expansion plug (prior to April 1997)—1–2 N•m (9–18 lb inch)

  14. Flexplate adapter-to-converter cover bolts—33–39 N•m (25–29 lb ft)

  15. Output flange bolt(s):

  16. 3000 Product Family transmission—30–35 N•m (22–26 lb ft)

  17. 4000 Product Family transmission—51–61 N•m (38–45 lb ft)

  18. 3000 and 4000 Product Families Transmissions built after

  19. December 1, 1998—70–80 N•m (52–59 lb ft)

  20. PTO cover bolts—51–61 N•m (38–45 lb ft)

  21. PTO mounting bolts—51–61 N•m (38–45 lb ft)

  22. Breather—12–16 N•m (9–12 lb ft)

  23. PTO pressure hose to transmission—10–13 N•m (7–10 lb ft)

  24. Rear cover bolts—90–110 N•m (66–81 lb ft)

  25. TPS to transmission bracket M6 bolts—10–13 N•m (84–120 lb inch); 1 / 4-20 bolts—12–15 N•m (108–132 lb inch)

Cooler Fluid Lines and Air Hose for:

  1. No leaks
  2. Connection tightness
  3. Correct routing

Throttle Sensor for:

  1. Proper adjustment
  2. Correct routing of cable and harness

Driveline for:

  1. Proper indexing of universal joints
  2. Proper drive shaft angles
  3. Driveline backlash
  4. Lubricated universals and slip-joints

Hydraulic System for:

  1. Recommended fluid (TranSynd® or Approved TES 668)
  2. Correct fluid level in transmission
  3. Dipstick correctly calibrated
  4. Fill tube tight
  5. Fill tube cap tight
  6. Breather clean and free of restrictions
  7. No fluid leaks during operation

Instruments and Electrical Equipment for:

  1. Proper wiring and electrical connections
  2. Instruments, gauges, and lights work correctly
  3. Shift selector display is on and CHECK TRANS light is off
  4. Fluid temperature gauge

Power Takeoff, if installed, for:

  1. Controls connected and operative
  2. Correctly coupled to driven equipment
  3. Lubrication line correctly installed and routed, if used
  4. Clutch apply line correctly installed and routed, if used

ROAD TEST AND VEHICLE OPERATION CHECKLIST

Crankshaft Hub Adapter Specs 3000/4000 Series Allison Transmission
RF Flexplate Specs Alliosn Transmission 3000:4000 Series

Complete this form after the transmission installation.

Technician Signoff

Questions? Contact us!

Allison parts are built like tanks—but even tanks need good diagnostics.
Let Reaction Force LLC help you fix it right the first time. Call us today at (503) 862-6322.

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