Manual de Reparacion para Transmision+Automatica+modelo+ALLISON

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CLU TCH AN D SO SOL L EN OI D APPL I CATI ON CH ART .... ........ ........ ........ ........ ........ ........ ........ ........ ........ ........ ........ ........ ........ ........ ........ ........ ........ ........ ........ ........ ........ ....... ... 4 TRAN SMI SS SSII ON ID EN TI F I CATI ON TAG TAG IN F ORM ATI ON ..... ......... ........ ........ ........ ........ ........ ........ ........ ........ ........ ........ ........ ........ ........ ........ ........ ........ ........ ...... 5 GEN ERA L DE SCRI PTI ON AN D OPERA TI ON .......... ..................... ...................... ..................... ..................... ...................... ...................... ..................... ..................... ............... .... 6 EL ECT RI CAL OPERA TI ON .......... .................... ..................... ...................... ...................... ..................... ..................... ...................... ...................... ..................... ..................... ...................... .............. ... 9 TH ROTT L E POSI TI ON SENSOR ................ ........................... ...................... ...................... ..................... ..................... ...................... ...................... ..................... ..................... .................... ......... 10 NE UT RAL STA RT BA CK UP SWI SWI TCH .......... ..................... ..................... ..................... ...................... ...................... ..................... ..................... ...................... ...................... ................. ...... 11 TRAN SMI SS SSII ON CONTROL M ODU L E CONNE CTOR I DE NTI F I CATI ON .... ........ ........ ........ ........ ........ ........ ........ ........ ........ ........ ........ ........ .... 12 DI AGN OS OSTI TI C TROUB L E COD E I DE NTI F I CATI ON ........... ............... ........ ........ ........ ........ ........ ........ ........ ........ ........ ........ ........ ........ ........ ........ ........ ........ ........ ........ ...... .. 14 SOL SO L EN OI D I DE NTI F I CATI ON AN D OPERATI ON .... ........ ........ ........ ........ ........ ........ ........ ........ ........ ........ ........ ........ ........ ........ ........ ........ ........ ........ ........ ........ ........ ........ ...... 16 I NTE RNA L WI RI NG H ARNE SS SC SCH H EM ATI C AND RESI ST STAN AN CE CHA RT ....... ........... ........ ........ ........ ........ ........ ........ ........ ........ ........ ........ .... 18 EXTE RNAL WI RIN G HARNE SS SCHE M ATI C AND TERM I NAL I DEN TI FI CA CATI TI ON ..... ........ ...... ..... ..... ...... ...... ...... ...... ...... ...... ..... 19 PRESSURE PRESS URE SWI TCH ASS ASSEM EM BL Y I DE NT I F I CATI ON AN D OPERATI OPERATI ON ......... ............. ........ ........ ........ ........ ........ ........ ........ ........ ........ ........ ...... .. 20 RET RI EV I NG DI AGN OSTI C TROU BL E CODE S .......... .................... ..................... ...................... ...................... ..................... ..................... ...................... ...................... ........... 22 L I NE PRESSURE TE STS ................. ............................ ..................... ..................... ...................... ...................... ..................... ..................... ...................... ...................... ..................... ..................... ........... 23 BE L L H OUSI NG OI L PASS PASSAGE AGE I DE NTI F I CA CATI TI ON ........... ............... ........ ........ ........ ........ ........ ........ ........ ........ ........ ........ ........ ........ ........ ........ ........ ........ ........ ........ ...... .. 24 M AI N CASE " F RONT" OI L PASSAGE PASSAGE I DE NTI F I CA CATI TI ON ...... .......... ........ ........ ........ ........ ........ ........ ........ ........ ........ ........ ........ ........ ........ ........ ........ ........ ........ .... 26 M AI N CASE " REA R" OI L PASSAGE I DE NTI F I CA CATI TI ON ........ ............ ........ ........ ........ ........ ........ ........ ........ ........ ........ ........ ........ ........ ........ ........ ........ ........ ........ ...... 27 OI L PUM P COVE R OI L PASS PASSAGE AGE I DE NTI F I CA CATI TI ON ........... ............... ........ ........ ........ ........ ........ ........ ........ ........ ........ ........ ........ ........ ........ ........ ........ ........ ........ ...... .. 29 SHI F T V ALVE BODY OI L PASS PASSAGE AGE I DE NTI F I CA CATI TI ON .......... .............. ........ ........ ........ ........ ........ ........ ........ ........ ........ ........ ........ ........ ........ ........ ........ ........ ....... ... 31 M AI N VALVE BODY " TOP VI EW" OI L PASSAGE PASSAGE I DE NTI F I CA CATI TI ON .... ........ ........ ........ ........ ........ ........ ........ ........ ........ ........ ........ ........ ........ ...... .. 32 M AI N VALVE B ODY " BOTTOM V I EW" OI L PASSAGE PASSAGE I DEN TI FI CA CATI TI ON .... ....... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ..... .. 33 M AI N CASE CASE " BOTT OM VI EW" OI L PASSAGE PASSAGE I DE NTI F I CA CATI TI ON .... ........ ........ ........ ........ ........ ........ ........ ........ ........ ........ ........ ........ ........ ........ ....... ... 35 TRA NSM I SS SSII ON DI SASS SASSEM EM BL Y PROCESS .......... ..................... ...................... ...................... ..................... ..................... ...................... ...................... ...................... ................ ..... 36 COMPONENT CO MPONENT REBUIL D TRA NSM I SS SSII ON CASE ASSEM BL Y ........... ...................... ...................... ..................... ..................... ...................... ...................... ..................... ..................... ...................... ............. .. 53 OI L PUM P AN D BE L L H OUSI NG ASSEM BLY .......... ..................... ..................... ..................... ...................... ...................... ..................... ..................... .................. ....... 55 F OUR DI F F ERE NT BE L L H OUSI NGS I DE NT I F I CA CATI TI ON .... ........ ........ ........ .......... ........ ........ ........ ........ ........ ........ ........ ........ ........ ........ ........ ........ ...... 66 C1/C2 CL UT CH H OUSI NG ASSEM BLY ........... ...................... ..................... ..................... ...................... ...................... ...................... ..................... ..................... ................. ...... 68 C1/C2 CLU TCH H OUSI NG SNAP RI NG I DE NT I F I CA CATI TI ON .... ........ ........ ........ .......... ........ ........ ........ ........ ........ ........ ........ ........ ........ ........ ........ ........ .... 72 VA LVE BOD Y ASSEM BLY ........... ..................... ..................... ...................... ...................... ..................... ..................... ...................... ...................... ..................... ..................... .................. ....... 80 SOLE NOI D AI R CH ECK S ........... ...................... ...................... ..................... ..................... ...................... ...................... ..................... ..................... ...................... ...................... ................... ........ 83 EX TE NSI ON H OUSI NG ASSEM BL Y .......... ..................... ..................... ..................... ...................... ...................... ..................... ..................... ...................... ...................... ............. .. 91 GEA R TRAI N PART S .......... .................... ..................... ...................... ...................... ..................... ..................... ...................... ...................... ..................... ..................... ...................... .................. ....... 96 CASE CL UT CH PARTS .......... ..................... ...................... ...................... ..................... ..................... ...................... ...................... ..................... ..................... ...................... ...................... .............. ... 100 F I NA L TR AN SMI SS SSII ON ASSEM BL Y PROCESS ........... ...................... ...................... ..................... ..................... ...................... ...................... ...................... .................... ......... 102 BOL T I DE NT I F I CAT I ON CH ART .............. ......................... ...................... ..................... ..................... ...................... ...................... ..................... ..................... ...................... .................... ......... 119 119 TORQU E SPECI F I CAT I ON CH ART .......................... ..................................... ..................... ..................... ...................... ...................... ...................... ..................... ..................... ............... .... 120

CAU TI ON: ATSG se servi ce manuals are are intended intended for u se by prof prof essional, qualif ied te techni chni cians. Attempting repair repair s or servi servi ce with out the prope properr tr ain in g, tools and equi equi pme pment nt coul d cause cause in ju r y to you you or oth ers and damage to the vehi vehi cle that may cause it not to operate proper proper ly.

AUTOMATIC TRANSMISSION SERVICE GROUP 9200 S. DADELAND BLVD. BLVD. SUITE 720 MIAMI, FLORIDA 33156 (305) 670-4161 Copyright © ATSG 2000

2

May, 2000

Updated October, October, 2003

INTRODUCTION ALLISON 1000/2000 SERIES Beginning at the start start of production for for the 2000 model year, General Motors introduced two new Allison Allison automatic transmissions referred to as the 1000 Series and the 2000 Series, for light duty (8600-19850 GVW) and medium duty (19850-3000 GVW) commercial trucks. The 1000 and 2000 Series transmissions transmissions both have helical helical cut planetary gear systems systems to minimize noise concerns and come in two different gear ratio ratio configurations. The 1000 Series uses closer steps to improve the shift quality that we now expect from an automatic automatic transmission. The 2000 Series uses wider steps steps to accommodate the greater vehicle weights associated with the 2000 Series. The gear ratios for both of the new units are shown in this Manual. The 1000 and 2000 Series transmissions transmissions have a Park position, Reverse, Neutral and five forward speeds with 5th gear being overdrive, and are completely electronic shift shift controlled. Notice that the standard General Motors case connector has been utilized, and the Park/Neutral switch is exactly the same switch used currently on the THM 4L60-E transmission. transmission. Two different different bottom pan configurations are are also provided to make these units even more versitile. versitile. The 1000 and 2000 Series transmissions utilize utilize five clutch packs (No Bands-No Freewheels) to obtain the five forward gears and reverse. This manual will cover the dis-assembly, rebuild of all all components and re-assembly of both the 1000 and 2000 Series units. No part of any ATSG publication may be reproduced, stored in any retrieval system or transmitted in any form or by any means, including but not limited to electronic, mechanical, photocopying, recording or otherwise, without written permission permission of Automatic Transmission Service Group. This includes all text illustrations, tables and charts. " Porti ons of materi als contain contain ed herein herein have bee been r epri nted under under li cense cense f r om General General M otors Corp, Se Ser vice & Parts Oper Oper ations." Th e in for mation and part n umbers contained in thi s bookl bookl et have bee been carefu ll y compil compil ed fr om in dustr dustr y sour sour ces ces known for their r eli abil ity, but ATSG ATSG does does not guar antee it s accuracy. accuracy. DALE ENGLAND FIELD SERVICE CONSULTANT CONSULTANT

Copyr Copyr igh t © AT SG 2000

JIM DIAL TECHNICAL CONSULTANT

WAYNE COLONNA

ED KRUSE

TECHNICAL SUPERVISOR

TECHNICAL CONSULTANT

PETER LUBAN PETER LUBAN

GREGORY LIPNICK

TECHNICAL CONSULTANT CONSULTANT


JON GLATSTEIN

DAVID CHALKER



JERRY GOTT

STANTON ANDERSON



GERALD CAMPBELL

ROLAND ALVAREZ



MIKE SOUZA TECHNICAL CONSULTANT CONSULTANT

AUTOMATIC TRANSMISSION T RANSMISSION SERVICE GROUP 9200 S. DADELAND BLVD. BLVD. SUITE 720 MIAMI, FLORIDA 33156 (305) 670-4161

1

Technical Service Informat ion ALLISON 1000/2000 SERIES En gin e Spe Speed ed Sensor

Tu r bin e Sp Spe eed Sensor

Outpu Ou tpu t Speed Speed Sensor

Allison

Neutral Star Star t Switch TWO WHEEL DRIVE

En gin e Spe Speed ed Sensor

Tu r bin e Sp Spe eed Sensor

Allison

Neutral Star Star t Switch FOUR WHEEL DRIVE

Copyright © 2000 ATSG

Figure 1

AUTO AU TOMAT MATIC IC TRA T RANS NSMI MISS SSIO ION N SERV SE RVIC ICE E GROU GR OUP P

3

Technica l Serv ice Inform ation ALLISON 1000/2000 SERIES TRANSMISSION "C2" CLUTCH

"C3" CLUTCH

"C4" CLUTCH

"C1" CLUTCH

Range

C1 Clut

C2 Clut

C3 Clut

C4 Clut

Park Rever se

ON ON

Sol "B"

Sol "C"

Sol "D"

Sol "E"

ON

** ** ** ** ** ** **

** ** ** ** ** ** **

X

X

X

X

X

X

X

**

**

ON ON

OD-3rd ON OD-5th

Sol "A"

ON

OD-2nd ON OD-4th

C5 Clut

ON

Neutral OD-1st

"C5" CLUTCH

ON

ON ON ON

ON

X

Sol "F"

4.49 5.09

X

3.10 3.51

X X

Ratios 1000 2000

X X

* * * *

1.81 1.90 1.41 1.44 1.00 1.00 0.71 0.74

X = El ectri cal Power Power Appli ed To To Solenoid Solenoid Solenoid noid " F " To Apply Apply Conve Converter Clu tch * = Apply Sole Solenoids noids " A" and " B" are " Tri m" sole olenoids noids us use ed to control control oncoming, oncoming, off-going, and * * = Sole hol din g pres presssur e to the f ive clut ch pac packs. ks. Copyright © 2000 ATSG

Figure 2

4

AUTO AU TOMAT MATIC IC TRA T RANS NSMI MISS SS IO ION N SERV SE RVIC ICE E GROU GR OUP P

Technica l Serv ice Infor mation

ALLISO ALLI SON IDE IDENTIFI FIC CATION TAGLOCATION

9 . 8

9 . 8

9 . 8 9 . 8

9 . 8

9 . 8

Allison

9 . 8

9 . 8

9 . 8

sosnion Allimis X X

9 . 8

DEL MROIES TXIDX 0 SE A TE 100 D NO. X X 21 AL X 99F SERIX XNX X X X FC X X X EX X X XX XX

Transmission

9

X XX -X X XX X X XX XX X X X X - X X X - XX X X XX X X X - X X X X X X XX X XX - X X X X X X XX X X X X X XX X XX

OR SC ORR A TO O T AN LM D I RA I N N E IS , GE OL OF A P O N IA N I SI N D D IV I

s an Tr

W UA3 3 3 3

P.

9 . 8

9 . 8

93 3

DIVISION OF GENERALMO TORSCORP. INDIAN APOLIS, INDIAN A

9 . 8

MODEL 1000 SERIES DATE TID 99F21 XX SERIAL NO. XXXXXXXXXX EFCN XXXXXXXXX

9 . 8

9 . 8

UAW

9 . 8

XX- XXXX

XX- XXXX

XX- XXXX

XX- XXXX

XX- XXXX

XX- XXXX

XX- XXXX

XX- XXXX

XX- XXXX

XX- XXXX


Figure 3

TRANSMIS ISS SION IDENTIF IFIC ICATION TAG Several different transmission configurations are available within the 1000/2000/2400 Series. The different models are identified as follows: 1000 Series

Heavy-duty automatic transmission with parking pawl. parking Maximum GVW = 19850 lb.

2000 Series

Heavy-duty automatic transmission without parking pawl. parking Maximum GVW = 30000 lb.

2400 Series

Heavy-duty automatic transmission with parking pawl. parking Maximum GVW = 26000 lb.

This information must be used when discussing discussing specific service issues, or when parts replacement is necessary. The transmission transmission identification tag also also includes the date of manufacture, and also the transmission identification number used with the diagnostic systems. Special N ote: Spe Allison Series 1000/2000/2400 transmissions are designed and manufactured to metric standards, and metric tools are required for service. Th e cooler por ts and the th e mai main n l i ne press pressur e tap are the onl onl y non-metri c fi tti ngs on the transmiss transmission case cas e. Th e output f lan ge ge/yoke /yoke r etain in g bolt bolt i s also non-metric.

Each transmission is identified by a model designation, group numbers, and serial number. This information is included on the transmission identification tag located on the right rear side of the transmission case, as shown in Figure 3.


5

Technica l Serv ice Inform ation

GENERAL DESCRI RIP PTION AND OPERATION Allison 1000/2000/2400 Series transmissions are torque converter driven driven fully fully automatic units. units. All models have neutral, reverse, reverse, and up to 5 forward speeds, with 5th gear being overdrive. Refer to Figure 2 for the different gears ratios available in the different models. The torque converter housings of these units mate directly to SAE No. 2, SAE No. 3, or direct to the engine block in some cases. Flexplate drive is used for all engine to transmission torque transfer. Several different torque converters are available to match the transmissions to a wide variety of diesel and gasoline engines. The torque converter is a single stage, three element unit, consisting of a pump, stator, and turbine, with the addition of a converter clutch to provide provi de direc directt drive from the engi engine ne to the transmission. The converter clutch is applied and released electronically, and changes the direction of fluid flow in the converter as in most typical converters today. Internally these units contain 2 rotating clutches (C1 and C2), and 3 brake clutches (C3, C4 and C5), to direct the flow of torque through the unit. All clutch packs are hydraulically applied and spring released, with automatic wear compensation, and their locations in the transmission are shown in the cutaway in Figure 2. The Transmission Transmission Control Module Module (TCM) signals six different solenoids, located on the valve body, to apply and release clutches based on vehicle speed and power combinations, and the range selected by the operator. The planetary gear train consists of three constant mesh, helical gear planetary sets, refered to as P1, P2, and P3. By the engagement of the 5 clutch packs in various combinations, the planetary gear sets react singly or together to provide 5 forward speeds, neutral, and reverse. A common hydraulic system provides fluid for all hydraulic operations, lubrication, and cooling. The front oil pump, driven by the converter, provides the pressure needed for the hydraulic system, and comes from the common sump in the bottom pan. A suction filter, filter, located in the the bottom pan provides general protection to the entire hydraulic system, and a spin-on filter provides full time protection for the control solenoids and multipass protection for the entire system.

The spin-on spin-on filter filter is located externally externally on the converter housing at the lower left front of the transmission. Some 1000/2000/2400 Series transmissions are available with an optional extension housing that accommodates an OEM installed two shoe, expanding type, drum parking brake. The 1000/2000/2400 Series transmissions transmissions use lever type shift selectors, selectors, as shown in Figure 4. The vehicle may be equipped with one or two shift selectors, depending on the number of operator stations for driving the vehicle and/or operating a variety of chassis mounted equipment. The shift shift positions positions on the shift selector can vary according to the shift selector installed in the vehicle. NOTE : Refer Refer to F igur e 5 for the va varr ious Shif t Sell ector positi ons, and corr Se cor r espondi ng r anges that can be attained for all 1000/2000/2400 Series models.

TYPICAL MANUAL SHIF IFT TTOWER

DO NOT SHIFT

P R N D 4 2 1 DO NOT SHIFT


Figure 4

6



ALL 1000 AND240 2400 0 SERIES SERIES Shift Selector Position

Gears Available

Shift Selector Position

Gears Available


Gears Available

P (Park)

Neutral*

P (Park)

Neutral*

P (Park)

Neutral*

R (Reverse)

Reverse

R (Reverse)

Reverse

R (Reverse)

Reverse

N (Neutral)

Neutral

N (Neutral)

Neutral

N (Neutral)

Neutral

D (Drive)

1-5

D (Drive)

1-5

D (Drive)

1-5 (1-4)**

4 (Fourth)

1-4

4 (Fourth)

1-4

3 (Third)

1-3

3 (Third)

1-3

2 (Second)

1-2

2 (Second)

1-2

1 (First)

1st

1 (First)

1st

1 (First)

1st

* With Park Pawl Engaged ** 4 Speed Calibration or Trailering Mode

ALL 2000 SERIES SERIES "W "WITH" AUTO-APP APPLY LY PARKI PARKIN NGBRAKE Shift Selector Position

Gears Available


Gears Available


Gears Available

PB = (Park)

Neutral*

PB = (Park)

Neutral*

PB = (Park)

Neutral*

R (Reverse)

Reverse

R (Reverse)

Reverse

R (Reverse)

Reverse

N (Neutral)

Neutral

N (Neutral)

Neutral

N (Neutral)

Neutral

D (Drive)

1-5

D (Drive)

1-5

D (Drive)

1-5 (1-4)**

4 (Fourth)

1-4

4 (Fourth)

1-4

3 (Third)

1-3

3 (Third)

1-3

2 (Second)

1-2

2 (Second)

1-2

1 (First)

1st

1 (First)

1st

1 (First)

1st

* With Auto-Apply Parking Brake Engaged ** 4 Speed Calibration or Trailering Mode PB = Auto-Apply Parking Brake

ALL 2000 SERIES SERIES "W "WITHOUT" AUTO-APP APPLY LY PARKI PARKING NGBRAKE Shift Selector Position

Gears Available


Gears Available


Gears Available

R (Reverse)

Reverse

R (Reverse)

Reverse

R (Reverse)

Reverse

N (Neutral)

Neutral

N (Neutral)

Neutral

N (Neutral)

Neutral

D (Drive)

1-5

D (Drive)

1-5

D (Drive)

1-5 (1-4)**

4 (Fourth)

1-4

4 (Fourth)

1-4

3 (Third)

1-3

3 (Third)

1-3

2 (Second)

1-2

2 (Second)

1-2

1 (First)

1st

1 (First)

1st

1 (First)

1st

** 4 Speed Calibration or Trailering Mode Copyright © 2000 ATSG

Figure 5


7


TYPICAL TRANSMIS ISS SION CONTROL MODULE ANDVEHI VEHIC CLE HARNESS TRAN T RANSMIS SMISSION SION CON CONT TROL MODULE (TCM)

VEHICLE (J1) VEHICLE (J 1) HARNESS

TRAN T RANSMIS SMISSION SION (J (J 2) HARNESS

J 1939 CONNECTOR (OPTIONAL)

"J 1" CONNECTOR (GRAY)

"J 2" CONNECTOR (RED)

VIW "X" CONNECTOR

VIW "Y" CONNECTOR

GP 19 CONNECTOR

7 PIN

4 PIN NSBU SWITCH CONNECTORS OUTPUT SPEED SENSOR CONNECTOR TPS T PS CONNECTOR THROT THRO TTLE POSITION SENSOR (TPS (TPS))

TURB T URBINE INE SPEED SENSOR CONNECTOR

ENGINE SPEED SENSOR CONNECTOR

Actual har nes nesss configur ation may dif fer fr om thi s il lustrati on. Copyright © 2000 ATSG

Figure 6

8



ELECTRI RIC CAL OPERATION

ENGINE SPEED SPEEDSENSOR

The electronic control of the transmission is performed by the Transmission Control Module (TCM). Transmissin Control Modules Modules are available in both 12V and 24V configurations, to match the configuration of the vehicle electrical system. The TCM, shown shown in Figure 6, recieves and processes signals from various switches and sensors. The TCM determines shift sequences, shift timing, and clutch apply and release pressures. The TCM uses this information to control solenoids and valves, supply system status, and provide diagnostic information for service technicians.

The Engine Speed Sensor is is externally mounted in the torque converter housing, and directed at the ribs protruding from the torque converter as shown in Figure 1.

EXTERN RNAL COMPO PONENTS SPEED SP EED SENSORS The speed sensors are variable reluctance devices which convert mechanical motion to an AC voltage. Each sensor consists of a wire coil wrapped around a pole piece that is adjacent to a permanent magnet. These elements are contained in a housing which is mounted adjacent to a rotating ferrous member, such as a gear tooth. Two signal wires extend from one end of the housing and an exposed end of the pole piece is at the opposite end of the housing. h ousing. As a ferrous object, such as a gear tooth approaches and passes through the gap at the end of the pole piece, an AC voltage pulse is induced in the wire coil. The TCM calculates the frequency of these AC pulses and converts it to a speed value. The AC voltage generated varies from 150mV at low speed to 15V at high speed. The signal wires from the sensor are formed as twisted pairs to cancel magnetically induced induced fields. The cable is also shielded to protect from voltage-related fields. fields. The typical speed sensor is shown in Figure 7. Noise from other sources is eliminated by using two-wire differential inputs at the TCM.

