Allison Transmission 1000 & 2000 Product Family Technician's Guide Manual - PDF DOWNLOAD

TECHNICIANS’ GUIDE

INSPECTION AND ANALYSIS OF THE

ALLISON 1000 & 2000 PRODUCT FAMILIES

GN4062EN (5/05)

INSPECTION AND ANALYSIS OF THE

ALLISON 1000 & 2000 PRODUCT FAMILIES

Glossary Of Terms . . . . . . . . . . 2 Introduction . . . . . . . . . . . . . . . . 3

NOTICE: This guide is intended

for use by technicians skilled in diagnosis and repair of automatic transmissions.

Contact an authorized Allison Transmission service outlet for further information or clarification if required. All specifications provided in this manual are subject to change without notice.

General Inspection Guidelines for Q Cast Parts & Machined Surfaces . . . . . . . . . . . . . . . . . . 4 Q Gears . . . . . . . . . . . . . . . . . . . . 5 Q Splines . . . . . . . . . . . . . . . . . . . 6 Q Bearings . . . . . . . . . . . . . . . . 7-8 Q Bushings . . . . . . . . . . . . . . . . . 9 Q Retaining Rings . . . . . . . . . . 10 Q Thrust Washers . . . . . . . . . . . 11 Q Clutch Plates . . . . . . . . . . 12-13 Q Springs . . . . . . . . . . . . . . . . . 14

P2 Planetary and P3 Ring Gear . . . . . . . . . . . 31-32 P3 Planetary Assembly . . . . . 33 Output Shaft . . . . . . . . . . . . . . 34 Front Support and Charging Oil Pump Module . . . . . . . . . . . . . . . . 35-39 Rotating Clutch Housing . . 40-41 Turbine Shaft . . . . . . . . . . . 42-43 C1 Clutch Pack Components . . . . . . . . . . . . 44-45 C2 Clutch Pack Components . . . . . . . . . . . . 46-47 C3 and C4 Clutch Pack Components . . . . . . . . . . . . 48-49

Control Valve Body Assembly . . . . . . . . . . . . . . 15-21

Main Housing . . . . . . . . . . . 50-51

Torque Converter . . . . . . . . 22-23

C5 Clutch Pack Components . . . . . . . . . . . . 52-53

Torque Converter Housing . . . . . . . . . . . . . . . 24-25

Park Pawl Components . . . 54-55

Rear Cover Assembly . . . . 26-27

Speed Sensors . . . . . . . . . . . . 56

Main Shaft . . . . . . . . . . . . . . . . 28

Neutral Start Backup (NSBU) Switch . . . . . . . . . . 57-58

P1 Planetary and P2 Ring Gear . . . . . . . . . . . 29-30

Wear Limits and Spring Data . . . . . . . . . . . . . 59-63

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GLOSSARY OF TERMS Abrade - Scrape off

Metal Transfer - Metal from one

Battering - Wear or damage due to

component embedded in a mating component

hard usage or repeated blows Brinelling - Permanent deformation

Nick - Small notch

of a bearing surface where rollers or balls contact a race; Results from excessive load or impact; Characterized by indentations on a bearing surface

Pit - Local areas where material has

Burr - Sharp metal extending

Score - Deep scratch

beyond normal surface

Scuff - Wear due to two moving

Chipped - Having a small piece

parts coming together with no lubricant

broken off Cone - A shape whose base is a

circle and whose sides taper up to a point Crimped - Pinched or pressed

together tightly

been removed Porosity - Porous area where air,

fluid, or light may pass through

Spalled - Damage characterized by metal flaking or breaking down on a wear surface; Similar to pitting damage Stripped - Threads broken or

Crocus cloth - Fine grit cloth

damaged so part will not hold torque

Discoloration - Change in color

TAN - Total Acid Number;

Erosion - Gradual uneven removal

Oil acidity should not change by more then 3 from the new fluid TAN when oil sampling is used to determine oil change intervals

of material

Twisted - Bent from original shape

Distortion - Change from original

shape

Fracture - A break or crack Gall - Wear between

parts such that metal transfer occurs Grooves - Long narrow depressions Inadequate -

Not enough Light Stoning - Using a

medium India oilstone to remove material

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TECHNICIANS’

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ALLISON 1000 & 2000 PRODUCT FAMILIES

INTRODUCTION TO INSPECTION & ANALYSIS The Technicians’ Guide is intended to provide additional guidance with the inspection and analysis of transmission parts. This guide should be used by technicians who overhaul Allison 1000 and 2000 Product Family transmissions in conjunction with the 1000 and 2000 Product Families Service Manual (SM3191EN) when inspecting parts to determine their serviceability and reuse.

General Rework Guidelines Replace parts that cannot be re-worked as outlined in this manual and Service Manual SM 3191EN. A soft stone or crocus cloth can be used to attempt removal of “high spots” from transmission parts. After the attempted rework, the part must meet specification if it is going to be reused. Some seal surfaces (for example the output yoke sealing surface and the converter pump hub sealing surface) cannot be reworked. Both of these seal surfaces have a controlled finish that can result in a fluid leak if the part is altered by rework.

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GENERAL INSPECTION GUIDELINES FOR CAST PARTS & MACHINED SURFACES A. Housings

B. Machined Surfaces

D. Splines A. Replace housings or other cast

parts that are cracked or broken.

Inspect clutch housing sealing surfaces for imperfections that could damage the piston seals or interfere with mating parts.

Inspect threaded holes for bad threads. Clean damaged threads with the correct size tap.

B. Inspect all machined surfaces

for damage that could cause fluid leakage. Inspect mounting faces and bores for damage.

C. Inspect all fluid passages for obstructions, porosity, broken lands, cracks and land surface imperfections.

D. Replace housings that have splines worn beyond wear limits.

Refer to the Wear Limits in Service Manual SM3191EN. NOTE: Do not use impact guns (air

wrenches, electric impact wrenches, etc.) when working with aluminum threads or when torque sequencing bolts.

NOTE: Use of caustic acid and hot

tanks can damage aluminum parts, including sealring grooves and machined surfaces.

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C. Fluid Passages

ALLISON 1000 & 2000 PRODUCT FAMILIES

GENERAL INSPECTION GUIDELINES FOR GEARS

A. Gear Teeth

Check gears for damaged or missing teeth.

B. Thrust Face Surface

A. Inspect gears for damaged or

broken teeth. Inspect gear teeth for wear that has changed the original tooth shape. If this condition is noted, replace the gear. Inspect gears for load pattern and signs of distress. Any signs of distress indicate the gear may fail during operation. Reusing distressed gears is an individual customer decision based on experience. Backlash cannot be used to establish critical gear wear. Pits, scuffs, scores or galling are typically evident long before backlash exceeds specification.

B. Inspect the thrust face of gears A. Gear Teeth ALLISON

for damage. If these defects cannot be removed with a soft stone, replace the gear.

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GENERAL INSPECTION GUIDELINES FOR SPLINES A. Splines

Inspect splined parts for burrs, damage and excessive wear.

A. Inspect splined parts for damage. Remove burrs with a soft stone. Spline wear is not considered harmful except where it affects the fit of the splined parts. Spline wear is determined by comparing feeler gauge thickness with the thickness of the worn area on the spline.

Replace parts having excessive spline wear. The maximum movement allowed at the splines is

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0.38 mm (0.015 inches) if not otherwise listed in Wear Limits in Service Manual SM3191EN. Do not reuse a splined part that exceeds the published maximum spline wear. Backlash cannot be used to establish critical spline wear.

Accurate backlash measurement requires the mating parts to be concentrically located.

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ALLISON 1000 & 2000 PRODUCT FAMILIES

GENERAL INSPECTION GUIDELINES FOR BEARINGS

A. Ball Bearing (Under Retainer)

B. Bearing Race

C. Retainer

A & B. Replace the bearing if any

rollers/balls or races are rusted.

Replace the bearing if balls/rollers have a feeling of looseness in the retainer or race compared to a new bearing. Replace the bearing if balls/rollers or races are discolored from heat, lack of lubrication or debris lapping. Replace the bearing if the balls/rollers or races are worn, galled or abraded. Replace the bearing if it catches or feels rough after being thoroughly cleaned.

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C. Replace the bearing if any retainer or retainer clip is fractured, bent, dented or missing.

Replace the bearing if any retainer is rusted. Replace the bearing if there is a feeling of looseness between the retainer and ball/roller compared to a new bearing. Replace the bearing if it catches or feels rough after being thoroughly cleaned.

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GENERAL INSPECTION GUIDELINES FOR BEARINGS (continued) When immersing in solvent, place bearings in a wire basket so there is plenty of space for cleaner to reach all parts. Tanks should have a screened false bottom to prevent settled debris from being stirred up into the bearings. Agitate the basket frequently until grease, oil or sludge is thoroughly loosened and can be flushed out. Blow solvent out of bearings using dry, filtered air. Be careful not to spin the bearing using air pressure.

Lubricate bearings immediately after drying t avoid rust.

General Bearing Handling & Storage Dirt is the greatest single enemy of any antifriction bearing.

Cleanliness - using clean tools in a clean environment - is at the top of the list of good service techniques. Keep bearings sealed in original containers. Do not allow anyone to open boxes and handle bearings. A new bearing, if not protected, can quickly pick up enough dust even in an apparently clean place to seriously affect its life and operation. Minimize the possibility of rusting or lubricant aging in storage by using the oldest bearings in stock first.

Wear eye protection and follow the appropriate safety guidelines when using solvents to clean components.

NOTE:

If any part of a bearing assembly has been compromised, replace all detail parts in the assembly (example - races, retainers and the bearing itself). Most bearings fail from preventable causes. Follow a regular system for inspection. Look for bearings with obvious damage first.

Badly discolored rollers and races are usually a sign of inadequate lubrication. Replace badly discolored bearings. Moderately discolored rollers, cages and races do not necessarily mean that the bearing needs replacement.

General Bearing Inspection Do not try to judge the condition of a bearing until after cleaning. Do not spin bearings while cleaning them. Rotate them slowly while washing. Do not spin any bearings with air pressure. Put bearings under axial pressure while rotating to bring the balls and races firmly in contact with each other. For single row angular contact bearings, pressure must always be applied on thrust faces.

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Technicians should always try to determine the root cause of failure when inspecting failed components.

It’s important the root cause be identified and repaired to avoid the same failure in the future. Bearings should be replaced for the following reasons: Rusted rollers, balls or raceways - rusted rollers, balls or raceways are usually caused by water passing worn or defective seals, or by condensation inside the housing.

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Fractured races - a fractured race can be caused by forcing a cocked bearing on or off a shaft. An excessively tight press fit can also cause a race to fracture.

Worn, galled or abraded surfaces - worn, galled or abraded

surfaces on a bearing may be the result of a loose fit on a shaft or in a housing. A locked bearing spinning on a shaft or in a housing can also create this type of damage.

General feeling of roughness -

inspect for a general feeling of roughness which remains unchanged by thorough cleaning.

This condition generally indicates damage to raceways or rollers caused by dirt, pitting, brinelling or corrosion.

