TM-9-2520-254-34
TRANSMISSION, AUTOMATIC, ALLISON, MODEL TX100-1
TECHNICAL MAUAL; DIRECT AND GENERAL SUPPORT MAINTENANCE MANUAL
OCTOBER 1971
TM-9-2520-254-34 - Page 51 of 126
CHAPTER 5
REPAIR AND OVERHAUL (REBUILD)
Section I. PRELIMINARY INSTRUCTIONS FOR TRANSMISSION
OVERHAUL (REBUILD)
5-1. General
a. Equipment Needed.
Proper equipment must
be available before disassembly is started. This
equipment includes a suitable hoist of at least
1
/
2
ton capacity. proper hand tools and special tools,
improvised tools. receptacles for small parts, wood
blocks. wiping cloths, and an arbor press. Refer to
paragraphs 3-4 and 3-5 for lists of special and
improvised tools.
b.
Parts to
Discard.
Cotter pins, lock wires, lock
strips, and gaskets should be discarded at trans-
mission disassembly. New parts should always be
supplied in such cases.
c. Avoiding Component Damage.
Care must be
used to avoid damage to transmission components
during disassembly, cleaning, inspection, repair,
and reassembly. Scratches. nicks, and dents caused
by careless handling may cause oil leakage or
improper functioning and could result in trans-
mission failure. All defective parts must be
replaced.
d. Torque Requirements.
All standard torquing
requirements for bolts, screws, and nuts are
tabulated in table 6-1. Where special torque
requirements apply. they will be found in the
applicable text.
5-2. Cleaning Recommendations
a. Importance of Cleanliness.
Cleanliness is of
paramount importance in servicing the trans-
mission. All components must be thoroughly
cleaned and kept clean throughout the rebuild
process. The presence of dirt can cause malfunction
and possible failure of the transmission. Refer to
TM 9-208-1 and TM 9-208-2.
WARNING
Forewarn personnel in the immediate area
when using compressed air for cleaning.
Compressed air. coming into contact with
the human skin or causing flying metal
chips. can cause serious injury.
b.
Cleaning Parts.
(1) Every component should be thoroughly
cleaned after the transmission is disassembled.
Cleaning is necessary to insure effective inspection
for wear, damage,
and serviceability of com-
ponents.
(2) The utmost care should be used in han-
dling of parts during cleaning and overhaul
(rebuild ) operation. Nicks, scratches, dents, or burs
can prevent proper assembly or cause malfunction
after assembly. This is especially true of valves and
valve body parts.
(3) Abrasives, files, scrapers, wire brushes,
and sharp tools should never be used on surfaces
where finish is important to the operation or sealing
of parts, except where specifically recommended.
(4) Gum or varnish may be removed by
soaking in dry cleaning solvent or mineral spirits
paint thinner and by the use of a soft bristle brush.
Crocus cloth may be used to remove minor surface
irregularities. Lapping compound may be used, if
required, in valve body bores to prevent valves from
sticking. Clean thoroughly to remove compound
after use.
(5) A soft wire (brass or copper) may be used
to clean oil passages. Always flush such passages
thoroughly after cleaning.
(6) If steam cleaning is used, dry the cleaned
parts immediately with compressed air, and apply a
film of oil to prevent rusting. Never use lye or
caustics which will corrode or etch metal surfaces.
(7) Do not clean the lubricant from new
bearings. Keep new bearings wrapped until they
are to be installed. Soak bearings which have been
in service in dry cleaning solvent or mineral spirits
paint thinner to loosen deposits of dirt. Do not spin
bearings during cleaning or drying. After cleaning,
turn bearings by hand and note any evidence of
grit. Reclean them if grit is present. Refer to TM 9-
214 for further information on cleaning bearings.
5-3. Inspection and Repair Recommendations
a. Castings. Forgings. and Machined Surfaces.
(1) Inspect all castings and forgings for
breaks, cracks, and wear or scoring that would
impair
serviceability. Remove nicks and small
surface irregularities with crocus cloth or a soft
stone.
(2) Inspect all oil passages for obstructions
and dirt. Reclean passages if necessary.
(3) Inspect mounting faces for nicks, scratch-
es, and scores. Remove minor defects with crocus
cloth or a soft honing stone. Replace any parts in
5-1
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