TURBINE SPEEDSENSOR The Turbine Speed Sensor is is externally mounted in the main transmission case, and directed at the tone wheel or PTO drive gear attached to the C1/C2 clutch housing as shown in Figure 1.

OUTPUT UTSP SPEED EEDSENSOR The Output Speed Sensor is externally mounted in the extension housing and directed at the teeth of a tone wheel splined to and rotating with the output shaft as shown in Figure 1.

TYPICAL SPEEDSENSOR


Figure 7


9

Technical Service Informatio n THROTTLE POSITION SENSOR AB

C


Figure 8

THROTTLE POSITION SENSOR The Throttle Position Sensor (TPS) can be mounted to the engine, chassis, or transmission. The TPS contains a pull actuation cable and a potentiometer. One end of the cable is attached to the throttle lever and the other end, inside a protective housing, to the potentiometer. Output voltage from the TPS is directed to the Transmission Control Module (TCM) through the external external harness. The voltage signal will vary and indicates the throttle position and in combination with other input data will determine shift timing. Refer to the chart provided in Figure 10 for approximate voltages at various throttle openings. It is basically the same as most current GM models with 0.5 volts at idle, to 5.0 volts at wide open throttle.

TPS Connector

Transmission Control Module (TCM)

Green, Gree n, Gr ound 20 Throttle A Bl ue, Signal Signal Re Ret. t. 9 Position B Pink , 5V Supply Supply Sensor C 19 (TPS)

TCM TC M " J2 J2"" (R (RED) ED) Connector

Figure 9

10

(TPS) (T PS) Di stance of Tr T r ave avell Ver Ver sus Volt Volts s mm/inch

Volts

0/0 1/.039" 2/.079" 3/.118" 4/.157" 5/.197" 6/.236" 7/.275" 8/.314" 9/.354" 10/.394" 11/.433" 12/.472" 13/.511" 14/.551" 15/.590" 16/.629" 17/.669" 18/.708" 19/.748" 20/.787" 21/.826" 22/.866" 23/.905" 24/.945" 25/.984" 26/1.023" 27/1.063" 28/1.102" 29/1.142" 30/1.181" 31/1.220" 32/1.260" 33/1.299" 34/1.339" 35/1.378" 36/1.417" 37/1.457" 38/1.496" 39/1.535" 40/1.575" 41/1.614" 42/1.654" 43/1.693" 44/1.732" 45/1.772" 46/1.811"

0 0.11 0.22 0.33 0.44 0.55 0.66 0.77 0.88 0.99 1.10 1.20 1.30 1.43 1.54 1.65 1.76 1.87 1.98 2.08 2.19 2.30 2.41 2.52 2.63 2.74 2.85 2.96 3.07 3.18 3.29 3.40 3.51 3.62 3.73 3.84 3.95 4.06 4.17 4.28 4.39 4.50 4.61 4.72 4.83 4.94 5.05

Figure 10


Technica l Serv ice Infor mation NEUTRAL START ARTBAC BACKK-UP UP SW SWITCH

NEUTRAL START RTBAC BACKK-UP UP SWITCH

The installation of a transmission mounted Neutral Start/ Reverse Signal switch is required. This switch commonly refered to as an "NSBU Switch", mounts directly onto the transmission case from the outside and detects the angular position of the manual shift selector shaft. This position is relayed to the TCM so that certain vehicle control functions can be coordinated with the position of the shift controls. The NSBU Switch has redundant circuitry to alert the TCM in the event of a single wire or switch failure. The switch is interfaced to the starter circuit, and the reverse signal provision may be used to activate vehicle back-up lights and/or reverse warning devices. Refer to Figures 11 and 12.


Figure 11

NSBU SWITCH WIRE SCHEMATIC Rev/Par k Acces Rev/Par Accesso sorr y Batt er y Feed Feed PK/NEU T Start Start Batt er y Feed Feed 7-Way NSBU Switch Rec Rece eptacle (F ace Vi ew)

Park Acces Accesso sory ry Back-up Lamps

A B C

G

G

F

F

E

E

D

A

A

B

B C

C

E F

D

G C D

A

A

B

B

C

B C

Transmission Control Module (TCM)

Green Blue Gray

A

D

Starter Relay

Tan Tan Blue Yellow Pink Orange

D

D

4-Way NSBU Switch Rec Recep eptacle tacle (F ace Vi ew)

Not Use Used d

White Yellow

NSBU Switch H arn es esss Connectors (F ace Vi ew)

20 5 7 8 6

TCM TC M " J2 J2"" (R (RED) ED) Connector


Figure 12


11

Technical Service Informati on

R E D

S I O T S S A D H N U C E O N L R C O G I H T I T E U O V A N C O D

G R A Y TCM " J2 J2"" (R (Re ed) Receptacle TCM TC M " J1 J1"" (G (Gray ray) ) Receptacle

TRANSMIS ISS SION CONTROL MODULE (TCM)

1 2

3 4 5

6 7 8 9 10 11 12 13 14 15 16

1 2

32 31 30 29 28 27 26 25 24 23 22 21 20 19 18 17

TCM " J2 J2"" (R (Re ed) Receptacle

16 15 14 13 12 11 10 9

8 7 6

5

4

3

3 4 5

6 7 8 9 10 11 12 13 14 15 16

32 31 30 29 28 27 26 25 24 23 22 21 20 19 18 17

TCM " J1 J1"" (G (Gray ray) ) Receptacle

2 1

16 15 14 13 12 11 10 9 8 7

17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32

6

5

4

3

2 1

17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32

TCM " J2 J2"" (R (Re ed) H ar arnes nesss Conn ector (F ace Vi ew)

TCM " J1 TCM J1"" (G (Gray ray) ) H ar arnes nesss Conn ector (F ace Vi ew)


Figure 13

12


Technica l Serv ice Infor mation TCM CONNECTOR PIN IDENTIF IFIC ICATION CHART

16 15 14 13 12 11 10 9

8 7 6

5

4

3

2 1

16 15 14 13 12 11 10 9

17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32

TCM " J2 J2"" (R (Re ed) H ar nes nesss Conn ector (F ace Vi ew) Ter m . Col or Ci r cu i t F u n cti on 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32

8 7

6

5

4

3

2 1

17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32

TCM " J1 TCM J1"" (G (Gray ray) ) H ar nes nesss Conn ector (F ace Vi ew) Ci r cu i t E n ds Ter m . Col or Ci r c u i t F u n cti on

B l u e PSA I n pu t T r an s-D Pink PS PSA A I nput Trans-F White PS PSA A I nput Trans-E Green PS PSA A I nput Trans-K Blue NS NSBU BU I nput NSBU-4A Yellow NS NSBU BU I nput NSBU-4D Gray NS NSBU BU I nput NSBU-4B White NS NSBU BU I nput NSBU-4C Blue Th rot tl e Pos Posit it ion Sensor Sensor TPS-B Tan Ta n Tr ans Sump Te Temp I nput Trans-G Orange Re Retarde tarderr Temp In put (Opt) R Temp-A Blue Engi ne Coolant Coolant Temp ECTS-A Orange Tu rbi ne Spe Speed ed Se Sensor nsor (H igh ) TSS-A Blue Tu rbi ne Spe Speed Sens Sensor or (L ow) TSS-B Yellow Outpu t Spee Speed Sensor Sensor (H igh ) OSS-A Green Outpu t Speed Speed Sensor Sensor (L ow) OSS-B Tan Ta n En gin e Spe Speed ed Se Sensor nsor (H igh ) ESS-A Orange En gin e Spe Speed ed Sens Sensor or (L ow) ESS-B Pink TPS Voltage Supply TPS-C Green Analog Ground Trans-H, ECTS-A,

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 Temp-B, Temp -B, N SBU-7D 21 R-Temp-B, TPS-A 22 Yellow TRANS I D Trans-T 23 Yellow Tri m Sole Solenoid noid A (H igh) Trans-L 24 White Tr im Solenoid Solenoid A (Low) Trans-M 25 Pink Tri m Sole Solenoid noid B (H igh) Trans-N 26 Orange Tr im Solenoid Solenoid B (Low) Trans-P 27 Green C Solenoid Solenoid Ground (On/Off ) Trans-A 28 Blue D Solenoid Solenoid Ground (On/Off ) Trans-B 29 Gray E Solenoid Solenoid Ground (On/Off ) Trans-W 30 White F Sole olenoid noid L ow (PWM) Trans-J 31 Orange G Solenoid Solenoid Low (PWM )(Opt) Trans-J 32 Tan Ta n C, D, E So Solenoid lenoid V Supply Trans-C Green F Solenoid Solenoid Hi gh (PWM) Trans-S

Gray B att er y Gr ou n d Yellow I gniti on Powe Power r Pink Batter y Power Power Yellow I gniti on Powe Power r Gray Battery Groun d Blue GP GPII 1 Orange GP GPII 2 Green GP GPII 3 White GP GPII 4 Yellow GP GPII 5 Green GP GPII 6 Blue GP GPII 7 Pink GP GPII 8 Orange GP GPII 9 Yellow Re Retar tar de derr M od. Reg. Reg. (Opt) White PWM Thr ot ottle tle Pink Se Sensor nsor Power Green Analog Ground Tan Ta n GPO 1 Orange GPO 2 White GPO 3 Blue GPO 4 Pink Rang Range e Inh ibit I ndica ndicator tor White GPO 6 Green CHECK TRANS Tan Ta n Ve Vehi hi cl cle e Spee Speed d Pink Ve Vehi hi cl cle e Spee Speed d Yellow Digital Ground Red CAN High Blue I SO 9141 9141 Green CAN Shield Black CAN Low

Ci r cu i t E n ds Veh i cl e System Vehi Ve hi cle Sys System tem Vehi Ve hi cle Sys System tem Vehi Ve hi cle Sys System tem Vehi Ve hi cle Sys System tem Vehi Ve hi cle Sys System tem Vehi Ve hi cle Sys System tem Vehi Ve hi cle Sys System tem Vehi Ve hi cle Sys System tem Vehi Ve hi cle Sys System tem Vehi Ve hi cle Sys System tem Vehi Ve hi cle Sys System tem Vehi Ve hi cle Sys System tem Vehi Ve hi cle Sys System tem RMR-B Vehi Ve hi cle Sys System tem RMR-C RMR-A Vehi Ve hi cle Sys System tem Vehi Ve hi cle Sys System tem Vehi Ve hi cle Sys System tem Vehi Ve hi cle Sys System tem Vehi Ve hi cle Sys System tem Vehi Ve hi cle Sys System tem Vehi Ve hi cle Sys System tem Vehi Ve hi cle Sys System tem Vehi Ve hi cle Sys System tem Vehi Ve hi cle Sys System tem J 1939 A or H Vehi Ve hi cle Sys System tem J 1939 C or S J 1939 B or L


Figure 14


13

Technical Service Informatio n

DIAG DI AGNOSTICTROUBLECODE(DT (DTC) CHART D TC

" Che Check ck Tr ans ans" " Light

D escr i pti on

P0117 En gin e Coolant Tempe Temperr atur e Cir cuit L ow Voltage Voltage (H igh Tempe Temperr atur e)

N O

P0118 En gin e Coolant Tempe Temperr atur e Cir cuit H igh Voltage (L ow Te Tempe mperr atur e)

N O

P0121 Th r ottle Positi Positi on Senso Sensorr Pe Perr f orman ce Pr Proble oblem m

N O

P0122 Th r ottle Pos Positi iti on Se Senso nsorr Ci r cui t Low Voltage Voltage

N O

P0123 Thr ottle Pos Positi iti on Sens Sensor or Ci rcui t H igh Voltag oltage e

N O

P0218 Tr ans ansmiss mission ion F lu id Over Over Tempe Temperr atur e

N O

P0562 Sys System tem Voltage Volt age L ow

YES YE S

P0563 Sy Sysstem Voltage H i gh

YES YE S

P0602 TCM Not Programmed Programmed

YES YE S

P0606 Tr ans ansmis misssion Control M odule I nte nterr nal Per Per for mance

N O

P0701 Tr ans ansmiss mission ion Contr ol Syste System m Perf orm ance

N O

P0703 Br ake Switch Cir cuit

YES YE S

P0705 Tr ans ansmis misssion Range Se Sens nsor or Ci rcui t (PRND L I nput)

YES YE S

P0706 Tr ans ansmiss mission ion Ran ge Senso nsorr Cir cuit Perf orm ance

YES YE S

P0708 Tr ans ansmis misssion Range Se Sens nsor or Ci rcui t H igh I nput

YES YE S

P0711 Tr ans ansmis misssion F lu id Tempe Temperatur ratur e Circui t Per Per for mance

YES YE S

P0712 Tr ans ansmiss mission ion F lu id Te Tempe mperr atur e Cir cuit L ow Voltage Voltage (H igh Tempe Temperr atur e)

YES YE S

P0713 Tr ans ansmiss mission ion F lu id Te Tempe mperr atur e Cir cuit H igh Voltage (L ow Te Tempe mperr atur e)

YES YE S

P0716 Tu r bin e Sp Spe eed Se Senso nsorr Cir cuit Pe Perr f orman ce

YES YE S

P0717 Tu r bin e Sp Spe eed Se Senso nsorr Cir cuit No Signal

YES YE S

P0721 Output Spe pee ed Se Senso nsorr Cir cui t Per Per for mance

YES YE S

P0722 Output Spe pee ed Senso Sensorr Cir cui t N o Signal

YES YE S

P0726 En gin e Spe pee ed Se Senso nsorr Cir cuit Pe Perr for mance

YES YE S

P0727 En gin e Spe Spee ed Senso Sensorr Cir cuit No Sign al

YES YE S

P0731 I ncorr ect 1s 1st Gear Gear Rati o

YES YE S

P0732 I ncorr ect 2nd Gear Gear Ratio

YES YE S

P0733 I ncorr ect 3rd 3rd Gear Gear Ratio

YES YE S

P0734 I ncorr ect 4th 4th Gear Gear Ratio

YES YE S

P0735 I ncorr ect 5th 5th Gear Gear Ratio

YES YE S

P0736 I ncorr ect Reve Reverr se Gear Gear Ratio

YES YE S

P0741 Torqu Torque e Convert Converte er Clu C lu tch System System Stuck Stuck Of f

YES YE S

P0742 Torqu Torque e Convert Converte er Cl Clut utch ch Sys System Stuck Stuck On O n

YES YE S

P0748 Pres Presssur e Control Tr im Sole Solenoid noid " A" El ectrical

YES YE S

P0763 Shif t Sole Solenoid noid " C" Elec Electrical trical

YES YE S

P0768 Shif t Sole Solenoid noid " D" Elec Electrical trical

YES YE S Figure 15

14




DIAG DI AGNOSTICTROUBLECODE(DT (DTC) CHART D TC

" Che Check ck Trans" Trans" Light

D escr i pt i on

P0773 Shif t Sole Solenoid noid " E" Elec Electri tri ca cal l

YES YE S

P0778 Pres Presssur e Control Tr im Sole Solenoid noid " B" El ectrical

YES YE S

P0840 Tr ans ansmi misssion Pres Presssur e Switch, Solenoid Solenoid C Ci r cuit

YES YE S

P0841 Tr ans ansmi misssion Pres Presssur e Switch, Switch, Solenoid C Cir cuit Stuck Ope Open n

YES YE S

P0842 Tr ans ansmi misssion Pres Presssur e Switch, Switch, Solenoid C Cir cuit Stuck Close Closed d

YES YE S

P0843 Tr ans ansmi misssion Pr essur e Switch, Solenoid Solenoid C Cir cuit H igh

YES YE S

P0845 Tr ans ansmi misssion Pres Presssur e Switch, Solenoid Solenoid D Ci r cuit

YES YE S

P0846 Tr ans ansmi misssion Pres Presssur e Switch, Switch, Solenoid D Cir cuit Stuck Ope Open n

YES YE S

P0847 Tr ans ansmi misssion Pres Presssur e Switch, Switch, Solenoid D Cir cuit Stuck Close Closed d

YES YE S

P0848 Tr ans ansmi misssion Pr essur e Switch, Solenoid Solenoid D Ci r cuit H igh

YES YE S

P1688 Un manage managed d En gin e Torqu Torqu e Deli Deli ve verr ed To TCM

YES YE S

P1709 Tr ans ansmi misssion Pres Presssur e Switch, Solenoid Solenoid E Cir cuit

YES YE S

P1710 Tr ans ansmi misssion Pres Presssur e Switch, Switch, Solenoid E Cir cuit Stuck Ope Open n

YES YE S

P1711 Tr ans ansmi misssion Pres Presssur e Switch, Switch, Solenoid E Cir cuit Stuck Close Closed d

YES YE S

P1712 Tr ans ansmi misssion Pr essur e Switch, Solenoid Solenoid E Cir cuit H igh

YES YE S

P1713 Tr ansmiss ansmission ion Pr es esssur e Switch Switch,, Reve Reverr se Ci Cirr cui t

YES YE S

P1714 Tr ansmiss ansmission ion Pr Pres esssur e Switch Switch,, Reve Reverr se Ci Cirr cui t Stuck Open

YES YE S

P1715 Tr ansmiss ansmission ion Pr Pres esssur e Switch Switch,, Reve Reverr se Ci Cirr cui t Stuck Cl os osed ed

YES YE S

P1716 Tr ans ansmi misssion Pres Presssur e Switch, Switch, Re Reve verr se Cir cuit H igh

YES YE S

P1720 Tr im Sole Solenoid noid " A" Co Controll ntroll ed Clutch Clutch N ot Engage Engaged d

YES YE S

P1721 Tr im Sole Solenoid noid " B" Co Controll ntroll ed Clutch Clutch N ot Engage Engaged d

YES YE S

P1723 Tr im Sole Solenoid noid " A" Co Controll ntroll ed Clutch Clutch N ot Engage Engaged d

YES YE S

P1724 Tr im Sole Solenoid noid " B" Co Controll ntroll ed Clutch Clutch N ot Engage Engaged d

YES YE S

P1726 Shi ft Sole Solenoid noid " D" Controll ed Clu Clu tch Not Engage Engaged d

YES YE S

P1727 Shi ft Sole Solenoid noid " E" Controll ed Clu Clu tch Not Engage Engaged d

YES YE S

P1760 TCM Supply Voltage Voltage

N O

P1835 Kickdo Kickdown wn Cir cuit

YES YE S

P1860 TCC (PWM ) Sole Solenoid noid Cir cuit-E lec lectri tri ca cal l

YES YE S

P1891 Thr ottle Pos Positi iti on Se Sens nsor or Cl utch PWM Signal L ow I nput

N O

P1892 Thr ottle Pos Positi iti on Se Sens nsor or Clu tch PWM Signal H igh I nput

N O

U1016 Class 2 Power Power tr ain Con tr oll er State Of H ealth

N O

U1300 Seri al D ata Communi Communi ca cation tion L in k L ow (Class (Class 2)

N O

U1301 Seri al Data Communi Communi ca cation tion L in k H igh (Cl as asss 2)

N O

U2104 CAN Bu s Re Resset Count er Ove Overr r un

N O

U2105 CAN Bus Error ECM

N O Figure 16



15


SOLENOIDLOCATIONS

Shif t Soleno Solenoid id " C" (Nor mally Clos Close ed) Tri m Sole Solenoid noid " A" (Nor mally Close Closed) d)

Tri m Sole Solenoid noid " B" (Nor mally Open) Open) Shif t Sole Solenoid noid " E" (Nor mally Clos Close ed) TCC (PWM (PWM ) Sole Solenoid noid " F" (Nor mally Clos Close ed)

Shif t Sole Solenoid noid " D" (Nor mally Clos Close ed) Copyright © 2000 ATSG

Figure 17

PRESSURE SWI TCH PRESSURE ASSEMBLY

I nte nternal rnal Wi ri ng Harn ess And Case Conn ector A ss ssembly embly


Figure 18

16



INTERNAL COMPO PONENTS Several components of the 1000/2000/2400 Series electrical control system are located inside of the transmission as part of the main control valve body. These components include three different types of solenoids for controlling the hydraulic action of the valves in the valve body, and the pressure switch assembly. An internal wiring harness and case connector assembly links the internal components with the Transmission Control Module.

SOLENOIDS The 1000/2000/2400 Series solenoid locations are shown in Figure 17. The solenoids may be normally closed or normally open. A normally no rmally closed solenoid remains closed until a signal from the TCM energizes the solenoid. A normally open solenoid remains ope n until the TCM energizes the solenoid. TCC (PWM ) Solenoid Solenoid F - This solenoid a normally closed, pulse width modulated, and operates at a frequency of 100 Hz (cycles per second) during a shift. The percentage of time time the voltage is ON during each 100th of a second is called the solenoid duty cycle cycl e.

INTERNAL WIRI RING NGHARNESS ASSEMBLY

A 100 percent duty cycle indicates a maximum signal to the solenoid. A zero percent duty signal indicates a minimum or no signal to the solenoid. The TCM, using pulse width modulation programming, varies the percentage of voltage ON time during a cycle. As the pulse width, or duty cycle is increased, the solenoid is ON longer. Shi ft Solenoids C, D, E - Shift Solenoids C, D, & E are normally closed solenoids that provide the necessary logic to distribute fluid to the correct clutch packs in the transmission. The shift solenoids provide either full control line pressure, or exhaust, to the lands of each of the corresponding Shift Valves C, D, and E. Shift Solenoids C, D, and E may operate in the open or closed state with no modulation capability at all. Tr im Solenoids A and B - Trim Solenoid A and B are used to control oncoming, off-going, and holding pressure to the five clutch packs. These solenoids are reffered to as Pressure Proportional to Current (PPC) solenoids, since the output hydraulic pressure supplied by these solenoids is proportional to the current commanded. Trim Solenoids A and B operate using a frequency of 1000 Hz. The current causes a force on the armature and shaft assembly, which is balanced by fluid pressure acting on the end of the shaft. The trim solenoids operate using battery voltage. Trim Solenoid A is a Normally Closed solenoid, providing 86 psi (590 kpa) at zero current, and no trim pressure at full current. Trim Solenoid A allows for limp-home capability in the event of a power or TCM failure. Trim Solenoid B is a Normally Open solenoid, and prrovides prrovides zero pressure at zero current.

INTERNAL WIRI RING NGHARNESS

Ser vi Ser viced ced as an assembl assembl y un der Al li son Part Number 15321154 15321154..


The Internal Wiring Harness Assembly connects the shift solenoids, clutch trim solenoids, torque converter clutch solenoid, pressure switch assembly and temperature sensor to the external harness that leads to the Transmission Control Module. Refer to Figure 18 and 19. Figure 20 on Page 18 gives you an internal wire schematic for all of the internal components, and pin identification for the external transmission case connector Continued on Page 18.