Catchy feeling - inspect for a

catchy feeling at one or more points which repeated flushing will not remove. This condition generally indicates a spalled or fatigued spot on the race. Thorough flushing is necessary to be sure the catchy or rough feeling is not caused by foreign debris in the bearing.

Excessive looseness - inspect for

excessive looseness which indicates lapping by dirt or an abrasive contaminate in the lubricant. If in doubt, compare the end play against the end play of an identical new bearing. The races, balls and rollers will appear dull gray when lapped by dirt.

ALLISON 1000 & 2000 PRODUCT FAMILIES

GENERAL INSPECTION GUIDELINES FOR BUSHINGS

A. Bushing

Bushing wear is strongly influenced by the quantity and condition of the lubricant.

A. Inspect bushings for wear

beyond service limits. Replace any bushing which is excessively worn.

Inspect bushings for discoloration and surface damage due to lack of lubrication. Replace any bushing which is damaged.

General Bushing Information Mechanically, bushings are the simplest type of journal bearing and are often referred to as “plain” bearings. A bushing is simply a sleeve of bearing material, such as bronze or aluminum, in which a component rides. Bushing wear is strongly influenced by the quantity and condition of the lubricant.

Bushing bearing surfaces are sometimes grooved to better distribute lubrication across the bearing surface.

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Some bushings are susceptible to material leaching. This can be caused by oxidized oil that has turned acidic combined with heat and mechanical loading. The TAN (Total Acid Number) of the transmission oil should not change by more than 3 from the baseline (new fluid) TAN. Changing transmission oil per recommended change intervals or based on a successful oil sampling program will help prevent material leaching.

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GENERAL INSPECTION GUIDELINES FOR RETAINING RINGS

A. Retaining Rings

A. Inspect retaining rings for

damage, distortion and excessive wear. Replace retaining rings if damage cannot be repaired using a soft stone or crocus cloth.

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Examine retaining rings for damage, distortion or excessive wear.

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ALLISON 1000 & 2000 PRODUCT FAMILIES

GENERAL INSPECTION GUIDELINES FOR THRUST WASHERS

A. Thrust Washers

A. Replace thrust washers if they are worn beyond service limits.

Replace thrust washers if they are galled, abraded or distorted.

Replace thrust washers if they are damaged due to a lack of lubrication.

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GENERAL INSPECTION GUIDELINES FOR CLUTCH PLATES Oil grooves appear shallow or worn away measure plate thickness and groove depth.

Spline teeth battered and worn - may be an indication of driveline issues. Replace clutch plates and check driveline.

D. Spline Teeth

C. Oil Groove Depth

A. Inspect friction plate contact faces and splines for excessive wear, damage and coning. Inspect the plates for burrs, pitted faces, cracks, distortion and damaged spline teeth.

C. Measure friction plate oil groove depth. Replace any plates that are not within Service Manual SM3191EN minimum groove depth specification.

B. Measure friction plate

excessive wear and battering.

Replace the clutch plate if damage cannot be repaired using a soft stone or crocus cloth. Replace the

thickness and coning. Reference the Service Manual SM3191EN for minimum thickness and maximum coning specifications. Do not reuse friction plates that do not meet published specifications. If reused plates are slightly coned (within specification), make sure each plate is stacked with the cone facing the same direction.

D. Inspect spline teeth for

B. Clutch Plate Thickness and Coning

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clutch plate if spline teeth are broken or missing.

NOTE: Anti-freeze (glycol) and/or water will adversely affect the bonding agent between the friction material and steel core. Replace any friction plates which have been exposed to water and/or glycol.Reference SIL 18-TR-98, Rev. A, for details.

(continued)

Coned Plate

Flat Plate Thickness

A. Contact Surface

Check Using Feeler Gauge

ALLISON 1000 & 2000 PRODUCT FAMILIES

GENERAL INSPECTION GUIDELINES FOR (continued) CLUTCH PLATES C. Tangs

Acceptable discoloration reuse plates.

Excessive scoring replace plates.

B. Thickness & Coning (see prior page graphic)

Broken tangs replace plates.

A. Contact Surfaces

A. Inspect reaction plates for

excessive wear, warping, coning and surface damage. Replace any plate with wear exceeding service limits or with damage which cannot be repaired using a soft stone or crocus cloth..

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B. Measure reaction plate thickness and coning. Reference the Service Manuals for minimum thickness and maximum coning specifications. Do not reuse plates that do not meet published specifications. If reused plates are slightly coned (within specification), make sure each plate is stacked with the cone facing the same direction.

C. Inspect reaction plate tangs

for damage. Replace the plate if damage cannot be repaired using a soft stone or crocus cloth.

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GENERAL INSPECTION GUIDELINES FOR SPRINGS

Reference the Service Manual Spring Data Charts for spring identification and specifications.

A. Springs

A. Inspect springs for permanent

set and wear due to rubbing adjacent parts. Replace the spring if any of these defects are identified or if the spring fails to meet published service limits. Reference the Service Manual SM3191EN Spring Data Charts for spring identification and service limit specifications.

Inspect springs for signs of discoloration, permanent set or wear due to rubbing adjacent parts.

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CONTROL VALVE BODY ASSEMBLY Identification Detail: Control Valve Body Assembly Reverse Signal Tube

Modulated Main Valve Body

Separator Plate

Shift Valve Body

Main Valve Body

Pressure Switch Manifold

General Valve Body Component Inspection Guidelines Inspect valve bodies. Inspect valve bores and oil passages for nicks, bores, scoring and debris. Replace the valve body if damage cannot be repaired using a soft stone or crocus cloth.

Valves must be free of nicks, burrs and scoring. A soft stone or crocus cloth can be used to attempt removal of slight irregularities.

Valves must operate in their bores smoothly without sticking or hanging.

Reverse Signal Tube

Pressure Switch Manifold

G Solenoid

A Solenoid

B Solenoid C Solenoid D Solenoid E Solenoid

(continued)

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F Solenoid (Lockup)

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Manual Selector Valve

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CONTROL VALVE BODY ASSEMBLY (continued) Identification Detail: Main Valve Body Assembly

Exhaust Backfill Valve

Control Relief Valve E Solenoid D Solenoid C Solenoid Retainer

F Solenoid

Identification Detail: Shift Valve Body Assembly C Shift Valve

Control Main Valve

B Solenoid Plug

Accumulators Trim Valve Gain Valve A/B Retaining Bracket

A Solenoid

E Shift Valve D Shift Valve Manual Selector Valve & Pin

NOTE: 1000/2000 Product Families valves are anodized aluminum. Do not remove the gray coating from the valve surface.

NOTE: Do not use impact guns (air wrenches, impact wrenches, etc.) when working with aluminum threads or when torque sequencing bolts.

Replace valve springs which are broken, cracked, permanently set or worn due to rubbing adjacent parts.

Reference the Spring Data Charts in the Service Manual for spring specifications and identification.

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Retaining clips and retention pins must be free of nicks, burrs, scoring, battering and other damage.

Replace retainers or pins which have damage that cannot be removed using a light stone or crocus cloth.

Replace solenoids if they are visibly damaged or if they have been exposed to anti-freeze and/or water. Check solenoid resistance following Troubleshooting Manual TS3192 guidelines and specifications. Replace the solenoid if resistance is not within Troubleshooting Manual specifications.

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Inspect the separator plate for scoring, scratches, burrs and nicks.

Replace the plate if damage cannot be repaired using a soft stone or crocus cloth, or if the plate is cracked or bent. (continued)

ALLISON 1000 & 2000 PRODUCT FAMILIES (continued) CONTROL

VALVE BODY ASSEMBLY

Identification Detail: Main Valve Body (front)

Inspect the internal wiring harness connectors and terminals for visible damage. Inspect the harness protective covering and plastic retainer for cracks, chafing, rubbing and broken pieces. Replace and repair components as necessary. Replace the main connector O-ring if it is cracked, fretted or does not properly fit in its groove or in the main housing.

NOTE: Reference the 1000/2000 Product Families Principles of Operation Manual (PO3065) for complete valve body oil passage detail.

(continued)

Identification Detail: Main Valve Body (back)

Identification Detail: Modulated Main Valve Body Detail

G Solenoid Valve Body

Retaining Clip

Supply Port (Control Main)

G Solenoid Pressure Output

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CONTROL VALVE BODY ASSEMBLY (continued)

Valve bores must be free of nicks, burrs and scoring.

B. Valve Bores

A. Valves Valves should move freeely in their bores, when dry, under their own weight.

A. Valves must be free of nicks,

B. Valve bores must be free of

burrs and scoring and operate smoothly in their bores without sticking. Dry valves must move freely in their bores by their own weight. Replace damaged valves.

A soft stone or crocus cloth can be used in an attempt to repair slight irregularities.

nicks, burrs and scoring. No honing of any kind is allowed. A soft stone or crocus cloth can be used in an attempt to repair slight irregularities.

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NOTE: Use caution not to round

land edges on valves or valve bores.

Excessive rounding can cause unwanted leakage.

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ALLISON 1000 & 2000 PRODUCT FAMILIES (continued) CONTROL

VALVE BODY ASSEMBLY

C, D, E and G Solenoids (on/off)

Identification Detail: Solenoids

Supply Port (Control Main)

F Solenoid Lockup (PWM)

Pressure Output

Pressure Output A Trim Solenoid (PPC)

Exhaust Trim Signal

Identification Detail: Pressure Switch Manifold Exhaust Backfill & Thermister

Supply Port

Not Used

B Trim Solenoid (PPC)

Reverse

D Pressure Switch

Reference the Troubleshooting Manual for switch testing procedures.

E Pressure Switch Reverse

C Pressure Switch

D Pressure Switch E Pressure Switch

Exhaust Backfill & Thermister

C Pressure Switch

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CONTROL VALVE BODY ASSEMBLY

(continued)

Identification Detail: Internal Wiring Harness Assembly

B Solenoid

F Solenoid

A Solenoid

D Solenoid G Solenoid E Solenoid

Supersession Information TCM And Calibration Updates - Reference SILs 2-1K2K-01, 4-1K2K-02, 3-1K2K-03, 7-1K2K-03, 26-1K2K-03

C Solenoid

Pressure Switch Manifold

Main Connector

TCM And Calibrations Have Evolved And Continue To Update (continued) 20

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ALLISON 1000 & 2000 PRODUCT FAMILIES (continued)

CONTROL VALVE BODY ASSEMBLY

The A/B solenoid bracket should be slightly bent as shown.

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Inspect the reverse signal tube for cracks, broken welds and improper bends.

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TORQUE CONVERTER B. Converter Stator (Inside Converter)

A. Converter Exterior C. Converter Hub

A. Visually inspect the converter exterior for impact damage and signs of discoloration. The ribs on the back of the pump housing are used by the engine speed sensor to detect converter rotation. Replace the converter if any ribs are damaged or deformed.

NOTE: Erratic speed sensor signals

B. Inspect the stator for proper

can be caused by a dented torque converter or deformed torque converter ribs. Inspect the converter carefully. Dents and deformities are sometimes hard to identify.

locking and freewheeling action.

The stator inner race should lock when rotated counterclockwise and rotate freely when rotated clockwise. Check the stator with the converter on its edge, and with the converter placed at a 45 degree angle, hub down. Replace the converter if the stator fails this inspection.

The converter must not show signs of leakage when pressurized to 517 kPa (75 psi) and submerged in water. If bubbles appear during this test, the converter is leaking and must be replaced.

After pressure testing the torque converter, all air pressure must be exhausted from the converter before loosening the test fixture nut.

NOTE:

Dented converter near rib creates erratic speed sensor signal.

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Check converter endplay following Service Manual SM3191EN guidelines. Replace the converter if endplay exceeds 1.015 mm (0.040 inch). (continued)

ALLISON 1000 & 2000 PRODUCT FAMILIES (continued)

TORQUE CONVERTER

D. Converter Pilot

C. Inspect the converter pump

hub for deep scratches, scoring, nicks, burrs and signs of overheating. DO NOT ATTEMPT to clean up hub damage using crocus cloth or a soft stone.

Polishing the hub will cause fluid leakage at seal areas. Minimum allowable pump diameter is 58.25mm (2.2933 inches). Minimum allowable distance between converter hub flats (the charging pump drive surface) is 51.816mm (2.040 inches).

NOTE: Damage to the torque

converter hub and/or the torque converter pilot may indicate an engine/transmission adaptation issue. Carefully inspect the

engine/transmission installation when this type of damage exists.

D. Inspect the converter cover

pilot for impact damage, nicks, burrs, cracks and signs of discoloration. Replace the converter if damage or discoloration is excessive. Minimum allowable pilot diameter is 43.080mm (1.696 inches).

E. Inspect for missing or damaged converter lugs. Inspect welds for cracks. Replace the converter if damage cannot be repaired using a soft stone or crocus cloth. Replace the converter if any lugs are missing. Replace the converter if lug threads are damaged and cannot be repaired.

E. Converter Lugs

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TORQUE CONVERTER HOUSING

B. Machined Sealing Surface

A. Housing

D. Filter Attachment Tube A. Inspect the housing for impact

damage, chips and cracks. Inspect bolt holes for damaged threads.

Replace the housing if damage cannot be repaired.

C. Cooler Ports and Pressure Tap Threads

damage cannot be repaired. Some models use a cooler manifold which bolts to the torque converter housing. When used, inspect the cooler manifold cooler port and

B. Inspect machined surfaces for

damage which might prevent proper sealing and/or seating.

Inspect for deep scratches, scoring, grooves, nicks, burrs, chips and cracks. Replace the housing if damage cannot be repaired using a soft stone or crocus cloth.

A magnet sits on top of the control main filter and fits over the filter attachment tube.

C. Inspect cooler port and

pressure tap threads for stripping and damage. Replace the housing if

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B. Machined Mounting Surface

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pressure tap threads for stripping and damage. Inspect the manifold channel plate for scratches, burrs and damage. Replace the manifold if damage cannot be repaired.

(continued)

ALLISON 1000 & 2000 PRODUCT FAMILIES (continued)

Knockdown (Overdrive)

TORQUE CONVERTER HOUSING

Main Pressure

Oil Passage Detail

Exhaust Overage

N/A Exhaust or Drain Back Exhaust or Drain Back

Suction

Lube Pressure

From Cooler

From Control Main Filter N/A

To Control Main Filter Main Pressure C1 Pressure

F. Input Speed Sensor

To Cooler C2 Pressure

To Control Main Filter From Control Main Filter

D. Inspect the filter attachment tube threads for stripping and damage. Replace the fitting if damage cannot be repaired. Replace the housing if the threaded bore is damaged and cannot be repaired.

E. Inspect the input speed sensor

E. Input Speed Sensor Bore

bore for scoring, nicks, burrs, chips or cracks. Replace the housing if the damage cannot be repaired using a soft stone or crocus cloth.

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Main Pressure

To Cooler

From Cooler

Inspect the input speed sensor for obvious external damage.

Inspect the seal ring for wear, damage and proper fit on the sensor and in the speed sensor bore. Speed sensor resistance can be checked using an ohmmeter. Reference Troubleshooting Manual TS3192 for procedures and specifications.

F.

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REAR COVER ASSEMBLY Standard Park Brake Rear Cover

B. Machined Sealing, Mounting, Bearing Surfaces

B. Machined Sealing, Mounting, Bearing Surfaces

A. Housing

C. Output Speed Sensor D. Output Tone Wheel

A. Inspect the housing for impact

damage, chips and cracks. Inspect bolt holes for damaged threads.

Replace the housing if damage cannot be repaired.

NOTE: If cracks are detected on the

four-wheel drive adapter housing, perform thorough driveline analysis checks to ensure driveline components are within specifications.

B. Inspect machined surfaces for

damage which might prevent proper sealing and/or seating.

Inspect for deep scratches, scoring, grooves, nicks, burrs, chips and cracks. Replace the housing if 26

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 2005 General Motors Corporation.

damage cannot be repaired using a soft stone or crocus cloth.

C. Inspect the output speed

sensor for obvious external damage.

Replace the sensor if it has body, terminal or connector damage.

Inspect the seal ring for wear, damage and proper fit on the sensor and in its bore. Speed sensor resistance can be checked using an ohmmeter. Reference Troubleshooting Manual TS3192 for procedures and specifications.

Inspect the output speed sensor bore for scoring, nicks, burrs, chips or cracks. Replace the housing if the damage cannot be repaired using a soft stone or crocus cloth.

TECHNICIANS’

GUIDE

D. Replace the output speed sensor tone wheel if any teeth are chipped, missing, damaged or worn in a way that changes a tooth’s original shape. Inspect the internal splines for burrs, twisting or signs of battering. Replace the tone wheel if spline damage cannot be repaired using a soft stone or crocus cloth.

Inspect the tone wheel’s contact surface faces for scoring, grooves, nicks and other damage which might prevent proper component seating. Replace the tone wheel if face damage cannot be repaired using a soft stone or crocus cloth. (continued)

ALLISON 1000 & 2000 PRODUCT FAMILIES (continued)

REAR COVER ASSEMBLY

B. Machined Sealing, Mounting, Bearing Surfaces

A. Housing

F. Spacer (4WD)

Four-Wheel Drive Adapter Housing

E. Selective Shim

C5 Feed Park Pawl Retaining Pin Bore E. Inspect the selective shim for

Tone wheel tooth imperfections - replace tone wheel.

chips, bends, cracks, wear or signs of deformity. Replace the shim if damage cannot be repaired using a soft stone or crocus cloth.

Inspect the output spacer on four-wheel drive models for cracks, burrs, chips and thrust surface face wear. Replace the spacer if damage cannot be repaired using a soft stone or crocus cloth.

F.

NOTE: If cracks are detected on the

four-wheel drive adapter housing, perform thorough driveline analysis checks to ensure driveline components are within specifications.

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TRANSMISSION

TECHNICIANS’

GUIDE

 2005 General Motors Corporation.

27

ALLISON 1000 & 2000 PRODUCT FAMILIES

MAIN SHAFT ASSEMBLY E. P3 Sun Gear F. Spacer D. P2 Sun Gear Main Shaft

B. Splines A. Journal and Pilot Surfaces

B. Splines

C. Oil Passages

A. Inspect the main shaft pilot

C. Oil passages must be clean and

and journal areas for scoring, burrs, nicks and signs of overheating.

Replace the shaft if damage cannot be repaired using a soft stone or crocus cloth. Minimum allowable pilot outside diameter is 19.987mm (0.7869 inch). Minimum allowable diameter for the P2 bushing journal surface is 35.405mm (1.4333 inches).

unobstructed. Inspect the edges of each orifice for cracks, chips, burrs and metal fatigue. Replace the shaft if damage cannot be repaired using a soft stone or crocus cloth.

B. Inspect the splines for step

wear, twisting, chips, burrs and signs of battering. Replace the shaft if damage cannot be repaired using a soft stone or crocus cloth.

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D. Inspect the P2 sun gear for

chipped, broken, pitted and missing teeth. Inspect the internal splines for step wear, twisting, chips, burrs and signs of battering. Replace the gear if damage cannot be repaired using a soft stone or crocus cloth.

E. Inspect the P3 sun gear for chipped, broken, pitted and missing teeth. Inspect the internal splines for step wear, twisting, chips, burrs

TECHNICIANS’

GUIDE

and signs of battering. Replace the gear if damage cannot be repaired using a soft stone or crocus cloth.

F. Inspect the spacer for cracks.

Inspect internal splines for step wear, twisting, chips, burrs and signs of battering. Inspect the thrust surfaces for nicks, burrs, scoring and excessive wear. Replace the spacer if damage cannot be repaired using a soft stone or crocus cloth.

ALLISON 1000 & 2000 PRODUCT FAMILIES

P1 PLANETARY AND P2 RING GEAR E. Pinion Needle Bearings (Internal)

G. Thrust Bearing Surface

C. Pinion Gears

A. Splines

D. Pinion Thrust Washers

B. Carrier Housing F. Bushing

P1 Planetary

A. Inspect the splines where the

B. Inspect the carrier housing for

D. Inspect the pinion thrust

P2 ring gear indexes to the carrier housing. Inspect the splines on the front hub. Inspect for step wear, twisting, chips, burrs and signs of battering. Replace the carrier if damage cannot be repaired using a soft stone or crocus cloth. With the P2 ring gear installed, maximum allowable carrier/ring gear spline movement is 0.38mm (0.015 inch).

Replace the ring gear and/or carrier as needed to bring spline movement within specification.

cracks, chips, impact damage and signs of discoloration. Replace the assembly if damage cannot be repaired using a soft stone or crocus cloth.

washers for damage, distortion and signs of overheating. Replac the carrier assembly if any damage is identified. Replace the carrier assembly if any pinion gear endplay readings exceed 1.010 mm (0.040 inch).

C. Inspect pinion gears for chipped, broken, pitted or missing teeth. Replace the carrier assembly if damage cannot be repaired using a soft stone or crocus cloth.

E. With the planetary clean and

oiled, check the pinion needle bearings by slowly spinning each pinion gear and feeling for rough spots. Replace the carrier assembly if any pinion gear wobbles, has rough spots or makes noise during the spin test. (continued)

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 2005 General Motors Corporation.

29

ALLISON 1000 & 2000 PRODUCT FAMILIES

P1 PLANETARY AND P2 RING GEAR

(continued)

H. Splines

P1 Ring Gear

Assembled P1 Planetary and P2 Ring Gear.

J. Tangs

I. Thrust Washer

Inspect the carrier bushing for nicks, burrs, scoring, signs of discoloration and signs that the bushing has spun in its bore.

Replace the bushing if damage cannot be repaired using a soft stone or crocus cloth. Maximum allowable bushing inside diameter is 50.690mm (1.9957 inches).

During bushing replacement, inspect the bushing bore in the carrier for scoring, burrs and nicks.

Replace the carrier assembly if damage cannot be repaired using a soft stone or crocus cloth.