Figure 19


17

Technical Service Informat ion

INTERNALWIRI RING NGSCHEMATIC

Sol en oi d A

B

D

C

Resi stance I n Ter mi n al s Resi Oh m s @ 72 7 2° F

TRIM "A"

L and M

5.5 - 8.0

E

F

G

H

J

K

TRIM "B"

N and P

5.5 - 8.0

L

M

N

P

R

S

SHIFT "C"

C and A

20 -30

SHIFT "D"

C and B

20 -30

SHIFT "E"

C and W

20 -30

TCC "F"

J and S

8 - 15

TEMP SENSOR

H and G

2.8K @ 72° F

T

U

V

W

PED 4 TRANSM I SSI ON EXTERNAL TRANSM CONNECTOR CO NNECTOR FACE FACE VI EW

A B C D E F G H J K L M N P R

Dar k Gr een Orange/Black Pink L ight Gr een Red Blue Orange Black

Red/Black Li ght Blue Gray Purple

(N/0) ) TRIM (N/C (N/C) ) TRIM (N/0 SOLENOID SOLENOID " B" " A"

N /A

T

Tan Ta n

W

A B C D E F

Tan Ta n

Black

V

To Pressur Pressur e Switch A ss ssembly embly

Brown

S U

SHIFT SHIFT SHIFT TCC SOLENOID SOLENOID SOLENOID SOLENOID " E" " D" " C" " F "

Green Green Black/Tan Copyright © 2000 ATSG

Figure 20

18


Technica l Serv ice Infor mation See Se e Pages 12 and an d 13 F or TCM Conne Connecto ctorr Pin I .D. C HECK TRANS LIGHT

EXTERNAL WIRE SCHEMATIC TCM "J "J 1" (Gray) CONNECTOR

25

TRAN ANS SMISSION C ONTROL MODUL M ODULE E (TC M)

Yellow Green

15 16

Orange

13 14

Blue Tan Tan Orange

17 18 IGNITION POWER

Yellow

IGNITION POWER

Yellow

BATTERY POWER POWER

Pink

TCM GROU GROUND ND

Gray Gray

2 4 3 1 5

23 22 24 25

White Yellow Pink Orange

31

Tan Ta n

26

Green

27

Blue

28 G R A Y

10A 10 A

D E R

29

IGNITION SWITC H

29 32

+ CAN 2.08 J =19 =1939 39 _ DATA LINK

Green

21

Yellow

1

Blue

2

Pink

3

White Green

4

Black

White

Tan Ta n

10 5V

19

Pink

9

Blue

12

10A 10 A

OPTIONAL SPEEDO SIGNAL SIG NAL RETURN

CAUTION Green

8

DO NOT GROUND TO VEHICLE CHASSIS

20

Green

5

Blue

6

Yellow

OUTPUTSPEED SENSOR

A B

TURBIN INE E SPEED SENSOR

A B

ENGINE SPEED SENSOR

Lt Blue Red/Black Gray

C

Pink

A

Dk Gr ee een n

SOL "A" SOL "B"

Purple

SOL "C"

Orange/Black

SOL "D"

W

Black/Tan

SOL "E"

J U V S R T D

Brown Green Black Orange Tan Ta n

SOL "F"

NOT USED

Lt Gr ee een n

A

C

F

Blue

B D

E

Red

C

K

Tan Ta n

D

Orange

G

Black

H

NOT USED

E R

NOT USED

E F

TEMP SENSOR

PRESSURE SWITC WITCH H ASSEMBLY

TRAN ANS SMISSION CAS CASE E CONN CONNE ECT CTOR OR C

THROTTLE B POSITION SENSOR A

Gray

7

White

8

Orange

TRAN ANS SMISSION NSBU SWITC WITCH H P C

12V OR 24V

TRANS ID

A B

M L N P

B

Gray

30 32

Green 31 Red

ALLISON RECOMMENDED WIRE WIR E COLORS CO LORS

TCM "J "J 2" (Red) CONNECTOR

Yellow

4C

STARTER RELAY PK/NEUT VOLT FEED VOLTFEED

4B

B

4D

A

4A

Pink

REVERSE LAMPS LAMPS

7D

SAE J -1939 BACKBONE

7A 7G

Blue

REV & PARK VOLTFEED VOLT FEED

7E ENGINE INTERFAC RFACE E

SAE STANDARD 9-PIN DIAGNOSTIC C ONNECT ONNECTOR OR

7F 7C

Tan Ta n

PARK ACCESSORY

7B


Figure 21


19


PRESSURE SWITCH ASSEMBLY NOT USED (N/O) " E " SH I F T ( N/ N/ O) O) " D " SH I F T ( N/ N/ O) O)

NOT USED (N/O)

" C" SHIFT (N/O) (N/O)

REVERSE (N/C) TEM P SENSOR SENSOR (THERMISTER) Copyright © 2000 ATSG

Figure 22

PRESS SSURE RESW SWITCHCONNECTOR PIN FUNCTION ANDIDENTIFI FIC CATION

Terminal Te rminal I de dentif ntif ication Cast I n Connector Cast Connector H ere A

B C D E F

A B C D E F

Pr es essur sure e Swit ch Assembl Assembl y Receptacl Rece ptacl e (F ace Vi ew) (A) SHI FT " C" SI GNAL TO PC PCM M (CASE (CASE CONNECTO CONNECTOR R TERMI TERMI NAL " D" ) (B) SHI FT " D" SI GNAL TO PC PCM M (CASE (CASE CONNEC CONNECTOR TOR TERMI NAL " F" ) (C)) SHI (C SHI FT " E" SI GNAL TO PC PCM M (CASE (CASE CONNECTO CONNECTOR R TERMI TERMI NAL " E" ) (D) REVERS REVERSE E SWITCH SWITCH TO PCM PCM (CASE (CASE CONNECTOR CONNECTOR TERMI NAL " K" ) (E) TEMP SENSO SENSOR R H I GH (CASE (CASE CONNECTOR CONNECTOR TERMI NAL " G" ) (F) TEM P SENSO SENSOR R LOW (CAS (CASE E CONNECTOR CONNECTOR TERMI NAL " H " )


Figure 23

20



PRESS SSURE RESW SWITCHCONNECTOR PIN FUNCTION ANDIDENTIFI FIC CATION TCM " J2 J2"" (R (Re ed) Connector

21

Transmission Case Conn ector

Yel l ow

T RA N S I D

Blue

T D

2

Pink

3

White

4

Green

1

10 20

Tan

Tan L t Green Green

A

F

Blue

B

E

Red

C

K

Tan

D

G

Green

Pr es essur sure e Swit Switch ch Connector

Orange

H

Black

C D

NOT USED

E R

NOT USED

E F

TEMP SENSOR

PRESSURE SWITC H ASSEMBLY Copyright © 2000 ATSG

Figure 24

PRESSURE SWITCHASSEMBLY The Pressure Switch Assembly (PSA) is made up of three normally open switches and one normally closed switch. There are also 2 additional switches in the PSA that are not used. All switches switches and their locations are identified identified in Figure 22. Fluid pressure is fed from shift valves C, D, and E to C, D, and E switches, and from the manual valve to the reverse switch. This logic indicates the current transmission operating range to the TCM. The three pressure switches corresponding to the shift valves are normally open (N/O) when there is no pressure to the switch, so that electrical current is stopped at the switch. When pressure is routed to the switch from the shift valves, the switch closes and allows current to flow from the positive contact and through the switch. switch. Refer to Figure 24. The pressure switch corresponding to reverse is a normally closed (N/C) switch, and pressure is fed to the switch when the transmission is placed into the reverse position. The Pressure Pressure Switch Switch Assembly also contains the temperature sensor (thermister) to notify the TCM of the current sump temperature. Changes in fluid temperature are indicated by changes in sensor resistance. Increasing temperature will create decreased sensor resistance.

The PSA terminal identification and functions are illustrated in Figure 23 to assist in switch diagnosis. There is also a complete wiring schematic from the Pressure Switch Assembly through the transmission case connector and to the TCM shown in Figure 24. We have also provided a pressure switch logic state chart in Figure 25.

Presssur e Switch Pres Switch L ogic State Char t Range

" C"

" D "

" E "

Reverse

Park

On

On

On

Of f

Rev

On

On

On

On

Neut

On

On

On

Of f

OD

Of f

Of f

On

Of f

4

On

Of f

On

Of f

3

On

Of f

Of f

Of f

2

Of f

Of f

Of f

Of f

1

Of f

On

Of f

Of f

Figure 25


21


RETRI RIEVI EVING NGDIAGNOSTICCODES A or H

2 F

1 F

S C E

1

~

W

a b T

k k c o o L L s C a p

A

Z

t f i h S

n n F

E S

l r t C

i n W

6

5

4

3 2

Q

`

5 5 F

F 4

3 F

R

T

F

D

8 F

7 7 F

6 6 F

7 Y

G

0 1 F

9 F

9

8

I U H B

:

L

;

n D g P

n d E

t f i h S ? /

>

l e D

. <

s n I

,

M

p U g g P

r e e t n n E

" '

O

J

e o m H

| \ } ]

{ [

P

e s a u P k a re B

l l c ro S k L o c

a c e p p s s k a c B

+ =

_ -

0

K N

t n n i i r P n n c r S

2 1 F 2

1 F 1

t l A

V C

X

B or L

l t A

C or S J-1939 Conn ec ector tor


Figure 26

CHECK TRANS LIGH LIGHT The electronic control system system is programmed to to inform the operator of any type problem with the transmission system and automatically take action to protect the operator, vehicle and transmission. To To do Check ck Tr ans this, the TCM turns on the Che light on the instrument panel, which will notify the operator that a Diagnostic Trouble Code (DTC) has been stored in the TCMs memory. Check ck Tr ans Each time the engine is started, the Che light will illuminate momentarily and then go off after a few seconds. This momentary lighting is to ensure Check ck Tr ans that the Che light circuit is working properly. Illumination of the Che light at any time after Check ck Tr ans start-up, indicates that the TCM has stored a DTC, or the TCM is not working properly. Anytime the Check light is on, upshifts and downshifts will be Trans restricted and direction changes may not occur. The converter clutch is also shut off when transmission shifting is restricted. If power is interrupted while while the transmission is operating in a forward range, the default positions of the shift valves and solenoids will enable application of two clutches to maintain forward range operation (Either 3 or 5th). If power is interrupted interrupted while the transmission is operating in R (Reverse) ( Reverse) or N(Neutral), the transmission defaults to or continues con tinues Neutral operation untill a key cycle.

22

Th e ope The operr ator may tur n off an d r estart th e engi ne, and the th e manu al sel sel ector l eve verr wi w i l l pr ovide reverse reverse when whe n i n R, N eutr al when in P/N, and 3rd Gear Gear wh en in any for ward r ange ange,, r egardl ess of th e r ange where the f ail ur e occ occur ur ed.

RETRI RIEVI EVING NGDI DIAG AGNOSTI STIC C CODES Currently you must use PC Tool Software called TransPro® which is available through Kent-Moore Heavy-Duty Division, and must be loaded onto a Windows 95/98 Lap-Top Lap-Top PC as shown in Figure 26. The TransPro® software transmits and recieves data to and from the TCM via the J-1939 connector, as shown in Figure 26, processes the data, and displays the appropriate information on the screen. The use of TransPro® is describeded in detail in the instruction manual that is furnished with each set of software. We have provided you with a typical screen, that is utilized in the TransPro® software, for retrieving DTCs in Figure 27. Hopefully aftermarket scanner manufacturers will be able to provide us with a cartridge for the more popular scanners in the future.


Technica l Serv ice Infor mation LINE LI NEPRESSURE TEST

TYPICAL TransPro® DIS ISP PLAY X

Allison TransPro

Transmission

Demo Dem o Mode O N

Code 34691260 58136522 64548910 43367338

P0713 P0722 P0748 P0763

Description

Trans Fluid Temp Sensor C ircuit High Input Output Speed Sensor Circuit No Signal Pressure Control Trim Solenoid A Electrica l ShiftSolenoid C Electrical

? Active

MIL

Y Y Y Y

Y Y Y Y

Check transmission fluid level. All transmission fluid level and pressure checks must be made at normal operating temperatures (160-200°F). Connect a 0-300 psi oil pressure guage to the main pressure tap as illustrated in Figure 28, an d compare readings with the pressure chart in Figure 28. Take precautions against vehicle movement during the pressure tests, and use a guage with an extended line so that it can be read from inside the vehicle.

DTC s Retrieve Retrieved d Start

Allison TransPro

10:45 AM


Figure 27

MAIN MAI N PRESSURE TAP LOCATION ANDSP SPEC ECIFI FIC CATIONS MAIN MAI N PRESSURE TEST ESTSPECI SPECIFI FIC CATIONS Range

Pre Pr essure @600 RPM

Pressure @1200 RPM

PARK/ ARK/NEU NEUTRAL

900-1 9001655 kpa (1 (130-240 psi) psi)

15155-1 1795 kpa (220(220-260 260 psi) psi)

REVERSE

800-1 8001380 kpa (1 ( 1155-200 200 psi) psi)

15155-1 1795 kpa (220(220-260 260 psi) psi)

FORWARD (T (TCCOff Off))

800-1 8001380 kpa (1 ( 1155-200 200 psi) psi)

15155-1 1795 kpa (220(220-260 260 psi) psi)

FORWARD (T ( TCC On)

1000000-1 1170 kpa (14545-1 170 psi psi) M ain Pres Presssur e Tap Tap

R E L O O C O T

R E L O O C M O R F

Figure 28


23


BELL HOUSI USING NGOIL PASSA PASSAGE ID IDENTIFI FIC CATION

16

3 3

29536810

16

3 3 2

1

1

9 16

8 13

1 16

2

16

15 14

7

10

9

1

6

2

11

16

1. PUMP SUC TIO ION N 2. LINE PRESSURE 3. OVER O VERAG AGE E (C (CON ONV V RE RELE LEASE ASE)) 4. CONVER CO NVERT TER IN 5. CONVER CO NVERT TER OUT 6. TO C OO OOLE LER 7. FR FROM OM C OO OOLE LER 8. LUBEOI OIL L 9. LOCK-UP LOC K-UPAPPL APPLY Y 10. C 1 CLUT CLUTC H 11. C 2 CLUT CLUTC H 12. LOC LOCK-U K-UP P SIGNAL 13. C UT-BAC -BACK K (5THGEAR) 14. LINE - TO FILT FILTER 15. LINE - FROM FROM FILTER 16.. EXHAUST 16

15

14

2

16

7 6

16

BOTTOM BELL HOUSI USING NGCOOLER MANIFOLD MANIFOLD SURFA SURFACE Copyright © 2000 ATSG

Figure 29

24

16



PUMP COVER SPAC SPACER PLAT PLATE OIL PASSAGE I. I.D. 16 16

16

3

16

2 3 2

16

16

3

2 16

9 16

8

16 1

2 7

1

6

9 16 10

11

2

13

14

15

1

1. PUMP SUC TIO ION N 2. LINE PRESSURE 3. OVER O VERAG AGE E (C (CON ONV V RE RELE LEASE ASE)) 4. CONVER CO NVERT TER IN 5. CONVER CO NVERT TER OUT 6. TO C OO OOLE LER 7. FR FROM OM C OO OOLE LER 8. LUBEOI OIL L 9. LOC LOC K-UPAPPL APPLY Y 10. C 1 CLUT CLUTC H 11. C 2 CLUT CLUTC H 12. LOC LOCK-UP K-UPSIGNAL 13. C UT-BAC -BACK K (5THGEAR) 14. LINE - TO FILT FILTER 15. LINE - FROM FILTER 16.. EXHAUST 16


Figure 30


25

Technical Service Informat ion

MAIN MAI N CASE"FRONT" PASSAGE I. I.D.

16 16

16

N/A N/ A

9 16

16

16 11

10

2

13 14

1. PUMP SUC TIO ION N 2. LINE PRESSURE 3. OVER O VERAG AGE E (C (CO ONV RELEASE) 4. CONVER CO NVERT TER IN 5. CONVER CO NVERT TER OUT 6. TO C OO OOLE LER 7. FR FROM OM C OO OOLE LER 8. LUBEOI OIL L 9. LOC LOC K-UPAPPL APPLY Y 10. C 1 CLUT CLUTC H 11. C 2 CLUT CLUTC H 12. LOC LOCK-UP K-UPSIGNAL 13. C UT-BAC -BACK K (5THGEAR) 14. LINE - TO FILT FILTER 15. LINE - FROM FILTER 16.. EXHAUST 16


Figure 31

26

15

1



MAIN CASE "REA "REAR" PASSAGE I. I.D.

C5 CLUTCH


Figure 32

COOLER MANIFOLD MANIFOLDPASSAGE I. I.D. MAIN LINE PRESSURE TAP

14

TO 15

CLR

FROM 6

7

CLR

6. TO C OO OOLE LER 7. FR FROM OM C OO OOLE LER 14. LINE - TO FILT FILTER


Figure 33


27


PUMP COVER OIL PASSA PASSAGE I. I.D.

9 3 9

5

4 16 12

6

9

4

2

3 3

12

2 8

3 2 6

16 13

9

1

8

1

16

16 2

11 10 7

6

1

10 16

1. PUMP SUC TIO ION N 2. LINE PRESSURE 3. OVER O VERAG AGE E (C (CO ONV RELEASE) 4. CONVERT CO NVERTER IN 5. CONVERT CO NVERTER OUT 6. TO C OO OOLE LER 7. FR FROM OM C OO OOLE LER 8. LUBEOI OIL L 9. LOC LOC K-UPAPPL APPLY Y 10. C 1 CLUT CLUTC H 11. C 2 CLUT CLUTC H 12. LOC LOCK-UP K-UPSIG IGNAL NAL 13. C UT-BAC -BACK K (5TH GEAR) 16. EXHAUST


Figure 34

28



OIL PUM PUMP PASSAGE I. I.D.

2 2

14

14 1 1

1. PUMP SUC TIO ION N 2. LINE PRESSURE 14. EXHAUST


Figure 35

SHIFT SHI FTVALVE BODY "T "TOP VI VIEW EW" PASSAGE I. I.D. Exhaust

Exhaust

Exhaust


Figure 36


29

Technica l Ser vice Information

LEGEND FOR FIG FI GURES 38, 39, AND 41.

Passage N o.

Rever se

Par k / N eu t

1st

2n d

1

Pump Sucti Sucti on

2

M ain L ine Pres Pressur e

9

TCC Apply

10

Exh aus austt Backfil l/ C-1 Clutch

11

3r d

C- 2 Cl u t ch / E x h au st B ack f i l l

13

Cut-Back (5th Gear)

14

Control M ain L ine Press Pressur e To Fi lter

16

Exh aus austt To Sump

15

Control M ain L ine Pres Pressure Fr om Fi lte lter r

30

Reverse Reve rse Pr es essure sure Swi tch

31

" D" Shift Val ve Pres Presssur e Sw Switch itch

32

" E" Shift Valve Pres Presssure Switch Switch

33

" C" Shift Val ve Pres Presssure Switch Switch E x h au st B ack f i l l / C- 3 Cl u t ch

C- 3 Cl u t ch

35

C-4 Clutch

36

C-5 Clutch

37

Exhaustt B ac Exhaus ackfil kfil l

38

" A" Trim Soleno Solenoid id Signal Signal

39

" B" Trim Soleno Solenoid id Signal Signal

40

" A" Clu Clutc tch h Trim

41

" B" Clu Clutc tch h Trim

42

" A" Clutch Trim Feedba Feedback ck

43

" B" Clutch Trim Feedba Feedback ck

44

" D" Sole olenoid noid Signal Signal

45

" E" Sole olenoid noid Signal Signal

46

" C" Sole olenoid noid Signal Signal

47


C-1/B C-1/ B Tri m

48 49 50 51

M ain L ine Pres Pressur e C-3/B C-3/ B Tri m

E B F / C - 3 C l u t ch

C - 3 Cl u t ch

C-1/B C-1 /B Tri m

C-1/EBF

B Trim

C-2/EBF

C-2/B C-2 /B Tri m

C-2/Main

Thermister C-3/EBF


Cut-Back

" D" Signa ignall TCC Interlock Interlock C-1/EBF

C-1/B C-1/ B Tri m


Exhaust C-1/Main C-2/EBF

C-1/B C-1 /B Tri m C-2/B C-2 /B Tri m

C-1/EBF

C-2/Main

Exh aus austt Backfil l/C-5 Clutch (Power Off State) State) C- 3/B T r i m

C-3/EBF

C-4/B C-4 /B Tri m

C- 4/E B F

OD / E B F

OD /B T r i m


Figure 37

30

" E" Shift Valve Interlo Interlock ck

56 57

C-1/Main


53 55

EBF / C-1 Clutch

Control Main After " B" Sole olenoid noid Scre Scree en

52 54

C - 2 C l u t ch

Lock-Up Signal

C- 3 Cl u t ch

5th

C-1 Clutch

12

34

4th



SHIFT SHI FT VALVE BODY "BO "BOTTOM VIEW VIEW" PASSAGE I. I.D.

37 16 30 30 56

16 30

31

56

37

32

31

53

47

37 47

56

10

11

55 37

37

11 37 37

37

36

35

56

57

16

53

37

51 2

49 16

37 2

54

32

57

44

37 37 33 15

57

32

52

37

2

52 45

44

44

14

41 2

40

37

14

53

2

47

37

11 16

44

37

54

34

2

49

13

37

2 31

56 13

10

2

31

31

13

16

2

44

15 40

46

37 41

16

16

15

2 41

40 37

46 15

15 48

16

15

LEG EGENDFOUND ON PA PAGE 30.


Figure 38


31


MAIN MAI N VALVE BODY "T "TOP VI VIEW EW" PASSAGE I. I.D.

16

16

16

16

16 16

16 30 16

30 16

39

38

15

39

37

44

37

38

40

15 45

16 34

35

41

2

36

44

56

2

56

2

42

43 37

16

16

37

45 34

44

36

37 40

33

37

56

35 51

57

44

40

54

47

2

9

37

30 31

31

13

2

30

37

14

16

15 10

11

30

2

10

47

11

32

5 6

40

53 31

14

30

15

2

16 16

11

32

16

9

34 51

54

14

11

40

2

44

55

36

37

2

16

37

9

33

32

9 53

51

57 2

34

37

40

15

32

15

9 2

15

32

16

10

11 14

9 13

15

14 14

16

LEG EGENDFOUND ON PA PAGE 30.


Figure 39

32



MAIN MAI N VALVE BODY "BO "BOTTOM VIEW VIEW" PASSAGE I. I.D.

30 16

16

39

16

38

16

50

31 33

e g a P u D

0 4 8 6 3 5 9 2

30 32

16

30 16 16

16. 30.. 30 31.. 31 32.. 32 33. 38. 39. 50.. 50

EXHAUST. REVERSEPRESSURE SWITC H. "D" SHIFT VALVE PRESSURESWITC H. "E"SHIFTVALVE PRESSURE SWITC ITCH. H. "C"" SHIFTVALVE PRESSURE SWITC H. "C "A"TRIM SOLENOID SIGNAL. SIGNAL. "B" TRIM SOLENOID SIGNAL. SIGNAL. FLUID TEMP EMPERAT ERATURESENSOR (THERMI ERMIST STER).


Figure 40


33

Technica l Ser vice Information

TYPICAL VALVE BODY SPACER PLATE

39 36

38

15

16 34

56

35

37

37

40

41 2

42

43

16

16 2

45

44 37

53

40

37

37

15

51 56

55

11

35

36

56

2

44

37

40

55

32

34 11

2

47

57 54

54

37 51

47 10 31

14

44

32

37

14

53

53

47

31 30

2

31

13

2 30

2

2

37

30 2

15

32

33

57

16

14

9 14

10

13

11

7 3 8 6

LEGEND FOUND ON PA PAGE 30.


Figure 41

34



MAIN MAI N CASE "BO "BOTTOM VIEW VIEW" PASSAGE I. I.D.