F.

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G. Thrust bearings are located inside and on the front of the carrier. Inspect thrust bearing surfaces for grooves, scoring, pitting and signs of overheating. Replace the carrier assembly if damage cannot be repaired using a soft stone or crocus cloth.

H. Inspect the ring gear internal

and external splines for step wear, twisting, chips, burrs and signs of battering. Replace the ring gear if damage cannot be repaired using a soft stone or crocus cloth.

Reference "A" in this section for installed spline wear check procedures.

TECHNICIANS’

GUIDE

NOTE: Inspect the P1 ring gear

following these same guidelines and procedures.

Inspect the thrust washer for cracks, bends, chips and deformity.

Replace the washer if any damage is identified.

I.

J. Inspect the thrust washer

tangs for chips, cracks, breaks, bends, impact damage and signs of battering. Replace the washer if any damage is identified.

ALLISON 1000 & 2000 PRODUCT FAMILIES

P2 PLANETARY AND P3 RING GEAR B. Carrier Housing

A. Splines H. Splines

C. Pinion Gears

P2 Planetary Assembly

A. Inspect the splines where the

P3 ring gear indexes to the carrier housing. Inspect the splines on the front hub. Inspect for step wear, twisting, chips, burrs and signs of battering. Replace the carrier if damage cannot be repaired using a soft stone or crocus cloth. With the P3 ring gear installed, maximum allowable carrier/ring gear spline movement is 0.38mm (0.015 inch).

Replace the ring gear and/or carrier as needed to bring spline movement within specification.

B. Inspect the carrier housing for cracks, chips, impact damage and signs of discoloration. Replace the

E. Pinion Needle Bearings (Internal)

P3 Ring Gear

D. Thrust Washers Inspect hub splines

Inspect ring gear splines

assembly if damage cannot be repaired using a soft stone or crocus cloth.

C. Inspect pinion gears for

chipped, broken, pitted or missing teeth. Replace the carrier assembly if damage cannot be repaired using a soft stone or crocus cloth.

D. Inspect the pinion thrust

washers for damage, distortion and signs of discoloration. Replace the carrier assembly if any damage is identified. Replace the carrier assembly if any pinion gear endplay readings exceed 1.010mm (0.040 inch).

Assembled P2 Planetary and P3 Ring Gear E. With the planetary clean and oiled, check the pinion needle bearings by slowly spinning each pinion gear and feeling for rough spots. Replace the carrier assembly if any pinion gear wobbles, has rough spots or makes noise during the spin test.

(continued)

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TRANSMISSION

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 2005 General Motors Corporation.

31

ALLISON 1000 & 2000 PRODUCT FAMILIES

P2 PLANETARY AND P3 RING GEAR G. Thrust Bearing Surface

(continued)

Supersession Information P3 Ring Gear Retaining Ring Groove Inspection Procedures Reference SIL 8-1K2K-03

INSPECT FOR CHAMBER

F. Bushing Retaining Groove Should Not Have A Chamfered Edge.

Inspect the carrier bushing for nicks, burrs, scoring, signs of overheating and signs that the bushing has spun in its bore.

Replace the bushing if damage cannot be repaired using a soft stone or crocus cloth. Maximum allowable bushing inside diameter is 35.575mm (1.440 inches). During bushing replacement, inspect the bushing bore in the carrier for scoring, burrs and nicks. Replace the carrier assembly if damage cannot be repaired using a soft stone or crocus cloth.

F.

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G. Thrust bearings are located inside and on the front of the carrier. Inspect thrust bearing surfaces for grooves, scoring, pitting and signs of distress. Replace the carrier assembly if damage cannot be repaired using a soft stone or crocus cloth.

Supersession Information P3 Ring Gear Update Reference SIL 31-1K2K-01

H. Inspect the ring gear internal

and external splines for step wear, twisting, chips, burrs and signs of battering. Replace the ring gear if damage cannot be repaired using a soft stone or crocus cloth.

Reference “A” in this section for installed spline wear check procedures.

TECHNICIANS’

GUIDE

Current Ring Gear Has Fewer Spline Teeth.

ALLISON 1000 & 2000 PRODUCT FAMILIES Park pawl equipped (left) and non-park pawl carriers with P3 Sun Gears installed.

P3 PLANETARY ASSEMBLY

C. Pinion Thrust Washers

E. Splines

A. Housing

Pinion Pin

P3 Sun Gear

A. Housing Pinion Pin E. Splines B. Pinion Gears B. Pinion Gears

Supersession Information

F. Park Pawl Engagement Cogs A. Inspect the carrier housing for

cracks, chips, impact damage and signs of discoloration. Replace the assembly if damage cannot be repaired using a soft stone or crocus cloth.

B. Inspect pinion gears for

chipped, broken, pitted or missing teeth. Replace the assembly if damage cannot be repaired using a soft stone or crocus cloth.

C. Inspect the pinion thrust

washers for damage, distortion and signs of discoloration. Replace the carrier assembly if any damage is identified. Replace the carrier assembly if any pinion gear endplay readings exceed 1.010mm (0.040 inch).

D. Pinion Needle Bearings (Internal)

P3 Sun Gear And T6 Bearing Updates Reference SIL 19-1K2K-02

D. With the planetary clean and oiled, check the pinion needle bearings by slowly spinning each pinion gear and feeling for rough spots.

Replace the carrier assembly if any pinion gear has rough spots or makes noise during the spin test.

E. Inspect the splines where

the output shaft indexes for Sun Gear and Bearing Updates step wear, twisting, chips, Enable Increased Capacity. burrs and signs of battering.

Replace the assembly if F. Inspect the park pawl cogs for damage cannot be repaired using a bending, distortion, step wear, soft stone or crocus cloth. scoring, chips, and rounded edges.

Replace the assembly if any damage is detected.

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33

ALLISON 1000 & 2000 PRODUCT FAMILIES

OUTPUT SHAFT

Shaft has normal journal surface wear and can be reused if within service limits.

Two-Wheel Drive Output Shaft

Shaft has excessive galling and wear on the journal surface - replace the shaft.

D. Oil Passages

B. Journal Surfaces A. Splines E. Yoke Retaining Bolt Threads

C. Output Nut Threads

Four-Wheel Drive Output Shaft A. Inspect the splines for step wear, twisting, chips, burrs and signs of battering. Replace the assembly if damage cannot be repaired using a soft stone or crocus cloth.

B. Inspect journal surfaces for

scoring, burrs, nicks and signs of overheating. Replace the shaft assembly if damage cannot be repaired using a soft stone or crocus cloth. Minimum allowable diameter of the output roller bearing journal 44.978mm (1.7708 inches).

NOTE: Damage to the output bearing

journal surface may indicate driveline issues. Perform thorough driveline analysis checks to ensure driveline components are within specifications.

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C. On four-wheel drive models,

inspect for damaged locknut threads. Replace the shaft assembly if damage cannot be repaired.

D. Oil passages must be clean and unobstructed. Inspect the edges of each orifice for cracks, chips, burrs and metal fatigue. Replace the shaft assembly if damage cannot be repaired using a soft stone or crocus cloth.

E. On two-wheel drive models, inspect for damaged yoke retaining bolt threads. Replace the shaft assembly if damage cannot be repaired.

NOTE: The output shaft threads use a Spiralok® design. Replace the output shaft assembly if the Sprialok® threads are damaged.

TECHNICIANS’

GUIDE

F. Inspect the bushing where the main shaft pilots for nicks, burrs, scoring, signs of overheating and signs that the bushing has spun in its bore. Replace the bushing if damage cannot be repaired using a soft stone or crocus cloth. Maximum allowable bushing inside diameter is 20.070 mm (0.7940 inch). Replace the shaft assembly if the bushing bore is damaged.

F. Bushing

ALLISON 1000 & 2000 PRODUCT FAMILIES

FRONT SUPPORT AND CHARGING OIL PUMP MODULE F. Separator Plate

E. Charging Pump Wearplate

B. Ground Sleeve

C. Charging Pump Body

G. Converter Flow Valve A. Front Support Housing

D. Charging Pump Gearset

I. Clutch Backfill Valve

L. Thrust Washer

K. Converter Relief Valve A. Inspect the front J. Lube support housing. Inspect Regulator Valve machined mating and H. Main sealing surfaces and oil Regulator passages for cracks, nicks, Valve grooves, scoring and damage which might prevent proper sealing or seating. Inspect valve Inspect the three sealring grooves bores for nicks, scoring, debris and on the back of the support for any damage which might prevent burrs, chips, cracks and impact proper valve operation. Replace the damage. Sealrings should fit housing if damage cannot be snuggly, but move freely in the repaired using a soft stone or crocus groove. Inspect the thrust washer cloth. Replace both the ground surface at the base of the backside sleeve and the housing if the sleeve hub for grooves, nicks, scoring, has rotated in the housing. burrs and scratches. Replace the housing if damage cannot be repaired using a soft stone or crocus ALLISON

Inspect the seal bore on the front of the charging pump housing.

Seal Bore

cloth. Inspect the ground sleeve needle bearing for rough rotation after cleaning and lubrication.

Inspect the bearing for scored, pitted, cracked and chipped races.

Replace the bearing if any defects are identified. (continued)

TRANSMISSION

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 2005 General Motors Corporation.

35

ALLISON 1000 & 2000 PRODUCT FAMILIES

FRONT SUPPORT AND CHARGING OIL PUMP MODULE (continued) Turbine Shaft Sealring Surface Area Ground Sleeve Bushing

Sealring Grooves

Stator Splines

Thrust Washer Surface

Needle Bearing Ground Sleeve Key inspection items on the front support backside.

Key ground sleeve inspection items.

B. Inspect the ground sleeve

splines for step wear, twisting, chips, burrs and signs of battering.

Replace the ground sleeve if any visible damage is detected. Inspect the ground sleeve bushing for nicks, burrs, scoring and signs that the bushing has spun in its bore.

Replace the bushing if damage cannot be repaired using a soft stone or crocus cloth. Maximum allowable bushing inside diameter is 33.820mm (1.3315 inches).

Inspect the turbine shaft sealring surface inside the rear of the ground sleeve for grooves, scoring and damage which might prevent proper sealing. Replace the ground sleeve if damage cannot be repaired

using a soft stone or crocus cloth. Maximum allowable ground sleeve diameter in this area is 45.450mm (1.7894 inches).

ALLISON

TRANSMISSION

Bushing

When replacing the ground sleeve, total runout cannot exceed 0.20mm (0.008 inch) once the sleeve is pressed into the front support.

NOTE: If the ground sleeve has rotated in the front support housing, replace the front support assembly.

(continued) 36

Gear Cavity Depth and Diameter

TECHNICIANS’

GUIDE

Dowel Pins

Sealring Groove

Key inspection items on the charging pump body backside.

ALLISON 1000 & 2000 PRODUCT FAMILIES

FRONT SUPPORT AND CHARGING (continued) OIL PUMP MODULE Identification Detail: Oil Passage Detail

Converter In

Overage

Lockup Apply

Exhaust Exhaust

To Cooler

Lockup Signal

Converter Out Exhaust

Main Overage Overage N/A Exhaust Knockdown (Overdrive)

Lube

Exhaust

Main

Exhaust

Exhaust From Cooler To Cooler

C2

Suction

C1

Exhaust C. Inspect the charging pump body housing. Inspect the sealring groove for burrs, chips, cracks and impact damage. Inspect the housing sealing surfaces and gear contact areas for scoring, burrs, nicks, chips, pitting and impact damage. Replace the housing if damage cannot be repaired using a soft stone or crocus cloth. Inspect dowel pins and only replace them if damaged. Maximum allowable gear cavity inside diameter is 109.191mm (4.2989 inches).

Inspect the housing bushing.

Replace the bushing if it has any damage which cannot be repaired using a soft stone or crocus cloth.

The bushing uses a burnt orange Teflon® coating. Replace the

bushing if this burnt orange color is not visible on the entire bushing contact area. Maximum allowable bushing inside diameter is 58.458mm (2.3015 inches).

On the front side of the housing, inspect the bore where the seal fits for burrs, nicks, scratches, scoring and any damage which might prevent proper seal installation or sealing. Replace the housing if damage cannot be repaired using a soft stone or crocus cloth.

D. Inspect the charging pump

gearset for scored, chipped, broken, missing or abnormally worn teeth.

Inspect the sides of the gears for scoring, nicks, grooves and

abnormal wear patterns. Replace the gearset if either gear has damage which cannot be repaired using a soft stone or crocus cloth. Inspect the flats on the drive gear for signs of battering. Replace the gearset if the flats are battered or damaged in any way. Maximum allowable distance between flats if 52.165mm (2.0537 inches). Minimum allowable driven gear outside diameter is 108.987mm (4.2908 inches).

Install the gearset in the housing.

Use a straightedge and feeler gauge to measure side clearance.

Maximum allowable side clearance for each gear is 0.066mm (0.0026 (continued)

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TECHNICIANS’

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37

ALLISON 1000 & 2000 PRODUCT FAMILIES

FRONT SUPPORT AND CHARGING OIL PUMP MODULE (continued) Supersession Information

Supersession Information

Main Regulator Valve Update Reference SIL 3-1K2K-04

Charging Pump Bushing Update Reference SIL 6-1K2K-02 Current

Former

Former

Identification

Main / Overage Clearance

Used with Separator Plate

No ID grooves

---

29537327

Beginning w/ 6310037977

One ID groove at the large valve end

.003

29531330

10-643

Beginning w/ 6310200277

Two gooves under the third land and no grooves on large end

.004

29531330

10-643, 10-649

*6310307722 Service Replacement

Three grooves at the large valve end

.004

29541148

6310374684

No ID grooves

.003

29541148

Service Replacement

Two grooves at the large valve end

.005

29531330

Main Pressure Valve Number

Group Number

Serial Number Implemented

29536693

10-628

Prior to 6310037977

29531323

10-642, 644, 648

29540486 Commercial Truck

29542361

♣

For Truck Applications between 63100010006310004116

29541138

10-651

29542193♦

10-650

Current Production

For Bus Applications between 6310001000 6310004116 and 6310037978-6310203135

Current Bushing Is Serviceable.

Also used in pre-production units: 6310292155-6310292563, 6310296468-6310296471, 6310301450-6310301451, 6310303122-6310303124 ♣ Modulated Main Implemented. ♦ Part was never production released-service only.

*

Inspect the separator plate for scoring and flatness. Replace the plate if damage cannot be repaired using a soft stone or crocus cloth.

F.

Inspect the front support valves, springs, stops and retainers for damage. Replace components if damage is detected.

G, H, I, J, K.

inches). Measure the clearance between the outer (driven) gear and the housing. Maximum allowable clearance is 0.204mm (0.008 inches). Measure the clearance between the inside (drive) gear and the crescent. Maximum allowable clearance is 0.455mm (0.0179 inch).

Replace worn parts as necessary.

E. Inspect the charging pump

wear plate for nicks, burrs, scores, scratches, cracks, flatness and any damage which might prevent proper seating and gear operation.

Do not attempt to repair damage using a soft stone or crocus cloth replace the wear plate if damage is detected. Minimum allowable wear plate thickness is 2.950mm (0.1161 inch).

L. Inspect the front support

thrust washer for scoring, grooves, bends, impact damage and signs of overheating. Replace the washer if damage cannot be repaired using a soft stone or crocus cloth, or if any of the thrust washer tangs are deformed or missing.

(continued)

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TECHNICIANS’

GUIDE

ALLISON 1000 & 2000 PRODUCT FAMILIES

FRONT SUPPORT AND CHARGING (continued) OIL PUMP MODULE Supersession Information

Supersession Information

Supersession Information

Lube Regulator and Converter Relief Valve Springs Update Reference SIL 29-1K2K-02

Double Lap Joint Sealrings Reference SIL 24-1K2K-02

Front Support, Charging Pump, Valves and Springs Update Reference SIL 3-1K2K-04

Spring Updates Work Together To Improve Charging Pump Prime.

Current Sealring Design Is Double Lap Joint - Must Be Used On All Models And All Pickup Truck Models Starting With Model Year 03.

Model Year 04i Updates Are Detailed In SIL 3-1K2K-04.

Exhaust to Sump

Identification Detail: Oil Passage Detail

Overage Overage Main Exhaust to Sump

Lube

Torque Converter Clutch Apply

Exhaust to Sump

Main

From Cooler

Exhaust to Sump

To Cooler C2

Suction ALLISON

C1 TRANSMISSION

TECHNICIANS’

GUIDE

 2005 General Motors Corporation.

39

ALLISON 1000 & 2000 PRODUCT FAMILIES

ROTATING CLUTCH HOUSING E. Turbine Shaft Inspect the internal splines where the C2 reaction plates index.

C. Bushing B. PTO Drive Gear A. Rotating Clutch Housing

F. P1 Sun Gear D. Speed Sensor Tone Wheel

Splines

A. Inspect the rotating clutch

pitting, grooves and scoring.

Replace the housing if damage cannot be repaired using a soft stone or crocus cloth.

housing. Replace the housing if it is cracked, dented or has damage which cannot be repaired using a soft stone or crocus cloth.

Inspect the internal splines where the C2 reaction plates index for step wear, twisting, chips, burrs and signs of battering. Replace the housing if damage cannot be repaired using a soft stone or crocus cloth.

Inspect the surface just below the bushing where the three front support sealrings ride for cracks,

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Inspect the C1/C2 piston housing snap ring and sealring grooves for burrs, chips and cracks. Replace the housing if damage cannot be repaired using a soft stone or crocus cloth.

NOTE: Use the appropriate special

tools during C2 clutch piston snap ring removal and installation to avoid damaging the C1 clutch sealring area. Reference Service Manual SM3191 for procedures.

TECHNICIANS’

GUIDE

B. Inspect the PTO drive gear teeth for chips, cracks and abnormal wear. Replace the rotating clutch housing assembly if damage cannot be repaired using a soft stone or crocus cloth, or if the gear is missing teeth or loose on the housing.

C. Inspect the rotating clutch

housing bushing. Replace the bushing if it has any damage which cannot be repaired using a soft stone or crocus cloth. Maximum allowable bushing inside diameter is 78.170mm (3.0776 inches). (continued)

ALLISON 1000 & 2000 PRODUCT FAMILIES (continued) ROTATING

CLUTCH HOUSING C1/C2 piston housing snap ring and sealring grooves.

C1 Clutch Feed

C2 Clutch Feed

Front Support Sealring Area

C1 C1 Return Return Spring Spring Retaining Retaining Ring Ring Groove Groove C1 Balance Piston Feed

C2 Snap Ring Groove (Top Groove)

C1 Sealring Groove (Bottom Groove)

D. Replace the speed sensor tone

E. Reference the "Inspection and

wheel if it is deeply scratched, scored, dented, out-of-round or shows signs of impact damage. Any of these conditions can cause an erratic turbine speed sensor signal.

Analysis of the Turbine Shaft" section of this manual for details.

F. Inspect the P1 sun gear for chipped, broken, pitted and missing teeth. Replace the gear if damage cannot be repaired using a soft stone or crocus cloth.

The PTO gear must be securely attached to the rotating clutch housing.

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41

ALLISON 1000 & 2000 PRODUCT FAMILIES

TURBINE SHAFT B. Bearing Journal

Turbine Shaft

A. Bushing Journal

E. Splines

D. Oil Passage (Lube) D. Oil Passage (Converter In)

E. Splines

C. Sealring Grooves

G. Bushing

A. Inspect the bushing journal

C. Inspect the sealring grooves for

surface for nicks, burrs, grooves, scoring, pitting and signs of discoloration. Replace the shaft if damage cannot be repaired using a soft stone or crocus cloth.

burrs, chips and cracks. Replace the turbine shaft if damage cannot be repaired using a soft stone or crocus cloth.

B. Inspect the bearing journal

surface for nicks, burrs, grooves, scoring, pitting and signs of discoloration. Replace the shaft if damage cannot be repaired using a soft stone or crocus cloth.

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D. Oil passages must be clean and

unobstructed. Inspect the edges of each orifice for cracks, chips, burrs and metal fatigue. Replace the shaft if damage cannot be repaired using a soft stone or crocus cloth. (continued)

TECHNICIANS’

GUIDE

F. Snap Ring Grooves

ALLISON 1000 & 2000 PRODUCT FAMILIES (continued) TURBINE

SHAFT

Supersession Information Turbine Shaft Updates Reference SIL 23-1K2K-04

E. Inspect the splines for step

G. Inspect the bushing. Replace

wear, twisting, chips, burrs and signs of battering. Replace the turbine shaft if damage cannot be repaired using a soft stone or crocus cloth.

the bushing if it has any damage which cannot be repaired using a soft stone or crocus cloth.

Maximum allowable bushing inside diameter is 20.117mm (0.7920 inch).

F. Inspect the snap ring grooves for burrs, chips and cracks. Replace the turbine shaft if damage cannot be repaired using a soft stone or crocus cloth.

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TRANSMISSION

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GUIDE

 2005 General Motors Corporation.

43

ALLISON 1000 & 2000 PRODUCT FAMILIES

C1 CLUTCH PACK COMPONENTS A. C1 Clutch Pack

B. C1 Clutch Backplate

E. C1 Drive Hub

F. C1 Piston Housing

G. Thrust Bearing

D. C1 Return Spring Assembly H. C1 Clutch Balance Piston

C. C1 Clutch Piston

A. Inspect friction plate contact faces for excessive wear, embedded metal particles, cracking and distortion. Inspect the plate splines for burrs, cracks and damaged spline teeth. Replace the plate if spline damage cannot be repaired using a soft stone or crocus cloth.

Minimum allowable friction plate thickness is 2.375mm (0.0935 inch).

Minimum allowable oil groove depth is 0.20mm (0.008 inch).

Maximum allowable coning is 0.225mm (0.009 inch).