16

14

1

11

13

10 2

15 9

8 0 8 6 3 5 9 2

35 16

34

16

56

36

1. SUC TIO ION. N. 2. MA MAIN IN LINE PRESSURE. 9. TC C APPLY. 10. 1 0. C -1 CLUT CLUTC H. 11. 1 1. C -2 CLUT CLUTC H. 13. C UT-BACK (OverDr (OverDrive). 14. C ON ONT TROL MAIN TO FILTER ER.. 15. C ON ONT TROL MAIN FROM FILTER ER.. 16. EXHAUSTTO SUMP SUMP. 34. 3 4. C -3 CLUT CLUTC H. 35. 3 5. C -4 CLUT CLUTC H. 36. 3 6. C -5 CLUT CLUTC H. 56. C -5 CLU C LUTC H (Power (Power-Off Sta Sta te).


Figure 42


35


TRANSMIS ISS SION DIS ISA ASSEMBLY EXTERNAL COMPO PONENTS 1. Remove the six six PTO cover retaining retaining bolts or the Power Take Of Offf whichever it is equipped with, on the right hand side of the transmission as shown in Figure 43. 2. Install holding fixture similar to the one shown in Figure 43, onto the PTO surface, to be used with the bench fixture base. Caution Caut ion : B ec ecause ause of t he mass mass and th e weight of thi s un unit, it, we fee feell it nec nece essary to use hol din g fi xtur e shown in F igur e 43, with the fi xtur e base bas e or in a sui table tur n-ove n-overr stand. 3. Using a suitable hoist, lift lift the transmission and install into bench fixture base, or the suitable turn-over stand. 4. With transmission assembly locked, locked, in the pan facing down position, remove the converter by pulling it straight out (See Figure 44). Cauti on: Th This is torque conve converr te terr we weigh igh s about 60 poun ds ds,, so exerci se extr eme cauti on.

5. Remove the engine speed sensor, sensor, turbine speed sensor and output speed sensor, as shown in Figure 45. Note Not e: Th e engi engi ne spe spee ed sensor, sensor, i f equi ppe pped, d, the tu turr bin e spe pee ed sens ensor or , and th the e outpu t spe pee ed sensor on 2WD models ar are e all the same part numbe nu mberr (Se (See e F igu r e 45). 6. Remove and discard the "O" rings from from the 3 speed sensors (See Figure 45). 7. Remove the Neutral Neutral Start Back-Up switch switch from the side of case, as shown in Figure 45. Note: T he NSBU Switch is exactly exactly th e same same as the 4L 4L60-E 60-E switch (Se (See e F igu r e 45). 8. Rotate the transmission transmission in the fixture so that the oil pan is facing up (See Figure 46).

Continued on Page 38

BENCH BENC H FIXTURE BASE 9 . 8

9 . 8

9 . 8 9 . 8

9 . 8

9 . 8

9 . 8 9 . 8

9 . 8

nn isosio Aanllsmis- X XX XX XX X XX X Tr - X DI

9 . 8

X XX . RP -X X XX XX X X XX - XX XX XX XX X X XX X X XX X X X X- X XX X XX X X XX X XX XX

O SC O RA TO T N MO IA A L ND ER , I EN LI S FG PO NO NA IO IA V I S IN D

L DE MROIES TIDX X E 0 S DA TE 100 NO. X X 21 IAL X X 99F SEXRX XN X X C X X X EXF X X XX XX

W U9 A3 3 3 3

9 . 8

9 . 8

9 . 8

9 . 8

9 . 8

9 . 8

HOLDING FIXTURE


Figure 43

36



on Allis 0 3 1 5 3 1 2 9


Figure 44

OUTPUT SPEED SENSOR SENSOR (2WD MODELS)

TURBIN INE E SPEED SENSOR (ALL MODELS)

ENGINE SPEED SENSOR (SOME MODELS)

on Allis

NSBU SWITC H

3 1 1 0 5 3 2 9

12450016 29536408


Figure 45


37

Technical Service Informatio n CONTINUED FROM PAG PAGE 36 9. Remove the twelve twelve bottom pan retaining bolts, using a 13 mm socket (See Figure 46). 10. Remove the bottom oil pan (See Figure 46). 11. Remove and discard the bottom pan gasket, a s shown in Figure 46. 12. Remove and discard the bottom pan filter and filter seal, as shown in Figure 47. 13. Remove the inside detent roller and spring assembly retaining bolts, using an 8mm socket, as shown in Figure 48. 14. Remove the inside detent roller and spring assembly, as shown in Figure 48. 15. Remove the pass through case connector from the case bore using the Teckpak ä GM harness removal tool, as shown in Figure 49.

BOTTOM PAN

16. Remove the 15 valve body to case retaining bolts, using an 8mm socket (See Figure 50). Note: Remove Remove " Onl y" the valve valve body body to cas case e boltss th bolt that at ar e shaded as shown in F igu r e 50.


PAN BOLTS 12 REQUIRED

BOTTOM PAN FILTER

PAN GASKET

FILT FI LTER SEAL

1 8

1 8

D u P a g e

D u P a g e 8 08 80 295 9536

536808 295


Figure 46

38


Figure 47


Technica l Serv ice Infor mation TECKP CKPAK AK ä GM HARNESS REMOVAL TOOL

DETENT ROLLER AND AND SPRING ASSEMBLY RETAINING BOLTS

DETENT ROLLER AND AND SPRING ASSEMBLY

8 . 9 9 8 .

. 9 8

9 8 . 8 . 9

8 . 9

1 8

8 . 9

. 9 8

D u P a g e

. 9 8

8 . 9

6808 29536

M O ED

D IV I NI SOI D AI ON N F A G OP E N L E , SI RA NI ML D O AI T AN OR CS O R .P

T ar n A sm ll si s si o oi n n



Figure 48

Figure 49

FOUR VALVE BODY TO CASE BOL OLT TS

29536808

0 4 8 6 3 5 9 2

D u P a g e

FIVE VALVE BODY TO CASE BOL OLT TS

SIX VALVE BODY TO CASE BOL OLT TS


Figure 50


39

Technica l Serv ice Inform ation CONTINUED FROM PAG PAGE 38 17. After the 15 valve body bolts are removed, you can remove the valve body, ensuring that you disengage the manual valve pin from the inside detent lever, as shown in Figure 51. 18. Set the complete valve body assembly aside for the component rebuild process. 19. Remove the external oil filter from the cooler manifold or the bell housing, depending on the design, as shown in Figure 52. 20. Remove the cooler manifold assembly retaining bolts, as shown in Figure 54. 21. Remove the cooler manifold assembly from the bell housing, as shown in Figure 54. 22. Remove and discard the 2 cooler manifold gaskets, as shown in Figure 54.

23. Rotate the transmission in the fixture so that the bell housing is facing up (See Figure 53).


VALVE BOD BODY TO CASE BOL OLT TS 15 REQUIRED

VALVE BOD BODY TO CASE BOL OLT TS 15 REQUIRED

D u P a g e

1 8

29536808


Figure 51

40



EXTERNAL OIL FILTER

7

1 8

6 29536808

5

3


4

Figure 52

3

1

1 8

08 80 295368

2

9 5 3 1

0

3

2

1

1. 2. 3. 4. 5. 6. 7.

TRANSMISSIO ION N C ASE ASE.. TRANSMI RANSMISS SSIO ION N BELLHOUSING HOUSING.. C OO OOLE LER R MAN MANIFO IFOLD LD SPACER PLAT PLATEGASKET(2 REQUIRED) QUIRED).. C OO OOLE LER R MAN MANIFO IFOLD LD SPACER PLATE. C OO OOLE LER R MAN MANIFO IFOLD LD ASSEMBLY. C OO OOLE LER R MAN MANIFO IFOLD LD RE RET TAININ AINING G BOLT, M8 x 1.25 x 30 (8 REQ). C OO OOLE LER R MAN MANIFO IFOLD LD RE RET TAININ AINING G BOLT, M8 x 1.25 x 40 (4 REQ).


Figure 53


Figure 54


41

Technical Service Informat ion 1

CONTINUEDFROM PAG PAGE 40

1

2

2

9 5

3 1

0

3 1

1

3 1

24. Remove 2 bell housing bolts from each side of the case that are not inside the bell housing, as shown in Figure 55. 25. Remove the bell housing to case bolts that are shaded, from inside the bell housing, as shown in Figure 56. N ote: Remove R emove th the e shaded bol bolts ts only, onl y, as sh own in Fi gure 56 56.. There wil l be 11 bolts that are 50mm lon g and 5 bolts that are 70mm lon g. The Th e r emain in g bolts r etain pump to be bellll . 26. Remove bell housing and oil pump assembly from the transmission case, by lifting straight up, as shown in Figure 55. 27. Remove and discard the pump spacer plate to case gasket (See Figure 55). 28. Set the bell housing and pump assembly aside for the component rebuild process. 29. Remove the C1/C2 clutch housing from the case by lifting straight up using the turbine, as shown in Figure 57. N ote: Remove Remove th the e sun gear/plan gear/ plan etar y car carrr ier thr ust be beari ari ng if it is not stuck to sun ge gear ar as shown in F igur e 57.

4

2 953103 1

5

1. BELL HOUSING TO C ASEBOLTS, M10 M10 X 1.5 1. 5 X 50, 50, (11 INSIDE BELL, 2 EAC ACH H SIDEON OUTSIDE, TOTAL 15 REQ.) REQ.) 2. BELL HOUSING TO C ASEBOLTS, M10 M10 X 1.5 1. 5 X 70, 70, (5 RE REQUIRED) QUIRED) 3. BELL HOUSING AND PUMP PUMP ASSEMBLY 4. BELLHOUSING SPAC SPACER ER PLATE TO C ASE GASKET 5. MAIN TRANSMISSIO ION N C ASE ASSEMBLY

5 BOLT BOLTS 70mm IN LENG LENGT TH OTHER 11 ARE 50mm IN LENGTH


Figure 55

42


Figure 56


Technica l Serv ice Infor mation 30. Set C1/C2 clutch housing aside for component rebuild process that is covered later. 31. Rotate transmission case so that the extension housing is facing up as shown in Figure 58. 32. Remove the yoke from the transmission if it is equipped with one, as shown in Figure 58. N ote: Some mode s ar are e equ ppe pped d w th t h th e parr k n g brake as shown n F gur e 58. Four pa Whee Dr ve mode s w have ne ther.

(SOME MODELS)

Continued on Page 45 (SOME MODELS)

C 1/C2 C LUTC H HOUSING ASSEMBLY

THRUST BEARING

9 8 . 8 . 9

. 9 8

9 8 . 8 . 9

8 . 9 8 . 9

8 . 9

8 . 9

. 9 8

M O ED

D IV I NI SI D ON I A O N F A G P E O N L E SI AR , NI ML D O AI T N O A SR C O R .P

T ar A n sm l si s si o oni n


Figure 57


Figure 58


43

Technica l Servi ce Inform ation EXTENSION HOUSING BOLTS M10 X 1.5 X 40 (16 REQUIRED)

P3 PLANETARY C ARRIER ASSEMBLY

OUTPUT SHAFT

EXTENSION HOUSING

THRUST BEARING P3 SUN GEAR

EXTENSION HOUSING GASKET

1 0 0 0 2 1

C 3 1 0 0 0 1 0 1 1

8 8 / 2 1

1 0 0 0 1 R M 8

1 0 0 0 2 1

A l l i s o n

T r a n s m i s s i o n


Figure 59

44

C 3 1 0 0 0 1 0 1 1

8 8 / 2 1

1 0 0 0 1 R M 8

A l l i s o n



Figure 60


Technica l Serv ice Infor mation CONTINUEDFROM PAG PAGE 43 33. Remove the 16 extension housing bolts, using a 15mm socket (See Figure 59). 34. Remove the extension housing assembly and set aside for the component rebuild process,as shown in Figure 59. 35. Remove and discard the extension housing gasket, as shown in Figure 59. 36. Grasp the output shaft splines and lift straight up, removing the output shaft and P3 planetary carrier as an assembly (See Figure 60). 37. Remove the P3 sun gear and the thrust bearing as shown in Figure 60. 38. Grasp the main shaft splines and lift straight up removing the main shaft, P2 sun gear and the sun gear spacer, as shown in Figure 62. 39. Remove the parking pawl shaft by pulling up and twisting motion at the same time. This will help in the removal as it is air locked in the case bore (See Figure 62). 40. Remove the parking pawl by slight twisting motion to disconnect from the parking pawl return spring (See Figures 61 and 62). Continued on Page 47

SUN GEAR SPAC SP ACER ER

P2 SUN GEAR

MAIN SHAFT

PARKING PAWL SHAFT

PARKING PAWL

PARKING PAWL RETURN SPRING SPRING

1 0 0 0 2 1

C 3 1 0 0 0 1 0 1 1

8 8 / 2 1

1 0 0 0 1 R M 8

A l l i s o n



Figure 61

Figure 62


45

Technical Service Informat ion C5 CLUTCH RETURN SPRING SPRING ASSEMBLY

C5 CLUTCH STEEL PL PLATE ATE (6 REQUIRED)

1

2

C5 CLUTCH LINED PLATE (6 REQUIRED)

C5 CLUTCH BACKING PLATE BACKING PLATE

1 0 0 0 2 1

C 3 1 0 0 0

1 0 1 1

8 8 / 2 1

1 0 0 0 1 R M 8

A l l i s o n


C 3 1 1 0 0 0 0 0 0 2 1 1 0 1 1

1. P2 PLANET PL ANETARY CARRIER/P2 CARRIER/P2 SUN GEAR THRUSTBEARING 2. P2 P2 PLANET PL ANETARY CARRIER CARRIER ASSEMBLY


Figure 63

46

8 8 / 2 1

1 0 0 0 1 R M 8

A l l i s o n



Figure 64


Technica l Serv ice Infor mation CONTINUED FROM PAGE 45 41. Remove the P2 planetary carrier assembly by lifting up with a slight twisting motion. Refer to Figure 63. Note: T he planetary planetary carr ier to P2 sun sun ge gear ar thr ust be beari ari ng wil l be r emove moved d wit h the planetary carr ier (Se (See e F igu r e 63). 42. Remove the C5 clutch return spring assembly from case, as shown in Figure 64. 43. Remove the C5 clutches both lined and steel from case, as shown in Figure 64. 45. Remove the C5 clutch backing plate from the case, as shown in Figure 64. 46. Remove the P1 planetary carrier assembly by lifting up with a slight twisting motion. Refer to Figure 65. Note: Th e P1 plan plan etar y carr carr ier/P2 planetary carr ca rr ier thr us ustt be beari ari ng, and the P2 r in g ge gear ar to P1 r in g ge gear ar thr ust was washer her wil l be r emove moved d with the carr ier as asssembly (Se (See e F igu r e 65).

1

2

3


C 1 3 1 0 0 0 0 0 0 2 1 1 0 1 1

8 8 / 2 1

1 0 0 0 1 R M 8

A l l i s o n


1. P1 PLANET PL ANETC ARRIER/P2 PLANET PLANETC ARRIER THRUSTBEARING 2. P1 P1 PLANET PL ANETARY CARRIER CARRIER ASSEMBLY 3. P1 RING RING GEAR/P2 RING RING GEAR "PEEK"THRUSTWASHER


Figure 65


47

Technical Service Informati on C 4 CLU C LUTC H BACKING PLATE BACKING PLATE SNAP RING

SPIRAL SNAP RING

C4 CLUTCH BACKING PLATE BACKING


C4 CLUTCH BACKING PLATE BACKING SNAP RING

C4 CLUTCH STEEL PLATE (4 REQUIRED)

SPIRAL SNAP RING

PARKING ACT AC TUATOR GUIDE

C4 CLUTCH APPLY PLATE

C 3 1 1 0 0 0 0 0 0 2 1 1 0 1 1

8 8 / 2 1

1 0 0 0 1 R M 8

RETURN SPRING SPRING ASSEMBLIES (3 REQUIRED)

1 0 0 0 2 1

A l l i s o n



Figure 66

48

C 3 1 0 0 0 1 0 1 1

8 8 / 2 1

1 0 0 0 1 R M 8

A l l i s o n



Figure 67


Technica l Serv ice Infor mation CONTINUEDFR FRO OM PAG PAGE 47

47. Remove the parking actuator guide from case as shown in Figure 66. 48. Remove the C4 clutch backing plate snap ring from the groove in case (See Figure 66). 49. From the same groove in the case, remove the groove spiral snap ring from case (See Figure 66). Note: Refer Refer to the cut-away in F igu r e 66 to see how th the ese snap r in gs ar are e in gr gr oove oove.. 50. Remove the C4 clutch backing plate p late from the case as shown in Figure 67. 51. Remove the C4 clutches both lined and steel from the case, as shown in Figure 67. 52. Remove the C4 clutch apply plate with the 3 return spring assemblies on it from the case as shown in Figure 67. N ote: Th ese th thrr ee r etu turr n spr spr in g ass assembl mblii es ju st cli p onto app apply ly plate (Se (See e F igu r e 67).

53. Remove the C4 clutch apply piston from case by blowing compressed air into the C4 clutch passage as shown in Figure 68. Note:F Note :F igur e 74 on on Page 51 will ide identif ntif y the C4 clu tch pas passsage f or th the e compr compre essed air . 54. Remove the P1 planetary ring gear from the C3 clutches in the case (See Figure 69).


P1 PLANETARY RING GEAR

C 4 CLU C LUTC H APPLY PISTON

C 1 3 0 1 8 0 8 0 0 0 0 / 2 2 1 1 1 0 1 1

1 0 0 0 1 R M 8

C 1 0 1 3 0 1 8 0 0 0 8 0 0 0 0 / 2 1 2 1 1 R M 1 0 1 8 1

A l l i s o n



Figure 68

A l l i s o n



Figure 69


49

Technica l Serv ice Inform ation CONTINUED FROM PAGE 49 55. Rotate the transmission in fixture so that the front of the transmission case is facing up, as shown in Figure 70. 56. Remove the C3 clutch backing plate snap ring from the case, as shown in Figure 70. 57. Remove the C3 clutch backing plate from the case, as shown in Figure 70. Note: I nsp nspe ect the thr ee thr ust washer washer sur f ace aces s that are pop r ivete iveted d onto the bac backi ki ng plate as shown in F igu r e 71. Th ese piece piecess ar e not servi ced se seperat perately. ely. 58. Remove the C3 clutch plates both the lined and steel, as shown in Figure 70. 59. Remove the C3 clutch apply plate with the 3 return spring assemblies on it from the case, as shown in Figure 72. Note Not e: T hes hese e thr ee r etu turr n spr spr in g ass assembl mblii es ju st cli clip p onto apply plate (Se (See e F igu r e 72). 60. Remove the C3 clutch apply piston from case by blowing compressed air into the C3 clutch passage, as shown in Figure 73. Note:: F igur e 74 Note 74 on Page Page 51 will ide identif ntif y the C3 clu tch pas passsage f or th the e compr compre essed air . 61. This ends transmission disassembly.

C3 CLUTCH BACKING BACKIN G PLATE PLATE SNAP RING

C3 CLUTCH BACKING BACKIN G PLATE PLATE


C3 CLUTCH STEEL PLATE PLATE (3 REQUIRED)

C3 CLUTCH BACKING PLATE BACKING WITH 3 THRUST WASHER SURFAC ES


Figure 70

50


Figure 71


Technica l Serv ice Infor mation C 3 CLU C LUTC H APPLY PLATE

C3 CLUTCH APPLY PISTON




Figure 72

Figure 73

C4 CLUTCH PASSAGE

29536808

C3 CLUTCH PASSAGE

Figure 74


51

Technical Service Informat ion LINKAGE/ LINKAG E/P PARK RELATED PARTS AND EXTERNALCASEPART PARTSEXPLOD EXPLODEDVIEW VIEW 4 5 3

2 6 7 8 1

5 4 3 N

15

16

10

12 11

14

9

1. 2. 3. 4. 5. 6. 7. 8. 9.

TRANSMI RANSMISS SSIO ION N C ASEASSEMBLY. IDENTIFI IFIC C ATIO ION N TAG AND RIVET. PTO COVER C OVER RETAININ AINING G BOLTS, M10 X 1.5 X 20 (12 REQUIRE REQUIRED). D). PTO CO COVERASSEMBLY (2 REQUIRED). PTO COVER C OVER TO CASE C ASEGASKET(2 REQUIRE REQUIRED). D). TURBIN INE E SHAFTSPEED SENSOR. TURBINE SHAFTSPEED SENSOR "O"RING RING.. SPEED SENSOR RETAIN AINING ING BOLT, M6 X 1.0 X 13 (1 REQUIRED). REQUIRED). MANUAL MA NUAL SHAFTASSEMBLY.

13

10. 11. 12. 13. 14. 15. 16. 17.

MANUAL SHAFTSEAL. MANUAL MANUAL MA NUAL DETENTLEVER. MANUAL MA NUAL DETENTLEVER FLANG FLANGE E NUT. PARKING PARKIN G PAWL APPLY ROD ASSEMBL ASSEMBLY. PARKING PAWL APPLY APPLY ROD GUIDE G UIDE. PARKING PARKIN G PAWL SUPPO UPPORT RTSHAFT. PARKING PARKIN G PAWL PAWL ASSEMBLY. PARKING PAWL RETURN SPRING.

Figure 75

52

17



Technica l Serv ice Infor mation COMP MPO ONENTREBUI REBUILD LD TRANSMIS ISS SION CASE 1. Remove the parking linkage as necessary and install a new manual linkage seal into the case bore, as shown in Figure 75. 2. Inspect Inspect the C3 clutch molded apply piston and replace as necessary (See Figure 76). 3. Lubricate C3 clutch piston with with a small amount of TransJelä, and install into the case bore, as shown in Figure 76. 4. Install Install the the three return spring assemblies assemblies onto the wide tabs of C3 apply plate and install the apply plate assembly on top of the piston, as shown in Figure 78. 5. Inspect Inspect the three washer surfaces that are pop riveted onto the C3 clutch backing plate, as shown in Figure 77. N ote: Thes T hese e 3 pieces pieces and r i ve vets ts are avail avail able as se serr vi vice ce i tems. Repl Replace ace as n ece ecess ssar ar y.

C3 CLUTCH BACKING PLATE BACKING WITH 3 THRUST WASHER SURFAC ES



Figure 77

C 3 CLU C LUTC H APPLY PLATE




Figure 76


Figure 78


53

Technical Service Informatio n CONTINUED FROM PAG PAGE 53 6. Install Install C3 clutch pack beginning with a lined plate on top of the apply plate and alternating with a steel plate until you have installed four lined plates and three steel plates, as shown in Figure 79. 7. Install Install the pre-inspected pre-inspected C3 backing plate with the 3 washer surfaces facing down, as shown in Figure 79. 8. Install the C3 clutch backing plate snap ring in the case groove (See Figure 79). 9. Check the C3 clutch clearance using a feeler gage, through the front opening in transmission case, as shown in Figure 80. 10. Correct clearance should be .040"-.060" N ote: Th er e ar are e no sel sel ectives ctives.. I f cl ear arance ance is not corr ec ect, t, th the er e is a mi miss-ass -asse embl mbly. y. 11. Rotate the transmission in the fixture so that the rear of the transmission is facing up, as shown in Figure 80.