NOTE: Anti-freeze (glycol) and/or

water will adversely affect the bonding agent between the friction material and steel core. Replace any

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ID

Minimum Thickness

2420

11.400 mm (0.4488 inch)

6221/8521

11.840 mm (0.4661 inch)

6222/8522 12.280 mm (0.4835 inch) 6223/8523

12.730 mm (0.5012 inch)

6224/8524

13.180 mm (0.5189 inch)

6225/8525

13.630 mm (0.5366 inch)

friction plates which have been exposed to water and/or glycol.

Friction material which is loose or flaking indicates that the plates have been exposed to glycol and/or water. Reference SIL 18-TR-98, Rev. A for details.

crocus cloth. Replace the plate if any tangs are broken, bent or otherwise distorted. Minimum allowable plate thickness is 2.135mm (0.0841 inch). Maximum allowable coning is 0.20mm (0.0079 inch).

NOTE: Battered and worn spline

B. Inspect the C1 clutch

teeth may be an indicator of driveline issues. Replace the clutch plates and check the driveline.

backplate. Replace the backplate if has burrs, scoring or other damage which cannot be repaired using a soft stone or crocus cloth. Replace the backplate if it is cracked or broken. Check the backplate for coning. Replace the backplate if any coning is detected. Minimum allowable plate thickness is indicated in the chart above.

Inspect reaction plate contact surfaces for chips, cracks, grooves, scoring and signs of discoloration.

Inspect reaction plate tangs for chips, cracks and signs of battering.

Replace the plate if damage cannot be repaired using a soft stone or TECHNICIANS’

GUIDE

(continued)

ALLISON 1000 & 2000 PRODUCT FAMILIES (continued) C1

CLUTCH PACK COMPONENTS

Inspect drive hub splines for wear and battering.

Supersession Information

Inspect the C1 clutch piston internal and external sealring grooves.

C. Inspect the C1 clutch piston

for burrs, chips and cracks. Inspect the internal and external sealring grooves for burrs, chips and cracks.

Replace the piston if damage cannot be repaired using a soft stone or crocus cloth.

C1 Drive Hub And T1 Thrust Bearing Updates - Reference SIL 23-1K2K-04

Piston housing check ball must have at least 1.00 mm free travel.

for spring specifications and identification.

E. Inspect the C1 drive hub.

D. Inspect the C1 clutch return

Inspect the rear of the hub for damage caused by contact with the main shaft. Replace the hub if damage cannot be repaired using a soft stone or crocus cloth.

spring plate for cracks, chips, burrs, bends and distortion.

Replace the plate if damage cannot be repaired using a soft stone or crocus cloth. Replace the assembly if springs are broken, cracked, permanently set, showing signs of wear due to rubbing or showing signs of discoloration. Reference the Service Manual Spring Data Charts

Inspect the internal and external housing splines and the hub splines for step wear, twisting, chips, burrs and signs of battering.

Replace the assembly if damage cannot be repaired using a soft stone or crocus cloth. Maximum allowable spline wear is 0.38mm (0.015 inch).

ALLISON

Drive Hub And Bearing Updates Necessitate New Clutch Pack Clearance Check Procedures And Tooling.

Inspect the C1 clutch piston housing for burrs, chips and cracks.

Inspect the area where sealrings ride for grooves and scoring.

Replace the piston if damage cannot be repaired using a soft stone or crocus cloth. The check ball must move freely and have a minimum of 1.00mm (0.040 inch) travel parallel to the housing’s centerline.

F.

G. Inspect the thrust bearings on

both sides of the C1 hub. Replace the bearing if it fails any of these inspection procedures.

H. The C1 balance piston includes a bonded seal. Replace the piston during overhaul.

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TECHNICIANS’

GUIDE

 2005 General Motors Corporation.

45

ALLISON 1000 & 2000 PRODUCT FAMILIES

C2 CLUTCH PACK COMPONENTS

Inspect C2 drive hub interal, external and hub splines.

B. C2 Clutch Piston C. C2 Return Spring Assembly

H. C2 Clutch Balance Piston

Inspect P1 sun gear teeth and splines.

E. P1 Sun Gear G. C2 Drive Hub F. Thrust Washer A. C2 Clutch Pack D. P1 Drive Flange A. Inspect friction plate contact faces for excessive wear, embedded metal particles, cracking and distortion. Inspect the plate splines for burrs, cracks and damaged spline teeth. Replace the plate if spline damage cannot be repaired using a soft stone or crocus cloth.

Minimum allowable friction plate thickness is 2.375 mm (0.0935 inch). Minimum allowable oil groove depth is 0.20 mm (0.008 inch). Maximum allowable coning is 0.225 mm (0.009 inch).

NOTE: Anti-freeze (glycol) and/or

water will adversely affect the bonding agent between the friction material and steel core. Replace any friction plates which have been 46

ALLISON

TRANSMISSION

 2005 General Motors Corporation.

exposed to water and/or glycol.

Friction material which is loose or flaking indicates that the plates have been exposed to glycol and/or water. Reference SIL 18-TR-98, Rev. A for details.

any tangs are broken, bent or otherwise distorted. Minimum allowable plate thickness is 2.135 mm (0.0841 inch). Maximum allowable coning is 0.240 mm (0.0094 inch).

NOTE: Battered and worn spline

B. Inspect the C2 clutch piston for burrs, chips and cracks. Inspect the internal and external sealring grooves for burrs, chips and cracks.

Replace the piston if damage cannot be repaired using a soft stone or crocus cloth.

teeth may be an indicator of driveline issues. Replace the clutch plates and check the driveline.

Inspect reaction plate contact surfaces for chips, cracks, grooves, scoring and signs of discoloration.

Inspect reaction plate tangs for chips, cracks and signs of battering.

Replace the plate if damage cannot be repaired using a soft stone or crocus cloth. Replace the plate if TECHNICIANS’

GUIDE

C. Inspect the C2 clutch return spring plate for cracks, chips, burrs, bends and distortion. Replace the plate if damage cannot be repaired using a soft stone or crocus cloth. (continued)

ALLISON 1000 & 2000 PRODUCT FAMILIES (continued) C2 Supersession Information

CLUTCH PACK COMPONENTS Inspect the P1 drive flange internal and external splines.

C2 Clutch Piston Update Reference SIL 24-1K2K-02

Spline surface roughness is caused by stamping process and is acceptable - reuse drive flange.

Inspect the three sealring grooves on the C2 piston for damage.

Rework Is Required If The Current Piston Is Used In GM MY01 and MY02 Pickup Trucks.

Replace the assembly if springs are broken, cracked, permanently set, showing signs of wear due to rubbing or showing signs of discoloration. Reference the Service Manual Spring Data Charts for spring specifications and identification.

D. Inspect the P1 drive flange for internal and external spline step wear, burrs, chips, distortion and signs of discoloration. Replace the flange if it is cracked or if it has damage which cannot be repaired using a soft stone or crocus cloth.

E. Inspect the P1 sun gear teeth for chips, burrs, scoring and pitting.

Replace the gear if it has missing or cracked teeth. Replace the gear if damage cannot be repaired using a soft stone or crocus cloth. Inspect splines for step wear, twisting, chips, burrs and signs of battering.

Replace the gear if damage cannot be repaired using a soft stone or crocus cloth.

Inspect the thrust washer between the C2 drive hub and P1 sun gear for scoring, burrs, nicks, cracks, distortion and signs of overheating. Replace the thrust washer if damage cannot be repaired using a soft stone or crocus cloth.

Replace the thrust washer if any of F.

ALLISON

its tangs are broken, distorted or missing. Minimum allowable thrust washer thickness is 2.59 mm (0.102 inch).

G. Inspect the C2 drive hub internal and external housing splines and the hub splines for step wear, twisting, chips, burrs and signs of battering. Replace the assembly if damage cannot be repaired using a soft stone or crocus cloth. Maximum allowable hub spline wear is 0.38 mm (0.015 inch). Maximum allowable clutch spline step wear is 0.100 mm (0.004 inch).

H. The C2 balance piston includes a bonded seal. Replace the piston during overhaul.

TRANSMISSION

TECHNICIANS’

GUIDE

 2005 General Motors Corporation.

47

ALLISON 1000 & 2000 PRODUCT FAMILIES

C3 AND C4 CLUTCH PACK COMPONENTS

B. C3/C4 Return Spring Assemblies

C. C3 Backplate

D. C4 Backplate

E. C3/C4 Clutch Pistons

A. C3/C4 Clutch Packs A. Inspect all friction plate contact faces for excessive wear, embedded metal particles, cracking and distortion. Inspect the plate splines for burrs, cracks and damaged spline teeth. Replace the plate if spline damage cannot be repaired using a soft stone or crocus cloth. Minimum allowable friction plate thickness is 2.375 mm (0.0935 inch). Minimum allowable oil groove depth is 0.20 mm (0.008 inch). Maximum allowable coning is 0.225 mm (0.009 inch).

NOTE: Anti-freeze (glycol) and/or

water will adversely affect the bonding agent between the friction material and steel core. Replace any 48

ALLISON

TRANSMISSION

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friction plates which have been exposed to water and/or glycol.

Friction material which is loose or flaking indicates that the plates have been exposed to glycol and/or water. Reference SIL 18-TR-98, Rev. A for details.

crocus cloth. Replace the plate if any tangs are broken, bent or otherwise distorted. Minimum allowable plate thickness is 2.440 mm (0.0961 inch). Maximum allowable coning is 0.40 mm (0.016 inch).

NOTE: Battered and worn spline

B. Inspect the C3 and C4 clutch

teeth may be an indicator of driveline issues. Replace the clutch plates and check the driveline.

Inspect reaction plate contact surfaces for chips, cracks, grooves, scoring and signs of discoloration.

Inspect reaction plate tangs for chips, cracks and signs of battering.

Replace the plate if damage cannot be repaired using a soft stone or TECHNICIANS’

GUIDE

return spring plates for cracks, chips, burrs, bends and distortion.

Replace the plate if damage cannot be repaired using a soft stone or crocus cloth. Replace the spring assembly if springs are broken, cracked, permanently set, showing signs of wear due to rubbing or showing signs of discoloration. (continued)

ALLISON 1000 & 2000 PRODUCT FAMILIES (continued) C3

AND C4 CLUTCH PACK COMPONENTS

Supersession Information C3/C4 Return Spring Assembly and Plate Updates Reference SIL 1-1K2K-04

Updates Aid The Assembly Process.

C. Clutch Plate Thickness and Coning

Coned Plate Check Using Feeler Gauge

Flat Plate Thickness

Reference the Service Manual Spring Data Charts for spring specifications and identification.

Minimum allowable backplate thickness is 3.110mm (0.1224 inch).

Maximum allowable backplate coning is 0.40mm (0.016 inch).

Replace any thrust plates showing signs of excessive or uneven wear, gouges, scoring or cracks. Calculate thrust plate thickness following the Service Manual guidelines.

Minimum allowable thrust plate thickness is 3.00mm (0.1181 inch).

C. Inspect the C3 clutch

D. Inspect the C4 clutch

backplate. Replace the backplate if has burrs, scoring or other damage which cannot be repaired using a soft stone or crocus cloth. Replace the backplate if it is cracked or broken. Check the backplate for coning. Replace the backplate if any coning is detected. Minimum allowable backplate thickness is 15.325mm (0.6033 inch).

backplate. Replace the backplate if has burrs, scoring or other damage which cannot be repaired using a soft stone or crocus cloth. Replace the backplate if it is cracked or broken. Check the backplate for coning. Replace the backplate if any coning is detected. Minimum allowable backplate thickness is 15.40mm (0.6063 inch).

ALLISON

Calculate thrust plate thickness following Service Manual guidelines.

E. C3 and C4 clutch pistons

include a bonded seal. Replace the pistons during overhaul.

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GUIDE

 2005 General Motors Corporation.

49

ALLISON 1000 & 2000 PRODUCT FAMILIES

MAIN HOUSING A. Main Housing

G. Speed Sensor Bore

J. Identification Plate

B. Front Sealing Surface

I. Filltube Bore

H. Selector Shaft Bore

D. PTO Mounting Pads

Rear View

Front View

F. Splines

A. Inspect the main housing for

C. Inspect the sealing surface at

impact damage, chips and cracks.

Inspect threaded holes for damage, stripping and cracking. Replace the main housing if damage cannot be repaired.

the rear of the main housing for nicks, burrs, scratches, scoring and other damage which might cause improper sealing or component seating. Replace the housing if damage cannot be repaired using a light stone or crocus cloth.

B. Inspect the sealing surface and

machined bore at the front of the main housing for nicks, burrs, scratches, scoring and other damage which might cause improper sealing or component seating. Replace the housing if damage cannot be repaired using a light stone or crocus cloth.

50

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C. Rear Sealing Surface

TRANSMISSION

 2005 General Motors Corporation.

D. Inspect the PTO mounting pad

surfaces for nicks, burrs, scratches, scoring and other damage which might cause improper sealing or PTO seating. Replace the housing if damage cannot be repaired using a light stone or crocus cloth.

TECHNICIANS’

GUIDE

E. Electrical Connector Bore

Inspect machined bores for nicks, burrs, scratches, scoring and other damage which might cause improper sealing or component seating. Replace the housing if damage cannot be repaired using a light stone or crocus cloth.

E, G, H, I.

(continued)

ALLISON 1000 & 2000 PRODUCT FAMILIES (continued) MAIN

Inspect the flat sealing surface and the machined bore at the front of the main housing.

Oil Passage Detail Front View

Torque Converter Clutch C3 Feed

Exhaust To Sump Exhaust

Oil Passage Detail Rear View

Exhaust To Sump

C3 Spline

HOUSING

N/A C4 Spline

Main

C4 Feed

C5 Spline

Control Main From Filter Suction C2 Exhaust Backfill

Knockdown Overdrive C1 Exhaust Backfill

Control Main To Filter

Park Pawl Support Pin Bore

C5 Feed

Main Connector Bore

Oil Passage Detail - Bottom View Inspect splines for step wear, twisting, chips, burrs and signs of battering. Replace the main housing if damage cannot be repaired using a soft stone or crocus cloth.

Control Main From Filter

F.

J. The identification plate

contains information necessary to perform service work on the transmission. The model number, serial number, electronic "E" number and date of manufacture are included, as well as individual component group numbers which are used to identify specific components used to build each major section of the transmission.

Remove and reattach the plate if it is not securely riveted to the transmission main housing.

Control Main To Filter

Torque Converter Clutch Apply

C5 / Exhaust Backfill

Knockdown Overdrive Main

C5 Feed

C1 / Exhaust Backfill

Exhaust To Sump

Suction C2 / Exhaust Backfill Exhaust C3 / Exhaust Backfill ALLISON

TRANSMISSION

C4 Feed

TECHNICIANS’

GUIDE

 2005 General Motors Corporation.

51

ALLISON 1000 & 2000 PRODUCT FAMILIES

C5 CLUTCH PACK COMPONENTS

B. C5 Piston

C. C5 Backplate

D. C5 Return Spring Assembly

A. C5 Clutch Pack

A. Inspect friction plate contact

NOTE: Anti-freeze (glycol) and/or

faces for excessive wear, embedded metal particles, cracking and distortion. Inspect the plate splines for burrs, cracks and damaged spline teeth. Replace the plate if spline damage cannot be repaired using a soft stone or crocus cloth.

Minimum allowable friction plate thickness is 2.375mm (0.0935 inch).

Minimum allowable oil groove depth is 0.20mm (0.008 inch).

Maximum allowable coning is 0.225mm (0.009 inch).

water will adversely affect the bonding agent between the friction material and steel core. Replace any friction plates which have been exposed to water and/or glycol.

Friction material which is loose or flaking indicates that the plates have been exposed to glycol and/or water. Reference SIL 18-TR-98, Rev. A for details.

NOTE: Battered and worn spline

teeth may be an indicator of driveline issues. Replace the clutch plates and check the driveline.

52

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Inspect reaction plate contact surfaces for chips, cracks, grooves, scoring and signs of overheating.

Inspect reaction plate tangs for chips, cracks and signs of battering.

Replace the plate if damage cannot

be repaired using a soft stone or crocus cloth. Replace the plate if any tangs are broken, bent or otherwise distorted. Maximum allowable coning is 0.295mm (0.0116 inch). Minimum allowable plate thickness is indicated in the chart below.

Part Number

Minimum Thickness

ID Number

29536481

1.935 mm (0.0762 inch)

1

29536482

2.435 mm (0.0959 inch)

2

29536483

2.935 mm (0.1156 inch)

3

(continued) TECHNICIANS’

GUIDE

ALLISON 1000 & 2000 PRODUCT FAMILIES (continued) C5

CLUTCH PACK COMPONENTS Inspect the piston internal and external sealring grooves.

Supersession Information C5 Friction Plate Update Reference SIL 31-1K2K-01

2WD C5 Piston (100%)

4WD C5 Piston (70%)

Current Friction Plates Have Sunburst Pattern.

B. Inspect the C5 clutch piston

C. Inspect the C5 clutch

D. Inspect the C5 clutch return

for burrs, chips and cracks. Inspect the internal and external sealring grooves for burrs, chips and cracks.

Replace the piston if damage cannot be repaired using a soft stone or crocus cloth.

backplate. Replace the backplate if it has burrs, scoring or other damage which cannot be repaired using a soft stone or crocus cloth.

Replace the backplate if it is cracked or broken. Check the backplate for coning. Replace the backplate if any coning is detected.

Minimum allowable backplate thickness is 17.90mm (0.7047 inch).

spring plate for cracks, chips, burrs, bends and distortion.

Replace the plate if damage cannot be repaired using a soft stone or crocus cloth. Replacethe assembly springs if broken, cracked, permanently set, showing signs of wear due to rubbing or showing signs of discoloration. Reference the Service Manual Spring Data Charts for spring specifications and identification.

C. Clutch Plate Thickness and Coning

Coned Plate

Flat Plate

Check Using Feeler Gauge

Thickness ALLISON

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GUIDE

 2005 General Motors Corporation.

53

ALLISON 1000 & 2000 PRODUCT FAMILIES

PARK PAWL COMPONENTS B. Pawl Support Pin A. Park Pawl

H. Spherical Pin

C. Pawl Return Spring

G. Detent Lever E. Apply Assembly D. Apply Guide

F. Selector Shaft I. Selector Shaft Nut Park pawl seated in the P3 carrier cogs.

A. Inspect the park pawl contact

faces for cracks, step wear, impact damage and signs of battering.

Inspect the park pawl pivot bore for burrs, nicks, scoring and out-ofround. Replace the park pawl if any damage is detected.

B. Inspect the park pawl support pin for burrs, nicks, scoring and grooves. Replace the pin if it doesn’t fit securely in the rear cover or main housing or if it has damage which cannot be repaired using a soft stone or crocus cloth.

damage or if it does not quickly recoil when released.

D. Inspect the

apply guide for grooves, scoring and deformities.

Replace the guide if damage cannot be repaired using a soft stone or crocus cloth. (continued)

C. Inspect the park pawl return

spring for damaged coils. Replace the spring if it has any signs of 54

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TRANSMISSION

 2005 General Motors Corporation.

TECHNICIANS’

GUIDE

Inspect the park pawl contact surfaces.

ALLISON 1000 & 2000 PRODUCT FAMILIES (continued) PARK

PAWL COMPONENTS Inspect the apply assembly spring rollers and indexing tang.

Indexing Tang Inspect the detent lever slots and detent teeth.

Slots Spring

Detent Teeth

Rollers

Mushroomed Areas

E. Inspect the slotted end of the

apply assembly for burrs, chips and cracks. Inspect the indexing tang for cracks and burrs. Inspect the spring for bent, cracked or broken coils. Inspect the rollers for scoring, burrs and pitting. The rollers should fit securely in the retainer and should roll freely without binding or sticking. Replace the assembly if damage cannot be repaired using a soft stone or crocus cloth.

Inspect the selector shaft for burrs, chips and cracks. Inspect the shaft flats for chips, burrs and nicks. Inspect the shaft threads for stripping and damage. Replace the

F.

selector shaft if damage cannot be repaired using a soft stone or crocus cloth, or if the shaft is bent.

NOTE: Burrs or raised metal on the

selector shaft flats (where the selector lever seats) may cause damage to the NSBU switch and selector seal if not removed or repaired.

G. Inspect the detent lever slots

for burrs, chips and cracks. Inspect the detent teeth for impact damage, step wear, bends and cracks.

Replace the detent lever if damage cannot be repaired using a soft stone or crocus cloth.

ALLISON

Selector Shaft

Inspect the selector shaft for mushrooming in the indicated areas. Avoid NSBU damage by removing mushrooming prior to switch removal or installation.

H. Inspect the spherical pin for nicks, burrs and deformities.

Replace the pin if it is bent or if it has damage which cannot be repaired using a soft stone or crocus cloth.

Inspect the selector shaft nut threads for stripping and damage.

Inspect the nut shoulder for burrs and deformities which might prevent proper seating. Replace the nut if damage cannot be repaired using a soft stone or crocus cloth.

I.

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 2005 General Motors Corporation.

55

ALLISON 1000 & 2000 PRODUCT FAMILIES

SPEED SENSORS Speed sensor retainer orientation is critical for proper operation.

A. Sensor Body

D. O-Ring

A. Inspect the sensor body for chips, cracks and broken pieces.

Replace the sensor if any damage is detected.

B. Inspect the sensor retainer for cracks, bends and deformities.

Sensor retainer orientation is critical to proper sensor and electronic control operation. Do not attempt to reposition the sensor in the retainer.

56

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C. Sensor Connector and Terminals

C. Inspect the connector body for

cracks and impact damage. Inspect the locking tangs for damage which might prevent proper harness connector installation and seating.

Replace the sensor if any damage is detected. Inspect the terminals for any damage which might prevent proper seating with mating terminals. Reference the Troubleshooting Manual TS3192 for terminal replacement procedures and ohmmeter pin-out checks.