C3 CLUTCH BACKING BACKIN G PLATE PLATE SNAP RING

C3 CLUTCH BACKING PLATE BACKING PLATE


CHECKING C3 CLUTCH CLEARA RANCE C3 CLUTCH STEEL PLATE PLATE (3 REQUIRED)


Figure 79

54


Figure 80



COMP MPO ONENTREBUILD (C (Cont ont''d) OIL PUMP ASSEMBLY 12. Install the P1 planetary ring gear into the case and engaging into the C3 lined plates until it is fully seated against the washer surfaces on the C3 backing plate (See Figure 81). 13. The transmission case is now ready for the final assembly process. Caution: Do n ot r ota otate te the transmis transmisssion fr om thi s pos positi iti on as the r in g ge gear ar may f all out and create damag damage e or in ju r y.

1. Remove the bolts from inside the the bell housing that are shaded, as shown in Figure 82, so that the oil pump assembly is seperated from the bell housing (See Figure 82). Continued on Page 57

3/4 Vi ew

P1 PLANETARY RING GEAR 9 . 8

9 . 8

. 9 8

. 9 8

F ront View View

2 953103 1

1 0 0 0 2 1

C 3 1 0 0 0 1 0 1 1

8 8 / 2 1

1 0 0 0 1 R M 8

A l l i s o n




Figure 81

Figure 82


55

Technical Service Informati on OIL PUMP PUMP ANDBELL HOUSI USING NG EXPLO EXPL ODEDVI VIEW EW

. 9 8


Figure 83

56


Technica l Serv ice Infor mation CONTINUED FROM PAG PAGE 55 2. Remove the five oil pump cover to oil pump retaining bolts to disassemble the oil pump, as shown in Figure 84. 3. Disassemble Disassemble the the oil pump and oil pump cover using Figures 85 and 86 as a guide. 4. Remove and discard the pump spacer plate to bell housing gasket and the pump spacer plate to case gasket (See Figure 83, 85 and 86). 5. Remove and discard the 3 sealing rings on the back side of pump cover (See Figure 85). 6. Remove and discard the 2 sealing rings on the stator shaft in front (See Figure 85).

7. Remove and discard the front front pump converter metal clad seal from the pump body, as shown in Figure 85. 8. Inspect all oil pump parts thoroughly for any wear and/or damage. 9. Clean all oil pump and cover parts thoroughly thoroughly and dry with compressed air.


PUMP COVER TO OIL OIL PUMP RETAINING BOLTS

29536810

1 8 6 6 3 5 9 2

2 26 20E9

PUMP PU MP CO C OVE VER R TO OIL OIL PUMP RETAINING BOLTS


Figure 84


57

Technica l Serv ice Infor mation OIL PUMP PUMP ASSEMBLY EXPLODED VI VIEW EW

18

15

14

13

17

12 16

14

6 5

4

3

2

9 . 8

8

7

4 9 . 8

9 . 8


Figure 85

58


Technica l Serv ice Infor mation OIL PUMP PUMP ASSEMBLY EXPLODED VI VIEW EW 10

9

11

1

1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13. 14. 15. 16. 17. 18.

PUMP SPAC PACER ERPLATE TO CASE C ASEGASKET. C 1/C 1/C2 2 SEALING RING INGS S(3 RE REQ Q UIRED). PUMP COVER COVER TO C1/C C 1/C 2 CLU C LUTC HHOUS HOUSING ING THRUSTWASHE HER. R. C AG AGED ED NEED NEEDLE LEBEARING ASSEMBL EMBLY. Y. PUMP COVER/PUMP COVER/PUMP BODY BO BOLTS, M8 x1. 1.25 25 x 55 (5 REQUIR UIRED) ED).. PUMP C OVER ASSEMBLY. PUMP STATOR SHAFTSEAL RING (LARGE). PUMP STATOR SHAFTSEAL RING (SMALL). PUMP SPACER PLATE. PUMP SPACER SPAC ER PLATE TO BELLHOUSING GASKET. PUMP WEAR PLATE. INNEROIL PUMP GEAR. GEAR. OUTEROIL PUMP GEAR. G EAR. PUMP BODY TO PUMP COVER C OVER DOWELPINS (2 REQUIRED). REQUIRED). OIL PUMP BODY BODY ASSEMBLY. OIL PUMP BODY/CO BODY/C ONVER NVERT TER HUBBUSHING ING.. OIL PUMP BODY METAL METAL CLAD CLAD SEAL. PUMP BODY TO BELL HOUSING SEAL RING.


Figure 86


59

Technical Service Informati on CONTINUED FROM PAG PAGE 57


10. Install new front pump body bushing into the pump body as necessary, using proper bushing driver (See Figure 88). 11. Install a new front pump body metal clad seal into pump body using the proper seal driver. Refer to Figure 88. 12. Install new pump body to bell housing "O" ring seal in pump body groove, and lubricate using a small amount of TransJelä. (See Figure 88). 13. Lubricate the inner and outer pump gears with transmission fluid and install in the pump body with marks facing up, as shown in Figure 87. 14. Install the two dowel pins into the pump body, if they were removed, as shown in Figure 88. 15. Assemble the valves, springs, bore plugs and retainers into the pump cover exactly as they as are shown in Figure 89. Note: L ubr icate all all valve valvess in the pump cove cover with L ube ubeGard® Gard® spray lubr icant.

Figure 87


OIL PUMP PUMP ASSEMBLY 18

15

14

17

13 12

16

12. 13. 14. 15. 16. 17. 18.

14

INNER OIL PUMP GEAR. GEAR. OUTEROIL PUMP GEAR. G EAR. PUMP BODY TO PUMP COVER C OVER DOWELPINS (2 REQ REQUIRED). OIL PUMP BODY ASSEMBLY. OIL OI L PUMP BODY/CON BODY/C ONVER VERTER HUBBUSHING ING.. OIL OI L PUMP BODY METAL CLAD CLAD SEAL. PUMP BODY TO BELL HOUSING SEAL RING.


Figure 88

60


Technica l Serv ice Infor mation OIL PUMP PUMP COVER ASSEMBLY VALVE ANDSP SPRI RING NGIDENTIFI FIC CATION 1

3

2

4

Fr ee Length = 1.3 1.388" 88" Number Coils = 7 Sprin g Diameter = .635" Wire D iamete iameterr = .055"

Fr ee Length = 2.82 2.825" 5" Number Coils = 11 Sprin g Diameter = .890" Wir e Di amete ameterr = .108"

6

5

7

F ree Length = 1.068" Number Coils = 8 Sprin g Diameter = .380" Wir e Di amete ameterr = .025"

9


12

1. 2. 3. 4. 5. 6. 7. 8. 9. 10.

C ONVER NVERT TERFLOW VALVE. C ONVER NVERT TERFLOW VALVESPRING ING.. C ONVERTERFLO FLOW WVALVESTOP. C ONVER NVERT TERFLOW VALVESTOP RETAININ AINING G PIN. MAIN MA IN PRESSUREREGUL REGULAT ATOR VALVE. MAIN MA IN PRESSUREREGUL REGULAT ATOR VALVE SPRING SPRING.. PRESSUREREG REGULA ULAT TOR VALVE STOP. PRESSUREREGUL REGULAT ATOR VALVESTOP RETAIN AINING ING PIN PIN.. C LUTC H BACKFILL VALVE. C LUTC H BAC ACKFILL KFILLVALVESPRING ING..

13

11


14

11. 12. 13. 14. 15.. 15 16. 17. 18. 19.

10

8

15

16

17

18

19

C LUTC H BAC ACKFILL KFILL VALVERETAIN AINER ER. C ONVERTERRELIEFVALVE. C ONVER NVERT TER RELIEF VALVESPR SPRING ING.. C ONVERTERRELIEFVALVESPRING RETAIN AINER. ER. LUBE REGULATOR VALVE. LUBE REGULATOR VALVESPRING SPRING.. LUBE REGULATOR VALVE SPRIN PRING G STOP. LUBE REGULATOR VALVESTOP "O" RING. RING . LUBE REGULATOR VALVESTOP RETAIN AINING ING PIN PIN..


Figure 89


61

Technica l Serv ice Infor mation CONTINUED FROM PAG PAGE 60 16. Install the C1/C2 clutch drum thrust washer on the pump cover and retain with a small amount of TransJelä (See Figure 90). 17. Install three new C1/C2 clutch drum sealing rings as shown in Figure 90. Note:: Ensure that the se Note sealin g r ings will r ota otate te fr eely in the r in g groove groovess (Se (See e F igu r e 90). 18. Install two new sealing rings onto the stator shaft in their proper grooves (See Figure 90). Note:: Ensure that the se Note sealin g r ings will r ota otate te fr eely in their r in g groove groovess (Se (See e F igu r e 90 19. Inspect the caged needle bearing and replace as necessary (See Figure 90). 20. Place the completed oil pump cover assembly on a flat work surface with the stator shaft facing up, as shown in Figure 91.

21. Install the bell housing to pump cover spacer plate onto the pump cover (See Figure 91). 22. Install the spacer plate to bell housing gasket on top of the spacer plate (See Figure 91). 23. Install the oil pump wear plate on top of spacer plate, as shown in Figure 91. 24. Install the pre-assembled oil pump assembly on top of the wear plate as shown in Figure 92.


6 5

4

3

2

9 . 8

8

7

4 9 . 8

9 . 8

1. 2. 3. 4. 5. 6. 7.

PUMP SPAC PACER ERPLATE TO CASE C ASEGASKET. C 1/C 1/C2 2 SEALING RINGS (3 REQ UIRE IRED). D). PUMP COVER CO VERTO C1/C C 1/C 2 CLU CLUTC H HOUSING THR HRUS USTWASHE HER. R. C AG AGED EDNEEDLE BEARING ASSEMBLY. PUMP COVER CO VER/PUMP BO BODY BOLTS, M8 x 1.2 1.25 5 x55 (5 REQUIRED) QUIRED).. PUMP C OVERASSEMBL EMBLY. Y. PUMP STATOR SHAFTSEALRING (LARGE). (LARG E).


Figure 90

62


Technica l Serv ice Infor mation OIL PUMP WEAR PLAT PLATE

SPAC ER PLATE TO SPACER BELL GASKET

OIL PUMP ASSEMBLY

2

9 5

3 1

0 3

1

BELL HOUSING SPACER SPAC ER PLATE

OIL PUMP COVER ASSEMBLY


Figure 91

Figure 92


63

Technica l Serv ice Infor mation CONTINUED FROM PAG PAGE 62

PUMP CO C OVER TO OIL PUMP RETAINING BOLTS

29536810

25. Install the 5 required pump cover to oil pump bolts, size identified in Figure 95 and location is identified in Figure 93, and torque the bolts to 27 Nm (20 ft.lb.). 26. Assemble the completed oil pump and cover assembly to the bell housing (See Figure 94). Note:: There are Note are curr ently f our diff erent bell bell housings ava availil able able.. Re Reff er to F igu r es 98 & 99 for the vari ous mode models. ls. 27. Install the 10 required bell b ell housing to pump cover bolts, size identified in Figure 95 and location is identified in Figure 96, and torque the bolts to 43 Nm (32 ft.lb.). Note: N otice in F igu r e 95 that these these 10 bolts bolts have a r equi r ed seal on the bolt. En sur e that new seals ar e in stal talled. led. 28. Set completed bell housing and pump assembly aside for the final assembly process, as shown in Figure 97.

1 8 6 6 3 5 9 2

2 26 20E9

PUMP CO C OVER TO OIL PUMP RETAINING BOLTS


Figure 93

OIL PUMP PUMP AND BELL HOUSI USING NGASSEMBLY

9 . 8

9 . 8

9 . 8

9 . 8

BELL HOUSING ASSEMBLY (4 DIFFERENT VERSIONS)

BELL HOUSING TO SPACER SPAC ER PLATE GASKE GASKET

OIL PUMP AND PUMP C OVER ASSEMBLY

Figure 94

64



Technica l Serv ice Infor mation 13mm H ead

15 mm H ead

SEAL 2 953103 1

Pump C ove overr To Oil Pump (5 Req) Req) M 8 X 1.25 1.25 X 55

Bell H ous ousin in g To To Pump Pum p Cover Cover (10 Req) M 10 X 1.5 1.5 X 50

Bolts Dr awn Actual Size Figure 95

Figure 96

COMP MPLET LETED BELL HOUSI USING NGAND PUMP PUMP ASSEMBLY CAUTION:

THERE ARE FOUR DIFFERENT BELL HOUSING HOUSINGCONFI NFIG GURATIONS REFER TOFI FIG GURES 98 AND99

2

9 5

3 1

0 3

1


Figure 97


65

Technica l Serv ice Infor mation SAE NUMBER 3 BELL HOUSING WITH INTEGRAL FIL FILTER TER AND COOLER PORTS

SAE NUMBER 3 BELL HOUSING WITH MANIFOLD FOR FILTER AND COOLER PORTS

9 7

8

6 3 2

5 4

1

10 1. MA MAIN IN CONT CO NTROL FILTERASSEMBLY. 2. MAIN CON CONT TROL FILTERMAG MAGNET NET. 3. MA MAIN IN CO CONTROL FILTERADAPTERTUBE. 4. MA MAIN IN LINE PRESSURETAP PLUG. 5. MA MAIN IN LINEPRESSUREPLUG "O"RING RING.. 6. TO COOLER CO OLERSHIPPING PLUG. 7. TO COO C OOLE LER SHIPPING PLUG PLUG "O" RING. 8. FROM COO COOLE LER SHIPPING PLU PLUG. 9. FROM COOLER CO OLERSHIPPING PLUG PLUG "O" RING. 10. C OO OOLE LER R MANIFOLD RETAINING BOLT, M8 M8 x 1.25 x 30 (8 REQ). 11. C OO OOLE LER R MANIFOLD RETAINING BOLT, M8 M8 x 1.25 x 40 (4 REQ).

9 7

3

5

2

4

Figure 98

66

6

11

1


8


Technica l Serv ice Infor mation SAE NUMBER 2 BELL HOUSING WITH MANIFOLD FOR FILTER AND COOLER PORTS

SAE NUMBER 8 BELL HOUSING WITH INTEGRAL FIL FILTER TER AND COOLER PORTS

13 3 2

5

12

4

1

10 9 7 6

11 3

5

2

4

1

8

1. MA MAIN IN CONT CO NTROL FILTERASSEMBLY. 2. MAIN CON CONT TROL FILTERMAG MAGNET NET. 3. MA MAIN IN CO CONTROL FILTERADAPTERTUBE. 4. MA MAIN IN LINE PRESSURETAP PLUG. 5. MA MAIN IN LINEPRESSUREPLUG "O"RING RING.. 6. TO COOLER CO OLERSHIPPING PLUG. 7. TO COO C OOLE LER SHIPPING PLUG "O"RING. 8. FROM COO COOLE LER SHIPPING PLUG. 9. FROM COOLER CO OLERSHIPPING PLUG PLUG "O" RING. 10. C OO OOLE LER R MANIFOLD RETAINING BOLT, M8 M 8 x 1.25 x 30 (8 REQ). 11. C OO OOLE LER R MANIFOLD RETAINING BOLT, M8 M 8 x 1.25 x 40 (4 REQ). 12. TO COO C OOLE LER R CONNEC CO NNECT TOR FITTING ASSEMBLY. 13. FROM COO C OOLER LERC ON ONNEC NECT TOR FITTING ASSEMBLY ASSEMBLY..


Figure 99


67

Technical Service Informati on C1/C2 CLUTCH HOUSI USING NG EXPLODED VIEW VIEW 3

4

2

1

13

14 15

16

17 18

12

19

30 28 27

29

LEGEND FOR FIG I GURES 100 AND 101F 1FOUND ON PAGE 70

31

Figure 100

68



Technica l Serv ice Infor mation C1/C2 CLUTCH HOUSING HOUSING EXPLODED VIEW VIEW

5

7

9

8

11 10

6

22

21

20

24

25

26

23

32 34 33

35 37

36

LEGEND FOR FIG I GURES 100 AND 101F 1FOUND ON PAGE 70


Figure 101


69

Technica l Serv ice Infor mation LEGEND FOR FI FIGURES 100 AND 101 1. TURBINE SHAFTSEALRING INGS S(2 REQUIRED). 2. TURBIN INE E SHAFTASSEMBLY. 3. C 1/C 2 C LUTC H HOUSING ASSEMBLY. 4. TURBINE SHAFTRETAIN AINING ING SNAP SNAP RING RING.. 5. C 2 CLU CLUTC H PISTON BALANC BALANCE E"D"RING SEAL. SEAL. 6. C 2 CLU C LUTC H PISTON OUT O UTER"D"RING SEAL. SEAL. 7. C 2 C LUTC H PIS PIST TON. 8. C 2 CLUTC H PISTON INNER LIP SEAL. 9. C 2 CLUT CLUTC H PISTON RETURN SPRING ASSEMBLY. 10. C 1 CLU C LUTC H HOUSING "O" "O"RING SEAL. SEAL. 11. C 1 CLU C LUTC H HOUSING ASSEMBLY. 12. C 1 CLU C LUTC H HOUS OUSING ING RE RET TAINING SNAP RING ING.. 13. C 2 CLU C LUTC H BALANC ALANCE E PIST PISTON ASSEMBL EMBLY Y (MOULDED). (MOULDED). 14. C 2 CLU C LUTC H BALANC ANCE E PISTON RETAININ AINING G SNAP RING. 15. C 1 CLU C LUTC H PISTON OUTER "D" RING SEAL. 16. C 1 CLUT C LUTC H PISTON ASSEMBLY. 17. C 1 CLU C LUTC H PISTON INNER TEFL EFLO ON LIP SEAL SEAL (iNNER LIP). 18. C 1 CLUT C LUTC H PISTON RETURN SPRING ASSEMBLY. 19. C 1 CLU C LUTC H PISTON RETURN SPRING SPRING SNAP RING ING..

20. 21. 22.. 22 23. 24. 25. 26. 27. 28. 29. 30. 31. 32. 33. 34. 35. 36. 37.

C 1 CLU C LUTC H BALANC ALANCE E PIST PISTON ASSEMBLY (MOULDED). (MOULDED). C 1 CLU C LUTC HBALANC ANCE E PISTON RETAININ AINING G SNAP RING. C 1 CLU C LUTC H STEELPLATES, INTERNAL SPLINE (6 REQUIRED). C 1 CLU C LUTC H LINED PLATES, EXTERNAL SPLINE (6 REQUIRED). C 1 CLU C LUTC H BAC ACKING KING PLATE (SE (SELE LEC C TIVE). C 1 CLU C LUTC H BAC ACKING KING PLATE SNAP RING (EXTER ERNAL). NAL). C 1 CLU C LUTC H BAC ACKING KING PLATE SPIRAL SNAP RING (INTER ERNAL). NAL). TURBIN INE E SHAFT/C HAFT/C1 1 CLUT C LUTC H HUBTHRUSTBEARING BEARING.. C 1 CLU C LUTC H HUBASSEMBLY. C 1 CLU C LUTC H HUB/C /C2 2 CLU C LUTC H HUBTHRUSTBEARING ARING.. C 2 CLU C LUTC H STEELPLATES(7 REQUIRED). C 2 CLU C LUTC HLINED PLATES(6 REQUIRED). C 2 CLU C LUTC H HUBASSEMBLY. C 2 CLUT C LUTC H HUB/IN UB/INPUT PUTSUN GEAR THRUSTWASHER. INPUT INP UTSUN GEAR GEAR ASSEMBLY. INPUT INP UTSUN GEAR/P1 GEAR/P1 PL PLANETARY CARRIER CARRIER THRUSTBEARING ARING.. P1 PLANET PLANETARYDRIVEFLANGE. P1 PLANET PLANETARYDRIVEFLANGE RETAININ AINING G SNAP RING. RING .

Figure 102

COMP MPO ONENTREBUILD (C (Cont ont''d)

C 2 CLU C LUTC H PISTON INNER LIP SEAL

C1/C2CLUTCHHOUSI USING NG 1. Disassemble Disassemble the C1/C2 C1/C2 clutch clutch housing using Figures 100 and 101 as a guide. 2. Remove and discard all "O" rings, rings, "D" rings and lip seals (See Figures 100 and 101). 3. Inspect all C1/C2 clutch housing parts for any wear and/or damage. 4. Clean all C1/C2 housing parts thoroughly, and dry with compressed air. 5. If turbine shaft was not removed, it should be removed at this time, as it makes the assembly of the C1/C2 clutch housing much easier. 6. Install the C2 clutch piston inner lip seal with with the lip facing direction shown in Figure 103. 7. Install Install the C2 clutch piston balance "D" ring seal into the piston groove (See Figure 103). 8. Install the C2 clutch piston outer "D" ring seal into the lower piston groove (See Figure 103). 9. Lubricate all three C2 clutch piston seals with a small amount of TransJelä. 10. Install the C2 clutch piston and seals into the C1/C2 clutch housing as shown in Figure 105. N ote: Car e shou houll d be use used d dur i ng asse assembl mbly y so as not to damage pi pisston seals. 11. Install the C2 piston return spring assembly on top of the C2 piston in the housing, as shown in Figure 105.

C2 CLUTCH PISTON

C 2 PISTON BALANCE "D" RING SEAL

C 2 PIST PISTON OUTER "D" RING SEAL


Figure 103

70


Technica l Serv ice Infor mation C 1 CLU C LUTC H HOUS HOUSING ING SNAP RING C 1 CLU C LUTC H HOUSING SNAP RING

C1 CLUTCH HOUSING

C 1 CLU C LUTC H HOUS HOUSING ING "O" RING SEAL C 1 CLU C LUTC H HOUSING "O" RING SEAL C 2 CLU C LUTC H RETURN SRING ASSEMBLY

C 2 CLU C LUTC H PISTON AND SEALS


Figure 104 12. Install the C1 clutch housing "O" ring seal into the lower groove groove in the C1/C2 clutch housing, as shown in the cut-away in Figure 104. 13. Lubricate the installed "O" ring seal seal and inside diameter of the C1 clutch housing with a small of TransJelä, and install the C1 clutch housing as shown in Figure 105. 14. Compress the C1 clutch housing against the return spring assembly and install the C1 clutch housing snap ring into the upper groove in the C1/C2 clutch housing, as shown in cut-away in Figure 104. Note:: Refer Note Refer to F igur e 106 for snap ri ng I .D. for all snap r ings in the C1/C C1/C2 2 hous housin in g.

C 1/C2 C LUTC H HOUSING



Figure 105


71

Technical Service Informati on SNAP RING RI NGIDENTIFI FIC CATION CHART HARTFOR FOR C1/C2 CLUTCHHOUSI USING NG Snap Ring Number 1 = .090 .090"" Thi ck, Larges Largest Di ame amete terr " Eye Eyelet" let" Snap Ring. (C1 Clutch H ous ousin in g Re Retaini taini ng Snap Ring) Snap Ring Nu mbe mberr 2 = .079" .079" Thi ck, Approxi Approxi mate 3-3/1 3-3/16" 6" Di ame amete ter. r. (C1 Clu tch Piston Re Retur tur n Spri Spri ng Re Retain tain in g Snap Rin g) Snap Ring Number 3 = .079 .079"" Thi ck, Approxi Approxi mate 6-1/2 6-1/2"" Di ame amete ter. r. (C1 Clu tch Bal ance Piston Re Retain tain in g Snap Rin g) Snap Rin g Number 4 = .092" .092" Th Thick, ick, Appr oxim ate 8-3/8" Di ame amete terr , Same Same as Snap Rin g Number 8. (C2 Clu tch Bal ance Piston Re Retain tain in g Snap Rin g) Snap Ring Nu mbe mberr 5 = .090" .090" Thi ck, Smalles Smallestt Di ame amete terr " Eye Eyelet" let" Snap Ring. (Tur bine Shaft Retaini Retaini ng Snap Ring) Snap Ring Number 6 = .078 .078"" Thi ck, Approxi Approxi mate 2-7/8 2-7/8"" Di ame amete ter. r. (C1 Clu tch Backi ng Plate Re Retain tain in g Snap Rin g) Snap Ring Number Number 7 = " Spir al" Snap Ring, Approximate 3-1/4 3-1/4"" Di ame amete ter. r. (C1 Clutch Backing Plate Snap Ring, " Spir al" Re Retaini taini ng Snap Ring) Snap Rin g Number 8 = .092" .092" Th Thick, ick, Appr oxim ate 8-3/8" Di ame amete terr , Same Same as Snap Rin g Number 4. (C2 Clu tch Backi ng Plate Re Retain tain in g Snap Rin g)

Snap Rin g Snap No. 8

Snap Rin g No. 7 Snap Rin g No. 6 Snap Rin g No. 5

Snap Rin g No. 4 Snap Rin g No. 3 Snap Rin g No. 2 Snap Rin g No. 1 Copyright © 2000 ATSG

Figure 106

72


Technica l Serv ice Infor mation CONTINUED FROM PAG PAGE 71 15. Install new C1 clutch piston inner lip seal, as shown in Figure 107. Note: Th is se seal is hard plastic plastic and dif fi cult to r emove move.. I f the in ner li p seal is goo good, d, leav leave e it alon e and r e-u -usse it it,, or r eplace as nece necesssar ary. y. 16. Install new C1 clutch piston outer "D" ring seal in piston groove, as shown in Figure 107. 17. Lubricate both the seals with a small amount of TransJel®, and install piston into the C1 clutch housing, as shown in Figure 108. 18. Install C1 clutch piston return spring assembly onto the C1 clutch piston (See Figure 108). 19. Compress the return spring and a nd install the snap ring into the groove ensuring that it is properly seated (See Figure 108). Note:: Thi s snap ri ng is also Note also diff icult to install install . Use the prope properr tools and r efer to F igu r e 106 for snap ri ng ide identi nti fi ca cation. tion.

C 1 CLU C LUTC H HOUS HOUSING ING SNAP RING

C 1 CLU C LUTC H HOUSING RETURN SPRING ASM.

Continued on Page 74 C 1 CLU C LUTC H PISTON AND SEALS

C 1 CLU C LUTC H PISTON INNER SEAL

C1 CLUTCH PISTON

C 1/C2 C LUTC H HOUSING

C 1 CLU C LUTC H PISTON OUTER "D" RING


Figure 107


Figure 108


73

Technica l Serv ice Infor mation CONTINUED FROM PAG PAGE 73 20. Lubricate the molded C1 clutch balance piston with small amount of TransJel®, and install in C1/C2 clutch housing (See Figure 109). N ote: Replace Repl ace bal balance ance piston as necess necessar ar y. 21. Install the C1 clutch balance piston snap ring as shown in Figure 109, and ensure that it is fully seated (See Figure 109).

22. Lubricate the molded C2 clutch balance piston with small amount of TransJel®, and install in C1/C2 clutch housing (See Figure 109). N ote: Replace Repl ace bal balance ance piston as necess necessar ar y. 23. Install the C2 clutch balance piston snap ring as shown in Figure 109, and ensure that it is fully seated (See Figure 109).

TURBIN INE E SHAF AFT T SNAP RING

C2 CLUTCH BALANC ANCE E PISTON SNAP RING

C 1/C2 C LUTC H HOUSING ASM.

C2 CLUTCH BALANC ANCE E PISTON

C1 CLUTCH BALANC ANCE E PISTON SNAP RING

TURBIN INE E SHAF AFT T ASSEMBLY

C1 CLUTCH BALANC ANCE E PISTON

TURBIN INE E SHAF AFT T SEALING RINGS


Figure 109

74


Figure 110


Technica l Serv ice Infor mation 24. Install two new sealing rings onto turbine shaft as shown in Figure 110. 25. N ow install the turbine shaft into the splines of install o f the C1/C2 clutch housing and install the eyelet snap ring in bottom groove (See Figure 110). N ote: Th is is the smal smaller ler of t he 2 eye eyelet let snap snap ri ngs in this hous housin in g. Re Refer fer to F igur e 10 106 6 for positi pos iti ve snap r in g identif ication . 26. Install C1 clutch pack beginning with a steel plate, and alternating with a lined plate until you have installed 6 required steel plates and 6 required lined plates (See Figure 111). N ote: Noti N otice ce that the t he stee steell pl ates have in tern al teeth tee th and th the e l in ed plat plate es have exter nal tee teeth th.. 27. Install the C1 clutch backing plate in housing in the direction shown in Figure 111, and make sure that it is fully seated. 28. Install the external C1 clutch backing plate snap ring as shown in Figure 111. Note: T he Spir Spir al snap r in g must be r emove moved d fr om the bac backi ki ng plate to in stall the external snap r in g. Re Reff er to F igu r e 106 for pos positi iti ve snap r ing ide identif ntif ication. 29. After the external backing plate snap ring has been installed, now install the "Spiral" snap ring on the inside groove of backing plate, as shown in Figure 111. Note: T he Spir Spir al snap ri ng mu st be in stall ed in bac backi ki ng plate to r etain the external snap fr om pos posssibly co coming ming off fr om ce centr ntr if ugal for ce ce.. Re Reff er to F igu r e 106 f or pos positi iti ve I .D. of snap r in gs in C1/C2 housing.

C1 CLUTCH "SPIRAL" SNAP RING C 1 CLU C LUTC H BACKING PLATE BACKING PLATE SNAP RING

C 1 CLU C LUTC H BACKING PLATE BACKING PLATE

C1 LINED PLATES (6 REQ.)

C 1 STEEL PLATES (6 REQ.)




Figure 111


75

Technica l Serv ice Infor mation CONTINUEDFROMPAG PAGE75

C 1 CLUT C LUTC H HUB TO C 2 CLU C LUTC H HUB THRUST BEARIN ING G

C 1 CLU C LUTC H HUB

TURBIN INE E SHAF AFT T TO C 1 CLU C LUTC H HUB THRUST BEARIN ING G

30. Install dial indicator onto C1/C2 clutch housing as shown in Figure 112, with indicator indexed against the C1 selective backing plate, and set backing the dial to zero. 31. Lift up on both sides of C1 clutch pack until the selective backing plate is against the snap ring, and record dial indicator reading. Note:: C1 clutch clearance Note clearance is .105 .105"" - .125" .125" . 32. Change the C1 backing plate as necessary to obtain correct clutch clearance. 33. Install the turbine shaft/C1 clutch hub thrust bearing assembly onto the turbine shaft in the direction shown in Figure 112. 34. Install the C1 clutch hub over the external teeth of the lined plates, in a twisting back and forth motion until fully seated (See Figure 112). 35. Install the C1 clutch hub/C2 clutch hub thrust bearing assembly onto the C1 clutch hub in the direction shown in Figure 112. 36. Install the C2 clutch hub over C1 clutch hub, as shown in Figure 113. 37. Install C2 clutch hub to input sun gear thrust washer, ensuring that tabs are engaged into the slots on C2 clutch hub, as shown in Figure 113

CHECKINGC1C 1CLUTCHCLEARA RANCE Clearan ce Should B e .105" - .125"

10

0

10

20

20

30

30

40

40 50

0

50

DIAL INDICATOR


Figure 112

76


Technica l Serv ice Infor mation 38. Install the C2 clutch pack into the housing, as shown in Figure 114, beginning with a steel plate and alternating with lined plates until you have installed 7 steel plates and 6 lined plates. Note: I n the C2 clut ch pack pack you begin begin wi th a stee teell pl plate ate and end wi th a ste steel el pl plate ate as show hown n in F igure 11 114. 4. Continued on Page 78

C 2 CLUT C LUTC H HUB TO INPUT SUN GEAR GEAR THRUST WASHER

C2 STEEL PLATES

C2 LINED PLATES

C2 CLUTCH HUB


Figure 113


Figure 114


77

Technica l Serv ice Inform ation CONTINUEDFROMPAG PAGE76

P1 PLANETARY DRIVE FLANGE SNAP RING

P1 PLANETARY DRIVE FLANGE WIDE TOOTH

36. Install the P1 planetary drive flange snap ring into the lower groove groove in the clutch housing, as shown in Figure 117. 37. Check the C2 clutch clearance using a feeler gage, as shown in Figure 117. Note: Cor r ect C2 clutch clea clearr ance shoul d be .060" .06 0" - .085 .085"" (See (See F igu r e 117 117). ). Th The er e are no selective lectivess for C2 clu tch. I f the clea clearr ance is not corr ect, ther e i s a mi s-ass -assembly. embly. 38. Remove the P1 planetary drive flange snap ring from the lower groove in the clutch housing. 39. Install P1 planetary (Input) sun gear through the P1 planetary drive flange from the bottom as shown in Figures 115 and 116. 40. Holding the assembly by the sun gear, install the sun gear and drive flange assembly into the C1/C2 housing engaging the drive flange teeth into the splines of housing (See Figure 115). Note: N otice that dr ive flan ge has thr ee wide teeth tee th that mu musst be i ndexed to 3 wi wide de gr oove ooves s in the housing (Se (See e F igu r e 115). 41. Install the P1 planetary drive flange snap ring into top groove in housing (See Figure 115). groove Note:: Refer Note Refer to F igur e 10 106 6 for C1/C2 clutch housing snap r in g identif icati on as nec nece essary.

P1 PLANETARY (INPUT) SUN GEAR

P1SUN GEAR AND DRI RIVE VE FLANGE ASSEMBLED P1 PLANETARY (INPUT) SUN GEAR

P1 PLANETARY DRIVE FLANGE


Figure 115

78


Figure 116


Technica l Serv ice Infor mation 42. Install the P1 sun gear to P1 planetary carrier thrust bearing onto the sun gear in the direction shown in Figure 118, and retain with a small amount of TransJel®. 43. Set completed C1/C2 Clutch Housing assembly aside for the final assembly process. Refer to Figure 118.

P1 SUN GEAR TO P1 PLANET PLANETARY CARRIER CARRIER THRUST BEARIN ING G

"COMPONENT REBUILD" Continued on Page 82

CHECKING C2 CLUTCH CLEARA RANCE Clearance should be .060" - .085"

C OM OMPLE PLET TED C 1/C2 C LUTC H HOUSING


Figure 117


Figure 118


79

Technical Service Informati on ALLISON SERIES 1000/2000 COMPLETE VAL VALVE VE BODY

Retainer Ass Assemb embly ly

Accumulator Valve Sprin gs

Accumulator Valves

TCC Sole Solenoid noid " F" (N/C PWM) Shif t Sole Solenoid noid " D" (Nor mally Close Closed) d)

PRESSURE SWI TCH PRESSURE ASSEMBLY

Shif t Sole Solenoid noid " E" (Nor mally Clos Close ed) Tri m Sole Solenoid noid " B" (Nor mally Open) Open) Tri m Sole Solenoid noid " A" (Nor mally Clos Close ed)

Shif t Soleno Solenoid id " C" (Nor mally Clos Close ed)


Figure 119

80



" Shif t" Valv alve e bo body dy (See (Se e F i gur e 124)

Space Sp acerr Plat Plate e

" M ain" Valv alve e bo body dy (See (Se e F i gur e 123)

1 5

4

I nte nternal rnal Wire H ar nes nesss Asm.

2

3 1. 2. 3. 4. 5.

PRESSURE SWITC HASSEMBLY. REVERSESIG SIGNAL NAL PIPE ASSEMBLY. VALVEBODY TO VALVE BODY BOLT, M6 M6 X 1.0 X 65 (1 REQUIRED). REQUIRED). VALVEBODY TO VALVE BODY BOLT, M6 M6 X 1.0 X 50 (23 (23 REQUIRED). VALVEBODY TO CASE C ASEBOLTS, M6 X 1.0 X 50 (15 REQUIRED). REQUIRED).


Figure 120


81

Technica l Servi ce Inform ation

COMP MPO ONENTREBUILD (C (Cont ont''d) VALVE BODY ASSEMBLY 1. Disassemble Disassemble the valve valve body assembly, using Figures 119 and 120 as a guide. 2. Remove the two bolts retaining the reverse reverse pipe, and remove the reverse pipe from valve body assembly (See Figure 121). Note: N otice the manual valve pin , as shown shown in F igur e 12 121. 1. Thi s pin ca can n fall out out and not be noti ce ced. d. Remove i t now and place i n saf afe e place un ti till r eas asssembl mbly. y. 3. Remove the wire wire connector from the pressure pressure switch assembly and all six solenoids as shown in Figure 119. 4. Remove the two solenoid retaining retaining clips clips from from valve body, shown in Figure 121 and remove the internal wire harness assembly. 5. Remove the three bolts from from the trim solenoid solenoid retaining bracket and remove the bracket, as shown in Figure 119.

6. Remove the two trim solenoids using caution caution so that valve trains behind them do not come out at this time. Note:: N otice that Tri m Sole Note Solenoid noid " A" has a gree gre en " O" ring, and Trim Sole olenoid noid " B" has a blackk " O" r in g. The snout diame blac diamete ters rs are als also o differe diffe rent, nt, .645" for " A" and and .665 65"" for " B" . Refer Re fer to F igu r e 122 122.. 7. Air checks and resistance readings for all of the solenoids are provided in Figure 122, that can be performed now to determine if replacement is necessary. Note: A ir che checks cks shoul d be made on f ix ixtur tur e with 40 PS PSII r egul ate ated d air pres presssur e.


VALVE BODY ASSEMBL ASSEMBLY I nternal Wir in g Harn ess retained with these thes e two solenoid solenoid r etaini ng cli ps ps.. Remove Rever Rever se Pi pe.

D u P a g e

CAU TI ON: Thi s manual valve pin i s eas asilil y lost, lost, as it may fall out un-n otice oticed. d. Copyright © 2000 ATSG

Figure 121

82



SOLENOID AIR CHECKS TRIM SOLENOID"A" (Normal allly Closed) Snout Diameter = .645"

TRIM SOLENOID"B" (Normal allly Open) 5.5 - 8.0 @ 72° F

Green " O" Ri ng ng

Snout Diameter = .665"

Blow Air I n Here Here

5.5 - 8.0 @ 72° F

Black " O" Ri ng ng

Blow Air In H ere

De-energized De-energize d = No A ir H ere Energize Energiz ed = Air H ere

De-energize De-e nergized d = Ai r H ere Energize Energiz ed

= No Air H ere

SHIFT FTSO SOLENOIDS "C "C", "D "D" AND"E" 20 - 30 @ 72° F Blow Air In H ere

Blow Air In H ere

De-energize De-e nergized d = Ai r Exi ts Here

Energize Energiz ed = A ir Exi ts Here Here

LOCKK-UP UP SOLENOID "F" "F" 8 - 15 @ 72° F

Blow Air In H ere

Energize Energiz ed = A ir Exi ts Here Here

De-energize De-e nergized d = Ai r E xi ts H ere


Figure 122


83

Technical Service Informati on "MAIN" VALVE BODY EXPLODED VIEW 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13.

MAIN VALVEBODY C ASTING MAIN ING.. ALIGNMENT ALIG NMENTDOWELS(5 REQUIRED). MAIN MAI N C ONTROL RE RELIEF LIEFVALVE. MAIN MAI N C ONTROL RE RELIEF LIEFVALVESPRING ING.. MAIN MAI N CO CONTROL REL ELIEF IEF VALVESPRING RETAINER. EXHAUSTBAC BACKFILL KFILL VALVESPRING RETAIN AINER. ER. EXHAUSTBAC BACKFILL KFILL VALVESPRING SPRING.. EXHAUSTBAC BACKFILL KFILL VALVE. BOLT, M6 X 1.0 X 50 (23 REQUIRED) SOLENOID "F" TRIM VALVE SPRING PRING.. SOLENOID SOLENO ID "F"TRIM VALVE. SOLENOID SOLENO ID "F" TRIM VALVE SLEEVE. SOLENOID "F"SMALL"O" RING ING..

14. SOLENOID "F"LARGE "O" "O" RING. 15. SOLENOID "F" (LOC (LOCK-UP K-UP PWM). 16. SOLENOID "F"RETAININ AINING G C LIP. 17. SHIFTSOLENOID "D" SMALL "O" RING. 18. SHIFTSOLENOID "D"LARGE "O" RING. 19. SHIFTSOLENO SOLENOID ID "D". 20. SHIFTSOLENO SOLENOID ID "D"RETAIN AINING ING C LIP. 21. SHIFTSOLENO SOLENOID ID "E"SMALL "O"RING RING.. 22. SHIFTSOLENOID "E"LARGE "O" RING. 23. SHIFTSOLENO SOLENOID ID "E". 24. TRIM PRESSUREAC ACC C UMULATORS. 25. TRIM PRESSUREAC ACC C UMULATOR SPRING PRINGS. S. 26. TRIM SOLENOI SOLENOID D "A"AND "B"RETAIN AINING ING BRAC BRACKET KET. 27. TRIM "B"VALVESPRING SPRING.. 28. TRIM "B"VALVE. 29. TRIM GAIN GAIN VALVE. VALVE. 30. TRIM SOLENO SOLENOID ID "B""O"RING (BLAC LACK). K). 31. TRIM SOLENO OLENOID ID "B" (N/O PWM) (Snout Diameter Diame ter = .665"). 32. TRIM SOLENOID SOLENOID "A" "A" (N/C PW PWM) M) (Snou noutt Dia Diameter meter = .645") .645").. 33. TRIM SOLENO SOLENOID ID "A""O" RING (GREEN). 34. TRIM GAIN GAIN VALVE. VALVE. 35. TRIM "A"VAL VALVE VE(Note I.D. I. D. Ring Between Betwee n Lands) Land s).. 36. TRIM "A"VALVESPRING SPRING..


5 4 6

3

2

8 7 1 Fr ee Length = .875 .875" " Number Coils = 11 Sprin g Diameter = .490" Wir e Di amete ameterr = .034"

Fr ee Length = .845 .845" " Number Coils = 7 Sprin g Diameter = .384" Wir e Di amete ameterr = .028"

36 35 34 33

27

32

28 29 30 21

17 9

22

31 23

24


18 19

10

2

25 20

Fr ee Length = .838 .838" " Number Coils = 7 Sprin g Diameter = .382" Wir e Di amete ameterr = .028"

11 12 13

26 14 15

9

16

Figure 123

84



Technica l Serv ice Infor mation "SHIFT" VALVE BODY EXPLODED VIEW 1. SHIFTVALVEBODY C ASTING ING.. 2. SOLE LENO NOID ID SCREEN. 3. SHIFTSOLENOID "C". 4. SHIFTSOLENOID "C "RE RET TAININ AINING G CLIP C LIP. 5. MANUAL M ANUAL SELEC ECT TOR VALVE. 6. MAN MANUAL UALSELE LEC C TOR VALVE VALVEPIN. 7. SOLENO SOLENOID ID "D"SHIFTVALVE. 8. SOLENO SOLENOID ID "D"SHIFTVALVESPRING SPRING.. 9. SOLENO SOLENOID ID "D"SHIFTVALVEBORE PLUG. 10. SOLENO SOLENOID ID "D" SHIFTVALVE LINE-UP RETAIN AINER. ER.

11. 12. 13. 14.. 14 15. 16. 17. 18. 19. 20.

SOLENOID "E"SHIFTVALVE. SOLENOID SOLENOID SOLENO ID "E"SHIFTVALVE SPRING PRING.. SOLENOID SOLENO ID "E"SHIFTVALVE BORE PLUG. SOLENOID SOLENO ID "E"SHIFT VALVE LINE-UP RETAIN AINER. ER. SOLENOID "C" "C " SHIFTVALV VALVE. E. SOLENOID "C" "C " SHIFTVALV VALVE E SPRING SPRING.. SOLENOID SOLENO ID "C" "C" SHIFTVALVELINELINE-UP UP RETAIN AINER. ER. MAIN CONTR C ONTROL VALVE VALVE.. MAIN CONTR C ONTROL VALVE VALVESP SPRING. RING. MAIN MAI N CON C ONT TROL VALVELINE-UP RET RETAINER.

3 5

6

4

2

1


7

11 15

18

8 9 12 10

13 14

19

16 17

Fr ee L engt ength h = 1.15 1.155" 5" Number Coils = 11 Sprin g Diameter = .435" Wir e Di amete ameterr = .037"

20


Fr ee Length = 1.70 1.705" 5" Number Coils = 13 Sprin Sp rin g Di ame amete terr = .550" Wir e Di amete ameterr = .057"


Figure 124


85

Technica l Serv ice Infor mation CONTINUED FROM PAGE 82 8. Place main valve body on a flat work surface, surface, remove the valve trains one at a time and lay them out in order, as shown in Figure 123. 9. Clean and inspect all main valve body parts thoroughly and dry with compressed air. 10. Assemble the main valve body valve trains exactly as they are shown in Figure 123. as Note: N otice that th e vari vari ous spri spri ng specs specs are in cluded in F igu r e 123 123,, to ensure that they are in stall ed in their prope properr locations. L ubr icate all valve valvess in the main valve bod body y with L ube ubeGard® Gard® spray lu bri ca cant. nt. 11. Place shift valve body on a flat work surface, remove the valve trains one at a time and lay them out in order, as shown in Figure 124. 12. Clean and inspect all shift valve body parts thoroughly and dry with compressed air. 13. Assemble the shift valve body valve trains exactly as they are shown in Figure 124. as Note: Noti ce that the vari ous spri ng spe pecs cs are in cluded in F igu r e 124 124,, to ensure that they are in stall ed in their prope properr locations. L ubr icate all valve valvess in the shi ft valve bod body y with L ube ubeGard® Gard® spray lu bri ca cant. nt.

14. Lay the main valve body on flat work surface as shown in Figure 126, and install the spacer plate over the dowel pins. 15. Install the shift valve body on top of the spacer plate and over dowels, as shown in Figure 126. 16. Turn the entire assembly over ov er on the flat work surface, as shown in Figure 125. 17. Install only 14, M6 x 1.0 x 50mm, main valve body to shift valve body bolts in the locations shown in Figure 125, and snug them down. Note: D o not tighten at thi s tim e. 18. Install both Trim Solenoids "A" and "B" in the exact locations shown in Figure 127. Note: T he tri m solenoids solenoids have dif ferent snout dimens dime nsions ions and " O" r in g co color lor s, as shown in F igur e 127. En sur e that they are in stall ed in their prope properr locations. 19. Install the trim solenoid retaining bracket and three M6 x 1.0 x 50mm bolts, as shown in Figure 127, and snug them down. Note:: Do not ti ghte Note ghten. n. Continued on Page 89

ASSEMBLE SHIFT SHI FTVALVE VALVE BODY TO MAIN VALVE BODY I nsta nstallll 14 Only, M 6 X 1.0 1.0 X 50, 50, Mai n Valve Body to Shif t Valve Body Bolts, I n Th e L oca ocations tions Shown Shown H ere, and Snug Them Down. Do Not ti ghte ghten. n.

e g a P u D

8 mm H ead 29536840

Actual Siz Size e


Figure 125

86



" Shif t" Valv alve e bo body dy

Space Spa cerr Pl Plate ate

" M ain" Valv alve e bo body dy

Figure 126

ASSEMBLE TRI RIM M SOLENOIDS e g a P u D

8 mm H ead

I ns nstall tall both both Tri m Sole Solenoids noids " A" and " B" in the exac exactt locati ons shown shown below, as they are dif f erent. I nstall t he retaini ng bracket and 3 M6 x 1.0 x 50 bolts bolts to retain retain bracket, bracke t, and snug down. Do N ot tighten.

Tr im Solenoids Solenoids Retaini ng Br acke Retaini acket t

29536840

Actual Siz Size e Trim Sole Solenoid noid " B" , (N/O), (N/O), Snout Diameter Diameter = .665" .665" , Requires Re quires Black " O" Ring. Trim Sole Solenoid noid " A" , (N/C), (N/C), Snout Diameter Diameter = .645" .645" , Requires Re quires Gre Gree en " O" Ring. Copyright © 2000 ATSG

Figure 127


87


e g a P u D

I nstall the Pressure Pressure Swit Swit ch Assembly Assembly and 5 M6 x 1.0 x 50 retain retain ing B olts in the location s shown h er e, and Snug Them Down. Do Not tighten.

8 mm H ead

29536840

Actu al Size Size

Pr es essur sure e Swit Switch ch Assembl Assembly y


Figure 128

8 m m H ea ead e g a P u D

8 m m H ea ead

One M 6 x 1.0 x 50mm Reve Rev er se Pipe Retain Retain in g Bol t.

29536840

Reverr se F ee Reve eed d Pi pe

Actu al Size Size

One M6 x 1.0 x 65mm 65mm Rever se Pipe Retain Reve Retain in g Bol t.

Figure 129

88



Technica l Serv ice Infor mation CONTINUED FROM PAGE 86 20. Inspect the pressure switch assembly a ssembly to verify the condition and location of the "O" rings on the back side (See Figure 130). 21. One of the six switches in the pressure switch assembly is Normally Closed (N/C) and the other five are Normally Open (N/O), as shown in Figure 130. Note: N otice that two of th e N.O. swit swit che ches s are not use used d in thi s un unit it (Se (See e F igu r e 130). 22. Check the operation of all switches with your DVOM with the leads placed on the pins on each side of each switch (See Figure 130). 23. To check the resistance values for the TFT sensor, place the leads of the ohmmeter across pins "E" and "F" of pressure switch connector. N ot ote: e: 30 3088 88-- 39 3942 42 Oh m s @20 20° ° C (68 ( 68° ° F ). 15915 9-19 198 8 Oh m s @ 100 00° ° C ( 21 212° 2° F ). 24. Install the pressure switch assembly onto the valve body using five M6 x 1.0 x 50mm bolts, and installed only in the locations that are shown in Figure 128, and snug them down. Note: D o not tighten at this tim e.

25. Install the reverse pipe onto the valve body, as shown in Figure 129, using one 50mm long bolt and one 65mm long bolt in the locations shown in Figure 129 and snug them down. Note: Do not ti ghten at thi s ti time me.. 26. Now torque all valve body bolts to 12 N.m, (9 ft.lb), beginning in the center and working outward in a circle (See Figure 129). Note: D o not over over -tor que.


BENCHTESTI ESTING NGPRESS RESSURE URE SWITCHASSEM ASSEMBLY BLY NOT USED (N/O) " E " SH I F T ( N /O /O ) " D " SH I F T ( N/ N/ O) O)

NOT USED (N/O)

" C" SHIFT (N/O) (N/O)

A

REVERSE (N/C) TEM P SENSOR SENSOR (THERMISTER)

B C D E F

A B C D E F

Pr es essur sure e Swit Switch ch Assembl Assembl y Receptacl Rece ptacl e (F ace Vi ew)

Pr es esssur e Switch Connector

C D

NOT USED

E R

NOT USED

TEMP SENSOR

PRESSURE SWITC H ASSEMBLY Copyright © 2000 ATSG

Figure 130


89

Technica l Serv ice Infor mation CONTINUED FROM PAGE 89 27. Orient both trim solenoids, TCC solenoid and shift solenoids with connectors pointed in the direction shown in Figure 131. 28. Install the internal wiring harness assembly, as shown in Figure 131, ensuring that connectors are fully seated and locked. N ote: Th e wi wirr e har nes nesss as asssembly is retain ed to the valve body wit h the two solenoid cli ps as shown in F igu r e 131. 29. Install the manual valve into the valve body and the manual valve pin, ensuring that the pin enters the slot in the valve body casting. Refer to Figure 131. 30. Set the completed valve body assembly aside for the final assembly process.

I nternal Wir ing H arnes arnesss retained with these thes e two solenoid solenoid r etaini ng cli ps ps..

D u P a g e

MANUAL VALVE MANUAL VALVE PIN


Figure 131

90


Technica l Serv ice Infor mation EXTENSI ENSION ON HOUSI USING NGFOR TWO WHEEL DRIVE DRI VE

ALL AL L MODELS

2WD AN 2WD AND D PA PAR RKI KING NG BRAKE MODELS

EXTENSI ENSIO ON HOUSI USING NGFOR MODELS WITH PARKI PARKING NGBRAKE

EXTENSI ENSIO ON HOUSI USING NGFOR FOUR WHEEL DRIVE DRIVE


Figure 132


91

Technica l Serv ice Infor mation EXTENSI ENSIO ON HOUSI USING NGPARTS EXPLO EXPLODEDVI VIEW EW

1 2

9

3

10

4

5

11

11 12

13

14


Figure 133

92


Technica l Serv ice Infor mation EXTENSI ENSIO ON HOUSI USING NGPARTS EXPLO EXPLODEDVI VIEW EW

6

15

16

7

17

18

8

19

1. P-3 PLANETARYC ARRIE ARRIER. R. (REFERE RENC NCE EONLY) 2. C AG AGED ED NEED NEEDLE LEBEARING RETAINING SNAP RING RING.. 3. C AG AGED ED NEED NEEDLE LEBEARING ASSEMBL EMBLY. Y. 4. OUTPUTSPEED SENS SENSO OR TONE WHEEL(M (MO ODEL SENSITIVE). 5. "SELEC ELECT TIVE" SPAC ACER. ER. 6. C -5 CLU CLUTC H PISTON ASSEMBLY. 7. C -5 CLU C LUTC H PISTON OUT OUTER"D"RING SEAL. SEAL. 8. C -5 CLU CLUTC H PISTON INNER LIP SEAL. 9. EXTENS ENSIO ION N HOUSING TO CASE C ASEGASKET. 10. EXTENS ENSIO ION N HOUSING (MO (MODEL DEL SENSITIVE). 11. EXTENS ENSIO ION N HOUSING HOUSING BOLTS, M10 x 1.5 x 40 (16 REQUIRED).

20

12. 12. 13.. 13 14. 15. 16. 17. 18. 19. 20. 21.. 21

21 21

OUTPUTSHAFTSPEED SENSOR (MO (MODEL SENSITIVE). OUTPUTSHAFTSPEED SENSOR "O" RING. RING . SPEED SENS ENSOR OR RETAINING BOLT, M6 M 6 x 1.0 1.0 x 13. FRET FRE TTING RING. RING . BALLBEARING ASSEMBLY. BALL BEARING RETAININ AINING G SNAP RING. RING . EXTENSIO ENSION N HOUSING METALC LAD SEAL (MO MODEL DELSENSIITIVE). TRANSMI RANSMISS SSIO IONYO NYOKE KE ASSEMBLY (MODEL (MODEL SENSITIVE). YOKE YOK E WASHER (MODEL (MODEL SENSITIVE). YOKE RETAININ AINING G BOLT, 1/2"-2 1/2"-20 0 (MODEL (MO DEL SENS ENSIT ITIVE).


Figure 134


93


COMP MPO ONENTREBUI REBUILD LD (C (Cont ont''d) EXTENSI ENSIO ON HOUSI USING NGASSEMBLY 1. Disassemble the extension housing assembly using Figures 133 and 134 as a guide. 2. Remove and discard the C5 clutch piston piston seals from the C5 clutch piston. 3. Inspect Inspect all extension housing parts for any wear and/or damage. 4. Clean all extension housing parts thoroughly and dry with compressed air. 5. Position Position the extension housing on a flat work surface with the rear facing up, as shown in Figure 135. 6. Install the ball bearing fretting fretting ring into the extension housing bore (See Figure 135). REAR SEAL ASSEMBLY

7. Install Install the ball bearing bearing and the retaining retaining snap ring, as shown in Figure 135. Note: E nsur e the snap snap r in g is fu ll y se seate ated. d. 8. Install the rear metal clad seal seal (if used) into the extension housing, using the proper seal driver as shown in Figure 135. 9. Turn the extension housing over so the front side is facing up, as shown in Figure 136. 10. Install the selective spacer against a gainst ball bearing in extension housing (See Figure 136). 11. Install output speed sensor tone wheel (if used) in the direction shown in Figure 136. Continued on Page 95

C AG AGED ED NEED NEEDLE LE BEARING SNAP RING

BALL BEARING SNAP RING C AG AGED ED NEED NEEDLE LE BEARING

BALL BEARING ASSEMBLY

SPEED SENSOR TONE WHEEL (MODEL SENSITIVE)

FRETTING RING (SPAC (S PACER ER))

EXTENSION HOUSING (MODEL SENSITIVE)

"SELEC LECT TIVE" SPAC SP ACER ER EXTENSION HOUSING (MODEL SENSITIVE)


Figure 135

94


Figure 136


Technica l Serv ice Infor mation CONTINUED FROM PAG PAGE 94 12. Install caged needle bearing in the extension housing bore, as shown in Figure 136. 13. Install the caged needle bearing retaining snap ring, as shown in Figure 136. Note: E nsure the snap snap r in g is fu ll y se seate ated. d. 14. Install the C5 clutch piston inner lip seal into the piston with the lip facing direction shown in Figure 137. 15. Install the C5 clutch piston outer "D" ring seal into the groove in piston (See Figure 137). 16. Lubricate both piston seals, and seal surfaces in the extension housing with a small amount of TransJel® (See Figure 137). 17. Install the C5 clutch piston assembly into the extension housing, using care so as not to cut or damage the seals (See Figure 137). 18. Set the completed extension housing assembly aside for the final assembly process.

C 5 CLU C LUTC H PISTON

C 5 CLU C LUTC H PISTON INNER LIP SEAL

C 5 CLU C LUTC H PISTON OUTER "D" RING SEAL

COMP MPLETED LETEDEXTENSI ENSIO ON HOUSI USING NGASSEMB ASSEMBLY LY

EXTENSION HOUSING (MODEL SENSITIVE)


Figure 137


Figure 138


95

Technica l Serv ice Infor mation GEAR TRAI RAIN N PARTS EXPLODEDVI VIEW EW 3 1 2 4

9

10

11

19

18 17

2WD Version

4WD Version

Figure 139

96



Technica l Serv ice Infor mation GEAR TRAI RAIN N PARTS EXPLODEDVI VIEW EW 5

6

7 8

12

13

14

15

1. INPUTSUN GEAR, P1SUN GEAR (INSTALLED IN C 1/C 2 HOUSING HOUSING). ). 2. INP INPUT UTSUN GEAR/P1 GEAR/P1 PLANET PLANETARY C ARRIERTHRUSTBEARING ARING.. 3. P1 PLANETARYINT INTER ERNAL NAL RING GEAR. GEAR. 4. P1 RING GEAR/P2 G EAR/P2 RING GEAR "PEEK"THRUSTWASHER. 5. P1 PLANET PLANETARYSNAP RING RING,, RETAINS P2 INTER ERNAL NAL RING GEAR. G EAR. 6. P1 PLANET PLANETARY C ARRIERASSEMBLY. 7. P2 PLANETARYINT INTER ERNAL NAL RING GEAR. GEAR. 8. P1 PLANET PLANETARY C ARRIER/P2 PLANETARY C ARRIERTHRUSTBEARING BEARING.. 9. P2 PLANET PLANETARYSNAP RING RING,, RETAINS P3 INTER ERNAL NAL RING GEAR. G EAR. 10. P2 PLANET PL ANETARY CARRIER CARRIER ASSEMBLY. 11. P3 PLANET PLANETARYINT INTER ERNAL NAL RING GEAR. G EAR. 12. TRANSMISSIO ION N MAIN MAIN SHAFT. 13. P2 PLANET PL ANETARY CARRIER/P2 CARRIER/P2 SUN GEAR THRUSTBEARING ARING.. 14. P2 SUN GEAR. 15. SUN GEAR SPAC PACER. ER. 16. P3 SUN GEAR. 17.. P3 SUN GEAR/ 17 GEAR/O OUTPUTSHAFTTHRUSTBEARING BEARING.. 18. OUTPUTSHAFT(M (MO ODEL SENSITIVE).. 19. P3 PLANET PL ANETARY CARRIER CARRIER ASSEMBLY.

16


Figure 140


97


COMP MPO ONENTREBUI REBUILD LD (C (Cont ont''d) GEAR TRAI RAIN N ASSEMBLY 1. Inspect all gear train parts thoroughly, that are shown in Figures 139 and 140, for any wear and/or damage. 2. Check all 3 planetary carriers carriers for proper proper pinion end play with a feeler gage (See Figure 143). Note:: End play should Note should be .02 .020" 0" -.03 -.030" 0" . 3. Lay the P2 ring gear (with notches) on a flat work surface in direction shown in Figure 141. 4. Install the P1 planetary carrier into the splines of the P2 ring gear, and install the P1 planetary snap ring, as shown in Figure 141.

P1 PLANETARY SNAP RING

5. Install the P1/P2 ring gear thrust washer onto the assembly as shown in Figure 142. Note:: This thrust was Note washe herr will " Snap nap"" in plac place e when it is f ul ly seate ated. d. 6. Set the completed P1 planetary assembly aside aside for final assembly (See Figure 145). 7. Lay the P3 ring gear (no notches) on the flat work surface in direction shown in Figure 144. 8. Install the P2 planetary carrier into the splines of the P3 ring gear, and install the P2 planetary snap ring, as shown in Figure 144. 9. Set the completed P2 planetary assembly aside aside for final assembly (See Figure 145). 10. After P3 planetary carrier has been inspected and correct pinion end play has been verified, set it aside for final assembly (See Figure 145).

P1/P2 RING GEAR THRUST WASHER P1 PLANETARY C ARR ARRIER IER

P1 PLANETARY C ARRIER ASSEMBLY P2 PLANETARY RING GEAR


Figure 141

98


Figure 142


Technica l Serv ice Infor mation C OM OMPLE PLET TED P1 PLANETARY AND P2 RING GEAR


Figure 143 P2 PLANETARY SNAP RING

C OM OMPLE PLET TED P2 PLANETARY AND P3 RING GEAR

P2 PLANETARY C ARRIER

C OM OMPLE PLET TED P3 PLANETARY P3 PLANETARY RING GEAR


Figure 144


Figure 145


99

Technica l Serv ice Infor mation 1

CASE CLUTCH PAR PARTS EXPLODED EXPLODEDVI VIEW EW

2

5

3

4

10 8

9

11 16

18

17


Figure 146

100


Technica l Serv ice Infor mation CASE CLUTCH PAR PARTS EXPLODED EXPLODEDVI VIEW EW 7

6

N

12

13

1. C 3 CLUTC HBACKIN BACKING G PLATERE RET TAININ AINING G SNAP RING RING.. 2. C 3 CLU CLUTC HBACKIN BACKING G PLATEASSEMBLY. 3. C 3 CLUTC HSTEELPLATES, .097" .097" THIC HICK K (3 REQUIRED). 4. C 3 C LUTC HLINED PLATES (4 REQUIRED). 5. C 3 CLU C LUTC HAPPLYPLATEWITH SPRING INGS, S, .125" THIC HICK. K. 6. C 3 CLU CLUTC HMO MOLDE LDED PISTON ASSEMBLY. 7. TRANSMISSIO ION N MAIN CASE ASSEMBLY. 8. C 4 CLU CLUTC HMO MOLDE LDED PISTON ASSEMBLY. 9. C 4 CLU C LUTC HAPPLYPLATEWITH SPRING PRINGS S.1 .125" 25" THIC HICK. K. 10. C 4 CLU C LUTC H STEELPLATES, .097 .097""THIC HICK K (4 REQUIRED). 11.. C 4 CLU 11 CLUTC H LINED PLATES (5 REQUIRED). 12. C 4 CLU C LUTC H BAC ACKING KING PLATE. 13. C 4 CLU C LUTC H "SPIR SPIRAL" AL"SNAP RING ING.. 14. C 4 CLU C LUTC H BAC ACKING KING PLATE SNAP RING.

14

15. 16. 16. 16. 16. 17.. 17 18.

15

C 5 CLU C LUTC H BAC ACKING KING PLATE. C 5 CLU C LUTC H "SELEC LECT TIVE"STEELPLATES, .097" .097" THIC HICK K (6 REQUIRED). C 5 "SEL ELEC ECT TIVE"STEE EEL L PLATE, 1.935 1.935 - 2. 2.065mm 065mm (.07 (.076" 6" - .081"). .081"). C 5 "SEL ELEC ECT TIVE"STEE EEL L PLATE, 2.435 2.435 - 2. 2.565mm 565mm (.09 (.096" 6" - .101"). .101"). C 5 "SEL ELEC ECT TIVE"STEE EEL L PLATE, 2.935 2.935 - 3. 3.065mm 065mm (.11 (.115" 5" - .120"). .120"). C 5 CLU CLUTC H LINED PLATES (6 REQUIRED). C 5 CLU C LUTC H RETURN SPRING ASSEMBLY.


Figure 147


101

Technica l Serv ice Infor mation FINA FI NAL TRANSMI SMISSI SSIO ON ASSEMBLY 1. Rotate the transmission transmission in the fixture so that the rear of the transmission is facing up, as shown in Figure 148. 2. Install Install P1 planetary ring gear into previously installed C3 lined plates, by turning back and forth, until ring gear teeth are engaged on all C3 plates and fully seated against the washer surface of C3 backing plate (See Figure 148). 3. Inspect Inspect the C4 clutch molded apply piston and replace as necessary (See Figure 149). 4. Lubricate C4 clutch piston with with a small amount of TransJel®, and install into the case bore, as shown in Figure 149. 5. Install Install the three return spring assemblies assemblies onto the wide tabs of C4 apply plate and install the apply plate assembly on top of the piston, as shown in Figure 150.

P1 PLANETARY RING GEAR

6. Install Install the C4 clutch pack beginning with a lined plate on top of the apply plate, as shown in Figure 150, and alternating with a steel plate until you have installed the required four steel plates and five lined plates. 7. Install the C4 clutch backing plate into the case in the direction shown in Figure 150. 8. Install the "spiral" snap ring into case groove as shown in Figure 151. 9. Install Install the C4 clutch backing plate snap ring ring into the same groove as th the e spir spir al snap r i ng, as shown in Figure 151. Continued on Page 104


1 0 0 0 2 1

C 3 1 0 0 0 1 0 1 1

8 8 / 2 1

1 0 0 0 1 R M 8

1 0 0 0 2 1

A l l i s o n



Figure 148

102

C 3 1 8 0 8 0 / 0 2 1 1 0 1 1

1 0 0 0 1 R M 8

A l l i s o n



Figure 149


Technica l Serv ice Infor mation C 4 CLU C LUTC H BACKING BACKIN G PLATE PLATE

"SPIRAL" SNAP RING

C4 CLUTCH BACKING BACKIN G PLATE SNAP RING

C 4 CLU C LUTC H LINED PLATE (5 REQUIRED)

C4 CLUTCH STEEL PLATE PLATE (4 REQUIRED)

C4 CLUTCH BACKING PLATE BACKING PLATE SNAP RING

SPIRAL SNAP RING

C 4 CLU C LUTC H APPLY PLATE


C 1 3 0 1 0 0 0 0 0 2 1 1 0 1 1

8 8 / 2 1

1 0 0 0 1 R M 8

C 1 0 1 3 0 1 8 0 0 0 8 0 0 0 0 / 2 1 2 1 1 R M 1 0 1 8 1

A l l i s o n



Figure 150

A l l i s o n



Figure 151


103

Technica l Serv ice Infor mation CONTINUED FROM PA PAGE102 10. Check the C4 clutch clearance using the feeler gage, through the rear opening in transmission case, as shown in Figure 152. 11. Correct clutch clearance should be .040"-.060", as shown in Figure 152. Note: Th The er e ar ar e no se selective lectivess. I f clea clearr ance is not corr ect, th the er e i s a mi miss-ass -asse embl mbly. y. Cor r ec ect t as n ece ecess ssar ar y. 12. Install the parking rod actuator guide into the case, as shown in Figure 153, ensuring that the rollers on the parking actuator rod are engaged inside the guide. 13. Install the pre-assembled P1 planetary carrier assembly, with the thrust washer in place, into the P1 ring gear by rotating back and forth, to ensure that the ring gear teeth engage with all C4 lined plates (See Figure 153).

14. Ensure that the thrust washer on the P2 ring gear is fully seated against the P1 ring gear. 15. Install the P1 Planetary Carrier to P2 Planetary Carrier thrust bearing onto the P1 carrier in the direction shown in Figure 153. 16. Install the C5 clutch backing plate in the case in direction shown in Figure 154. 17. Install C5 clutch pack beginning with a lined plate and alternating with steel plates until you have installed six of each (See Figure 154). Note: T he C5 ste stee el plates are " selective lective"" and ther e ar are e 4 dif f er ent th thick icknes nesss plat plate es avail able. 18. Next we must check the C5 clutch clearance and this requires an "H" gage.


CHECKIN INGC4 CLUTCH CLEA EARANCE Corr ec ectt Clearance Shoul Shoul d Be .040" .060"


Figure 152

104


Technica l Serv ice Infor mation C5 CLUTCH RETURN SPRING SPRING ASSEMBLY 1

C5 CLUTCH STEEL PLATE (6 REQUIRED) 2

3

PARKING AC TUATOR ACT GUIDE C5 CLUTCH LINED PLATE (6 REQUIRED)

C5 CLUTCH BACKING PLATE BACKING

C 1 3 1 0 0 0 0 0 0 2 1 1 0 1 1

8 8 / 2 1

1 0 0 0 1 R M 8

A l l i s o n


C 1 0 1 3 0 1 8 0 0 0 8 0 0 0 0 / 2 1 2 1 1 R M 1 0 1 8 1

1. P1 PLANET PL ANETC ARRIER/P2 PLANET PLANETC ARRIER THRUSTBEARING 2. P1 PLANET PL ANETARY CARRIER CARRIER ASSEMBLY 3. P1 RING GEAR/P2 RING RING GEAR "PEEK"THRUSTWASHER


Figure 153

A l l i s o n



Figure 154


105

Technica l Serv ice Infor mation CONTINUED FROM PA PAGE104 19. Place the pre-assembled extension housing on flat work surface with the piston facing up, as shown in Figure 155. 20. Place the extension housing to case gasket on the extension housing as shown in Figure 155. N ote: Thi T hi s step is impor tant as th the e gas gasket ket thick th icknes nesss mu musst be i ncl uded i n th the e eq equati uati on for C5 clutch clea clearr ance (Se (See e F igu r e 155). 21. Place the "H" gage on the transmission case, as shown in Figure 155. 22. Loosen the set screw knob and allow the pin to go down so that it is resting on the top steel plate, as shown in Figure 155, and re-tighten set screw knob with pin in this position. Note: Slidi ng pin must be be r estin g fl ush on stee teell plat plate e f or accur ate meas measur ur ement.

23. With the set screw knob k nob tight carefully turn the "H" gage over and set it on extension housing gasket, with the sliding pin over one portion of C5 piston, as shown in Figure 155. 24. With a feeler gage check and record clearance between the sliding pin and the C5 piston, as shown in Figure 155. 25. Correct C5 clutch clearance is .090" - .110", as shown in Figure 155. N ote: Ch ange se sel ecti ctive ve stee teell plate to obtai n corr ect C5 clu tch clearan ce ce,, as be bell ow. C5 ste tee el 295 2953648 36481 1 = .076 .076"" to .081 .081"" th ick. C5 ste tee el 295 2953648 36482 2 = .096 .096"" to .101 .101"" th ick. C5 ste tee el 295 2953648 36483 3 = .115 .115"" to .120 .120"" th ick.

CHECKIN ING C5 CLUTCH CLEA EARANCE Corr ec ectt Clearance Shoul Shoul d Be .090" .110"

SETSC SCREW REW KNOB

SLIDING PIN




Figure 155

106


Technica l Serv ice Infor mation 26. After C5 clutch clearance has been verified, install the C5 clutch return spring assembly on top of the last steel plate with the springs facing up, as shown in Figure 156. Note: En sur e that the locatin locatin g tab is in the properr pos prope posit ition. ion. 27. Install the pre-assembled P2 planetary plane tary carrier assembly by rotating back and forth, into the P2 ring gear and ensure that ring gear teeth engage with all C5 lined plates, and is fully seated against bearing (See Figure 157). 28. Install P2 Planetary Carrier to P2 Sun Gear Thrust Bearing into the P2 carrier, in direction shown in Figure 157.

1

2


C 5 CLU C LUTC H RETURN SPRING SPRING ASSEMBLY

1 0 0 0 2 1

C 3 1 0 0 0 1 0 1 1

8 8 / 2 1

1 0 0 0 1 R M 8

1 0 0 0 2 1

A l l i s o n


C 3 1 0 0 0 1 0 1 1

8 8 / 2 1

1 0 0 0 1 R M 8

A l l i s o n


1. P2 PLANET PL ANETARY CARRIER/P2 CARRIER/P2 SUN GEAR THRU THRUSTBEARING 2. P2 PLANET PL ANETARY CARRIER CARRIER ASSEMBLY


Figure 156


Figure 157


107

Technica l Serv ice Infor mation CONTIN INUED FRO ROM PA PAGE 107 29. Install the parking pawl return spring into the hole in the case, and connect the other end of the spring to the parking pawl with a slight twisting motion (See Figure 159). 30. Align the pin hole in the parking pawl with the parking pawl pin bore in the case, and install parking pawl pivot pin through the park pawl and into case bore (See Figures 158 and 159). Note: You You wil l h ave to tur n th e park pawl pivot pin sev eve er al ti times mes to ge gett i t f ul ly seated. Thi s wil l help in the in stallation as it is air locked locke d duri ng insta installll ation. 31. Install the P2 sun gear and sun gear spacer on the main shaft splines, and install the assembly into carrier, as shown in Figure 158. 32. Install the P3 sun gear and thrust bearing onto main shaft in direction shown in Figure 160. 33. Install output shaft through carrier, ca rrier, as shown in Figure 160, and install assembly into case. Note:: Ensure that P3 planetary Note planetary carr ier and outpu t shaf t ar e f ul l y seated ated,, as shown in F igur e 16 161. 1. 34. Install new extension housing to case gasket on case, as shown in Figure 161. 35. Install the pre-assembled extension housing assembly onto the case (See Figure 161). 36. Install 16 extension housing bolts and torque to 50 N.m (37 ft.lb.) (See Figure 161).

SUN GEAR SPAC SP ACER ER

P2 SUN GEAR

MAIN SHAFT

PARKING PAWL SHAFT

PARKING PAWL


PARKING PAWL RETURN SPRING SPRING

1 0 0 0 2 1

C 3 1 0 0 0 1 0 1 1

8 8 / 2 1

1 0 0 0 1 R M 8

A l l i s o n



Figure 158

108

Figure 159


Technica l Serv ice Infor mation EXTENSION HOUSING BOLTS M10 X 1.5 X 40 (16 REQUIRED)

P3 PLANETARY C ARRIER ASSEMBLY

OUTPUT SHAFT

EXTENSION HOUSING

THRUST BEARING P3 SUN GEAR


1 0 0 0 2 1

C

3 1 0 0 0 1 0 1 1

8 8 / 2 1

1 0 0 0 1 R M 8

1 0 0 0 2 1

A l l i s o n



Figure 160

C 3 1 0 0 0 1 0 1 1

8 8 / 2 1

1 0 0 0 1 R M 8

A l l i s o n



Figure 161


109

Technica l Serv ice Infor mation CONTINUEDFROMPAG PAGE108 37. Rotate transmission in fixture so that the front of case is facing up, as shown in Figure 162. 38. Rotate the main shaft back and forth until it is fully seated in the splines of sun gear spacer. Refer to the dimensions in Figure 162 to ensure that the main shaft is fully seated. N ote: I t is sometimes sometimes nece necesssar y to li f t str str aigh t up on the P2 planetary carr ier shaf t to r eseat the main shaf t (Se (See e F igu r e 162 162). ). 39. Ensure that the P1 sun gear to P1 planetary carrier thrust bearing is either in the P1 carrier or on the sun gear as shown in Figure 163.

40. Install the pre-assembled C1/C2 clutch housing into the transmission by rotating back and forth until fully seated, as shown in Figure 163. 41. Install a new bell housing to case gasket onto the case, as shown in Figure 164. N ote: I t is recommended recommended that dowel dowel s, made f r om extr a bolts i f nece necesssar ary, y, be use used d to ali gn gasket gas ket and be bell l hou houssin g. 42. Install the pre-assembled bellhousing and pump assembly over dowel pins and onto the case, as shown in Figure 164. Continued on Page 112

M ain Shaft Shaft " I S NOT" NOT" Fu lly Se Seat ate ed MAIN SHAFT

Appr oxi mately .290" " Not F ull y Se Seate ated" d"

P2 PLANETARY C ARRIER SHAFT

M ain Shaft Shaft " I S" Ful ly Se Seat ate ed MAIN SHAFT

Appr oxi mately .100" " F ully Seate ated" d"

P2 PLANETARY C ARRIER SHAFT


Figure 162

110


Technica l Serv ice Infor mation 1

INSTALL LLIINGC1/C2CLUTCHHOUSI USIN NG

1

2

2

9 5

3

1

0

3

1


1

3 1

THRUST BEARING

4

5

1. BELL HOUSING TO C ASEBOLTS, M10 M10 X 1.5 1. 5 X 50, 50, (11 INSIDE BELL, 2 EAC ACH HSIDE ON OUTSIDE, TOTAL 15 REQ.) 2. BELL HOUSING TO C ASEBOLTS, M10 M10 X 1.5 1. 5 X 70, 70, (5 RE REQUIRED) QUIRED) 3. BELL HOUSING AND PUMP ASSEMBLY 4. BELL HOUSING SPAC SPACER ER PLATE TO C ASE GASKET 5. MAI MAIN N TRANSMISS TRANSMISSIO ION N C ASE ASSEMBLY


Figure 163


Figure 164


111

Technica l Serv ice Inform ation CONTINUEDFR FROMPA PAGE110 15mm H ead 50mm Length (15 Requi Requi red)

15mm H ead 70mm Length (5 Requi Requi r ed)

Actual Siz Size e

Actu al Size Size

43. Install 11 of the 50mm length bolts in locations shown in Figure 165, and five 70mm length bolts in locations shown in Figure 165. Note:: H and tighten Note tighten onl y at this time. time. 44. Install total of four 50mm bolts, 2 on each side, in the locations shown in Figure 166. 45. Torque all bell housing to case bolts that you have just installed, to 50 N.m (37 ft.lb.). Note: Torqu Torqu e using " cri ss-cross -cross"" patte patterr n. 46. Check the turbine shaft end-play using a dial indicator set up as shown in Figure 167. Note:: F r ont end-play Note end-play should should be .030 .030"" -.04 -.045" 5" . 47. Rotate transmission so that the output o utput shaft is facing up (See Figure 167). 48. Check the output shaft end-play using a dial indicator set up as shown in Figure 167. Note: Rear Rear end-play shoul shoul d be be .01 .018" 8" -.032 -.032"" . 49. Now you can install the appropriate hardware on the rear of trans as shown in Figure 168. Note: Not e: Al l of thes these e part s ar are e mode modell sensiti sensiti ve ve.. 50. Rotate transmission in fixture so that pan p an side is facing up.


2 953103 1

2

9 5

3

1

0

3

1

5 BOLTS 70mm IN LENGTH OTHER 11 ARE 50mm IN LENGTH


Figure 165

112

TWO OF THE 50 50MM MM LENGTH BOLTS GO HERE ON EACH EAC H SIDE


Figure 166


Technica l Serv ice Infor mation CHECKI KING NGFRONT NTEN ENDD-P PLAY 10

0

(SOME MODELS)

10

20

20

30

30

40

40 50

0

50

(SOME MODELS)

2

9 5

3

1

0

3

1

CHECKI KING NGREAR END-PLAY

9 8 . . 9 8

8 . 9

8 . 9 8 . 9

8 . 9 8 . 9

9 8 .

8 . 9

8 . 9

M O ED NI D IA N A OP L SI , IN D AI N A

D IV SI OI N O F G EN RE LA M O OT R CS O PR.

T ar A n sm ll i i s o s si n o n


Figure 167


Figure 168


113

Technica l Serv ice Infor mation CONTIN INUEDFRO ROMPA PAGE112 13mm H ead 40mm Length (4 Requir ed)

13mm H ead 30mm Length (8 Requir ed)

51. Install cooler manifold assembly onto the bell housing, if used, using 2 new cooler manifold gaskets with spacer plate (See Figure 169). 52. Install the four long bolts in holes around the external filter, as shown in Figure 169, and the the eight short bolts in the remaining holes. 53. Torque all cooler manifold bolts to 30 N.m, (22 ft.lb.). 54. Install a new external e xternal transmission filter onto cooler manifold, as shown in Figure 170. Note: Ti ghten by hand onl y. 55. Install the pre-assembled valve body assembly onto the case, as shown in Figure 171. Note: E nsure that dur in g ass assembly manu al valve pin is engaged i nto th the e i nside de detent tent leverr sl ot, and cas leve case e conn conne ector i s f ul ly seated in conn conne ector cas case e bor bore e. 56. Install 15 valve body assembly to case bolts in the locations shown in Figure 172. 57. Torque the valve body to case retaining bolts to 12 N.m, (9 ft.lb.).

Actual Siz Size e Actual Siz Size e 7 6

5

3


4

3

1 EXTERNAL OIL FILTER

1 8

8 08 680 295368

1 8

29536808

1. 2. 3. 4. 5. 6. 7.

2 TRANSMISSIO ION N C ASE. TRANSMI RANSMISS SSIO ION N BELLHOUSING HOUSING.. C OOLERMAN MANIFO IFOLD LDSPAC SPACER ERPLATE GASKET(2 REQUIRE REQUIRED). C OOLERMAN MANIFO IFOLD LDSPAC SPACER ERPLATE. C OOLERMAN MANIFO IFOLD LDASSEMBLY. C OOLERMAN MANIFO IFOLD LDRE RET TAININ AINING G BOLT, M8 x 1.25 x 30 (8 REQ). C OOLERMAN MANIFO IFOLD LDRE RET TAININ AINING G BOLT, M8 x 1.25 x 40 (4 REQ).



Figure 169

114

Figure 170


Technica l Serv ice Infor mation VALVE BODY TO CASE BOL OLT TS 15 REQUIRED

VALVE BOD BODY TO CAS CASE BOL OLT TS 15 REQUIRED

D u P a g e

M anual Valve Valve Pin M us ustt Be Engaged I nto I nside Dete Engaged Detent nt Leve Lev er Slot Dur ing I ns nstall tall 1 8

INSIDE DETENT LEVER 29536808


Figure 171

FOUR VALVE BODY TO CASE BOL OLT TS

8mm H ead 50mm Length (15 Requi Requi r ed)

29536808

0 4 8 6 3 5 9 2

D u P a g e

FIVE VALVE BODY TO CASE BOL OLT TS

Actu al Size Size

SIX VALVE BODY TO CASE BOL OLT TS


Figure 172


115

Technical Service Informati on CONTIN INUEDFRO ROMPA PAGE114 58. Install the inside detent roller and spring onto the valve body, as shown in Figure 173. 59. Install the two detent roller and an d spring retaining bolts and torque to 12 N.m, (9 ft.lb.). (See Figure 173). 60. Install a new bottom bo ttom pan filter and filter seal in transmission, as shown in Figure 174. Note: L ubr icate the fil te terr seal seal wit h a small small amount amo unt of Tr ans ansJe Jel® l® be befor for e in stallation. 61. Install a new bottom pan gasket onto the case, as shown in Figure 175. 62. Install the bottom pan magnet into the bottom pan in the location shown in Figure 175. Note: M agne agnett location i n the bottom bottom pan is verr y im ve important portant to pe perr f orm prope properr ly. 63. Install the bottom pan and twelve bottom pan retaining bolts, as shown in Figure 175. 64. Torque all of the bottom pan retaining bolts to 27 N.m, (20 ft.lb.) (See Figure F igure 175).

65. Install new "O" rings on all three speed sensors and lubricate "O" rings with a small amount of TransJel® (See Figure 176). 66. Install all three speed sensors in their p roper locations, as shown in Figure 176, and torque the retaining bolts to 12 N.m, (9 ft.lb.). 67. Install the Neutral Safety Back Up switch, as shown in Figure 176, and torque the retaining bolts to 27 N.m, (20 ft.lb. 68. Lubricate the torque converter hub with a small amount of TransJel®, and install the converter into transmission, ensuring that it is fully seated into the pump gear (See Figure 177).

THIS CONCLUDES THE FINA FI NAL ASSEMBLY PRO PROCESS

8 mm

DETENT ROLLER AND AND SPRING ASSEMBLY RETAINING BOLTS

DETENT ROLLER AND AND SPRING ASSEMBLY

Actual Siz Size e

1 8

D u

P a g e 29536808


Figure 173

116


Technica l Serv ice Infor mation BOTTOM PAN FILTER

FILT FI LTER SEAL

1 8

D u P a g e 2 9536808 29


Figure 174 BOTTOM PAN

PAN BOLTS 12 REQUIRED

13 mm

Actu al Size Size

PAN GASKET

BOTTOM PAN MAGNET

n o s i l l A

1 8

D u P a g e 8 2953680


Figure 175


117

Technica l Serv ice Infor mation TURBIN INE E SPEED SENSOR (ALL MODELS)

ENGINE SPEED SENSOR (SOME MODELS)

OUTPUT SPEED SENSOR SENSOR (2WD MODEL MO DELS) S)

13 mm

on Allis

NSBU SWITC ITCH H

Actu al Size Size

3 1 1 0 5 3 2 9

10 mm

12450016 29536408

Actu al Size Size Copyright © 2000 ATSG

Figure 176

INSTALL TORQUE CONVERTER LUBRIC BRICAT ATE CO C ONVERTER HUB WITH SMALL AMOUNT OF TRAN ANS SJ EL® on Allis 3 1 1 0 5 3 2 9


Figure 177

118



BOLT IDE IDENTIFI FIC CATION CHART 13 m m

13 mm

13 m m

13 m m

13 m m

10 mm 8 mm

8 mm

8 mm

D

E F

A

G H

Bolts Dr awn Actual Size

B

J C 15 m m

15 m m

15 mm

15 m m

M

N

15 m m

K A. DETENTSPRING TO VALVE BODY, M6 M6 X 1.0 1.0 X 12 (2 REQUIRED). B. MA MAIN IN VALVE BODY TO SHIFTVALVE BODY, M6 M6 X 1.0 1.0 X 50 (23 REQ). B. VALVEBODY ASSE ASSEMBLYTO C ASE ASE,, M6 M6 X 1.0 1.0 X 50 (15 REQUIRED). C . MAI MAIN N VALVEBODY TO SHIFTVALVEBODY, M6 M6 X 1.0 1.0 X 65 (1 REQ). REQ). D. SPEED SENSOR RETAIN AINING ING BOLT, M6 M6 X 1.0 X 13 (3 REQUIRED). E. NSBUSWITC HTO MAIN MAIN CASE C ASE,, M8 X 1.25 1. 25 X 15 (2 REQUIR UIRED) ED).. F. BOTTOM PAN TO MAIN MAIN CASE CASE, M8 X 1. 1.25 25 X 20 (12 REQUIRED) QUIRED).. G. C OO OOLE LER R MANIFOLDTO CAS C ASE, E, M8 X 1.25 X 30 (8 REQUIR REQUIRED). H. C OO OOLE LER MANIFOLD TO CASE C ASE, M8 X 1.25 1.25 X 40 (4 REQUIR REQUIRED ED). ). J . PU PUMP COVER TO PUMP BOD ODY Y, M8 X 1. 1.25 25 X 55 (5 REQU QUIR IRED). K. PTO COVER C OVER TO CASE C ASE,, M10 M10 X 1.5 X 20 CO C OATED(12 REQUIRED) REQUIRED).. L. EXTENS ENSIO ION N HOUSING TO C ASE ASE,, M10 M10 X 1.5 1.5 X 40 (16 REQUIRED). REQUIRED). M. BEL ELL L HOUS HOUSING ING/PUMP /PUMP COVER C OVER & "O" RING, M10 X 1.5 X 50 (10 REQ). N. BELLHOUSING TO MAI MAIN N CASE C ASE, M10 M10 X 1.5 X 50 (15 REQUIRED). REQUIRED). P. BELLHOUSING TO MAIN MAIN CASE C ASE,, M10 M10 X 1.5 X 70 (5 REQUIRED) REQUIRED)..

L

P Copyright © 2000 ATSG

Figure 178


119


TORQUE SPECIF IFIC ICATION CHART DETENTSPR DET PRING ING TO TO VALVE BOD ODY Y, M6 X 1.0 X 12 (2 RE REQUIR QUIRED ED)..... )........ ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ... 12 N.m, (9 ft.lb.). MAIN VALVE VALVEBODY TO SHIFT SHIFTVAL VALVE VEBODY, M6 X 1.0 X 50 (23 REQUIR REQUIRED ED)... )..... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... 12 N.m, (9 ft.lb.). ft.lb.). VALV VA LVE E BOD ODY Y ASSEMBLY TO C AS ASE, E, M6 X 1.0 X 50 (15 RE REQUIR QUIRED ED)..... )........ ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ... 12 N.m, (9 ft.lb ft.lb.). .). MAIN VALVE VALVEBODY TO SHIFT SHIFTVAL VALVE VEBODY, M6 X 1.0 X 65 (1 REQUIR EQUIRED ED)... )..... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .. 12 N.m, (9 ft.lb.). ft.lb. ). SPE PEED EDSEN ENS SOR RET RETAINING BOL BOLT T, M6 M6 X 1.0 X 13 (3 RE REQUIR QUIRED ED)..... )........ ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ..... 12 N.m, (9 ft.lb.). ft.lb. ). NSB NS BUSWITC H TO MAIN MAIN C AS ASE, E, M8 X 1.25 X15 (2 REQUIR QUIRED ED)..... )........ ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ... 27 N.m, (20 ft.lb.). BOT OTT TOM PAN TO MAIN CASE, CASE, M8 X1.25 X 20 (12 REQU EQUIRE IRED) D)... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ..... .. 27 N.m, N.m, (20 (20 ft.lb ft.lb.). .). BOT OTT TOM PAN DR DRAIN AIN PL PLU UG .......... ..... ........... ........... ........... ............ ............ ............ ........... ........... ........... ........... ........... ........... ............ ............ ............ ........... ........ ... 35 N.m, N.m, (26 ft ft.lb.). .lb.). MANUAL MANU ALSHAFTNU NUT T(INTERN RNAL AL& EXT EXTERNAL NAL)) ........ ........... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ..... 23 N.m, (17 (17 ft.lb.). C OO OOLE LERMANIFOLDTO BEL BELLHSG, M8 M 8 X1.25 X 30 (8 REQU EQUIRE IRED)...... D)......... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ..... 30 N.m, (22 (22 ft.lb ft.lb.). .). C OO OOLE LERMANIFOLDTO BEL BELLHSG, M8 M 8 X1.25 X 40 (4 REQU EQUIRE IRED)...... D)......... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ..... 30 N.m, (22 (22 ft.lb ft.lb.). .). PUMP COVER COVERTO PUMP PUMP BODY, M8 X 1.25 X 55 (5 REQUIR QUIRED ED)..... )........ ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ... 27 N.m, (20 (20 ft.lb ft.lb.). .). PTO COVER C OVERTO MAIN MAIN CASE, CASE, M10 X 1.5 X 20 C OAT OATED ED(12 REQU EQUIRE IRED)...... D)......... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ..... 56 N.m, (41 (41 ft.lb.). EXTENS NSION ION HOUSING HOUSING TO TO MAIN CAS C ASE, E, M10 X 1.5 X 40 (16 REQU REQUIR IRE ED)...... D)......... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ..... 50 N.m, (37 ft.lb.). ft.lb.). BELL HOUSING TO PUMP PUMP CO C OVE VER RWITH "O"RING, M10 M 10 X 1.5 X 50 (10 REQUIR REQUIRED ED)... )..... .... .... .... .... .... .... .... .... .... .... .. 43 43 N.m, (32 ft.lb.). ft.lb .). BELLHOUS OUSING ING TO TO MAIN MAIN CASE, CASE, M10 X 1.5 X 50 (15 (15 RE REQUIR QUIRED ED)..... )........ ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ..... 50 N.m, (37 ft.lb.). BELLHOUS OUSING ING TO TO MAIN MAIN CASE, CASE, M10 X 1.5 X 70 (5 (5 RE REQUIR QUIRED ED)..... )........ ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ... 50 N.m, (37 ft.lb ft.lb.). .). REARYOK YOKE E NU NUTWHEN US USED ............ ...... ........... ........... ............ ............ ............ ........... ........... ........... ........... ........... ........... ............ ............ ............ ........... ........ ... 123 N.m, (91 (91 ft.lb. ft.lb.). ). TRANSMI MIS SSIONTO ENGIN GINE E.. .... .... ..... ..... .... .... .... .... ..... ..... .... .... .... ..... ..... .... .... .... .... ..... ..... .... .... .... .... ..... ..... .... .... .... .... ..... ..... .... .... .... .... ..... ..... .... .... .... .... ..... ..... .... .... .. 50 N.m .m,, (37 ft.l .lb.) b.).. TRANSFERCASETO TRANSMI MIS SSION.. .... .... ..... ..... .... .... .... ..... ..... .... .... .... .... ..... ..... .... .... .... .... ..... ..... .... .... .... .... ..... ..... .... .... .... .... ..... ..... .... .... .... .... ..... ..... .... .... .... 50 N.m .m,, (37 ft.l .lb.) b.).. TRANSMI MIS SSIONMOU MOUN NTTO ADAPTERHOU OUS SIN ING G .. .... .... .... .... .... ..... ..... .... .... .... ..... ..... .... .... .... .... ..... ..... .... .... .... .... ..... ..... .... .... .... .... ..... ..... .... .... .... .... .. 47 N.m .m,, (35 ft ft.l .lb.) b.).. TRANSMI MIS SSIONMOU MOUN NTNUTS.. .... .... ..... ..... .... .... .... .... ..... ..... .... .... .... .... ..... ..... .... .... .... .... ..... ..... .... .... .... .... ..... ..... .... .... .... ..... ..... .... .... .... .... ..... ..... .... .... .... .... ..... ..... .... 40 N.m .m,, (30 ft.l .lb.) b.)..

Figure 179


120


Manual de Reparacion para Transmision+Automatica+modelo+ALLISON

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