TECHNICIANS’

GUIDE

B. Sensor Retainer D. Replace the sensor O-ring if it is fretted or if it does not properly fit on the sensor or in the sensor bore.

NOTE: During installation, sensors must be properly and thoroughly seated in their bores before installing retaining bolt. Improper installation can cause sensor damage and erratic speed sensor signals which can affect shift quality.

ALLISON 1000 & 2000 PRODUCT FAMILIES

NEUTRAL START BACKUP (NSBU) SWITCH First Version

Current Version

NSBU switch evolution from left to right - earliest to current singleconnector version.

P/N 12450016

P/N 29540193

P/N 29541852

Supersession Information NSBU Switch Improvements - Reference SILs 32-1K2K-01 and 14-1K2K-03

(continued)

Current NSBU Switch Is A Single Connector Design.

ALLISON

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57

ALLISON 1000 & 2000 PRODUCT FAMILIES

NEUTRAL START BACKUP (NSBU) SWITCH

(continued)

A. Switch Body B. Connector

D. Retainer

C. Splash Shield

Current switch backside view.

58

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TRANSMISSION

A. Inspect the switch body for

C. Inspect the splash shield for

cracks, bends and impact damage.

Replace the switch if any damage is detected.

cracks, bends and deformities.

Replace the switch assembly if the splash shield is damaged.

B. Inspect the connector body for

D. Inspect the splash shield

cracks and impact damage. Inspect the locking tangs for damage which might prevent proper harness connector installation and seating.

Replace the switch if any damage is detected. Inspect the terminals for any damage which might prevent proper seating with mating terminals. Reference Troubleshooting Manual TS3192 for terminal replacement procedures and ohmmeter pin-out checks.

retainer for cracks and deformities.

The retainer is non-serviceable and is included with a new switch.

Switches which are reused can be installed without the retainer (the selector lever and nut will retain the shield).

TECHNICIANS’

GUIDE

ALLISON 1000 & 2000 PRODUCT FAMILIES

WEAR LIMITS AND SPRING DATA 7–1. WEAR LIMITS DATA A. Maximum Variations. Wear limits information in this Section are the maximum wear at which components are expected to function satisfactorily.

Table 7–1 lists the Wear Limits Data.

meet the load height speciÞcations according to Table 7–2, Spring Data.

B. Cleaning and Inspection. Parts must be clean to permit effective inspection for wear or damage. Refer to Section 3.

B. Inspection. Inspection criteria (load vs. height) and identiÞcation characteristics of the springs are presented in Table 7–2. The Spring Data are keyed to the exploded views (Foldouts 5 through 20) in the back of this manual.

7–2.

NOTE:

SPRING DATA

A. Spring Replacement. Replace springs if there are signs of overheating, wear due to rubbing adjacent parts, or permanent set. Discard springs which do not

When more than one spring part number is listed for the same location, refer to the latest edition of Parts Catalog PC3062EN to determine which spring is used in your specific assembly number.

Table 7–1. Wear Limits Data

Wear Limit

Description

mm

(inches)

TORQUE CONVERTER MODULE Maximum Torque Converter End Play—Used

1.015

0.0400

Maximum Torque Converter End Play—New

0.762

0.0300

Minimum OD

58.250

2.2933

Minimum Distance Between Flats

51.816

2.0400

43.080

1.6960

Bushing, Maximum ID The pump bushing must have a complete burnt-orange color Teßon® coating. If any portion of the Teßon® coating is worn and bronze material is visible, replace the pump.

58.458

2.3015

Gear Cavity, Maximum Depth

24.940

0.9819

109.191

4.2989

Driven Gear, Max. Diametric Clearance w/ Pump Body

0.204

0.0080

Driven Gear, Maximum Tooth Clearance w/ Crescent

0.455

0.0179

108.987

4.2908

Wear Plate, Minimum Thickness

2.950

0.1161

Gear-to-Wear Plate, Maximum Side Clearance

0.064

0.0025

Drive Gear, Maximum Distance Between Flats

52.165

2.0537

0.066

0.0026

Converter Pump Hub:

Cover Pilot, Minimum OD FRONT SUPPORT AND OIL PUMP MODULE Charging Pump:

Gear Cavity, Maximum ID

Driven Gear, Minimum OD

Drive Gear, Side Clearance ALLISON

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59

ALLISON 1000 & 2000 PRODUCT FAMILIES

WEAR LIMITS AND SPRING DATA Table 7–1. Wear Limits Data (cont’d)

(continued) Wear Limit

Description Front Support and Ground Sleeve: Ground Sleeve, Maximum ID at Turbine Shaft Sealring Bore

mm 45.450

(inches) 1.7894

Ground Sleeve, Maximum Spline Wear

No visible wear allowable

Ground Sleeve Bushing, Maximum ID

33.820

1.3315

1.49

0.059

Bushing, Maximum ID

78.170

3.0776

Rotating Seal Bore, Maximum ID

74.050

2.9154

Maximum Cone

0.255

0.0100

Minimum Thickness

2.375

0.0935

Minimum Oil Groove Depth

0.200

0.0079

Maximum Cone

0.200

0.0079

Minimum Thickness

2.135

0.0841

0.000

0.0000

Part # 29532420

11.400

0.4688

Part # 29538521

11.840

0.4661

Part # 29538522

12.280

0.4835

Part # 29538523

12.730

0.5012

Part # 29538524

13.180

0.5189

Part # 29538525

13.630

0.5366

Maximum Cone

0.225

0.0089

Minimum Thickness

2.375

0.0935

Minimum Oil Groove Depth

0.200

0.0079

Maximum Cone

0.240

0.0094

Minimum Thickness

2.135

0.0841

20.117

0.7920

2.59

0.102

Thrust Washer

No visible wear allowable

ROTATING CLUTCH MODULE Rotating Clutch Housing:

C1 Friction Plates:

C1 Steel Reaction Plate:

C1 Backplate: Maximum Cone Minimum Thickness (Selective)

C2 Friction Plates:

C2 Steel Reaction Plate:

Turbine Shaft Bushing, Maximum ID Thrust Washer 60

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TRANSMISSION

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TECHNICIANS’

GUIDE

ALLISON 1000 & 2000 PRODUCT FAMILIES (continued) WEAR

LIMITS AND SPRING DATA

Table 7–1. Wear Limits Data (cont’d)

Wear Limit

Description MAIN HOUSING MODULE

mm

(inches)

C3/C4 Friction Plate: Maximum Cone

0.225

0.0089

Minimum Thickness

2.375

0.0935

Minimum Oil Groove Depth

0.200

0.0079

Maximum Cone

0.400

0.0157

Minimum Thickness

2.440

0.0961

Maximum Cone

0.400

0.0157

Minimum Thickness

3.110

0.1224

0.000

0.0000

15.325

0.6033

3.000

0.1181

0.000

0.0000

15.400

0.6063

Maximum Cone

0.225

0.0089

Minimum Thickness

2.375

0.0935

Minimum Oil Groove Depth

0.200

0.0079

0.295

0.0116

Part # 29536481

1.935

0.0762

Part # 29536482

2.435

0.0959

Part # 29536483

2.935

0.1156

0.000

0.0000

17.900

0.7047

C3/C4 Steel Reaction Plate:

C3/C4 Spring Plate:

C3 Backplate: Maximum Cone Minimum Thickness Thrust Plate Inner Rim, Minimum Thickness C4 Backplate: Maximum Cone Minimum Thickness C5 Friction Plate:

C5 Steel Reaction Plate: Maximum Cone Minimum Thickness (Selective)

C5 Backplate: Maximum Cone Minimum Thickness P1 Ring Gear, Maximum Spline Wear (Notching) Main Housing Clutch Plate, Spline Wear (Notching)

ALLISON

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Detectable

Detectable

1.150

0.0450

TECHNICIANS’

GUIDE

 2005 General Motors Corporation.

61

ALLISON 1000 & 2000 PRODUCT FAMILIES

WEAR LIMITS AND SPRING DATA

(continued)

Table 7–1. Wear Limits Data (cont’d)

Wear Limit

Description

mm

(inches)

PLANETARY GEAR MODULE P1 Carrier Assembly: Pinion Gear, Maximum End Play Bushing, Maximum ID Thrust Washer, Minimum Thickness P2 Ring Gear, Maximum Spline Wear (Notching)

1.010

0.0400

50.690

1.9957

1.490

0.0590

Detectable

Detectable

1.060

0.0417

36.575

1.4400

P2 Carrier Assembly: Pinion Gear, Maximum End Play Bushing, Maximum ID P3 Ring Gear, Maximum Spline Wear (Notching)

Detectable

Detectable

Pilot, Minimum OD (Turbine Shaft and Output Shaft)

19.987

0.7869

Journal, Minimum OD (P2 Carrier Bushing)

36.405

1.4333

Output Shaft Bushing (2WD and 4WD), Maximum ID

20.070

0.7940

Output Shaft (2WD and 4WD), Minimum Bearing Surface OD

44.978

1.7708

Pinion Gear, Maximum End Play

1.010

0.0400

Parking Pawl Gear Wear

0.000

0.0000

65.080

2.5622

Main Shaft:

REAR COVER MODULE

P3 Carrier Assembly:

OUTPUT YOKE Output Seal Surface, Minimum OD

62

ALLISON

TRANSMISSION

 2005 General Motors Corporation.

TECHNICIANS’

GUIDE

ALLISON

TRANSMISSION

11

14

7

19

16

25

14, 6

3

9

9

9

9

10

10

19B, 19C

19C

Exhaust BackÞll

Control Main/Control Relief

C1 Return Spring Assembly

C2 Return Spring Assembly

C1 Clutch BackÞll

Lube Regulator

Converter Flow

Converter Relief

Main Pressure Regulator

TECHNICIANS’

 2005 General Motors Corporation.

GUIDE

4

16A

Park Pawl Return

C5 Return Spring Assembly

C, D, and E Shift

A Trim

* Individual Springs ** For the complete Spring Assembly

5

4, 8, 11

19B

16A

13

19C

11, 17, 28 A, B, and F Trim

22

9

Spring C3/C4 Return Spring Assembly

29531147

29531134

29531176

29537230

29536313

29531161

29541153

29536198

29536104

29542713

29541228

29540523

29541296

29531017

Part No. 29531046

No Code

No Code

No Code

No Code

No Code

Orange Stripe

No Code

No Code

No Code

No Code

No Code

Light Blue

No Code

No Code

6

7.8*

11.55

7.21

7.44

11.35

11.85

7.99*

5.77*

7.24

12.38

6.79

12.18

11.87

No. Coils 8.78*

0.75 (0.030)

1.702* (0.0670)

1.00 (0.039)

1.30 (0.051)

0.76 (0.030)

0.90 (0.035)

1.50 (0.059)

1.295* (0.0510)

1.143* (0.0450)

0.81 (0.032)

1.47 (0.058)

1.60 (0.063)

1.42 (0.056)

2.77 (0.109)

Wire Dia. mm (in.)

1.588* (0.0625)

8.70 (0.343)

13.5* (0.531)

11.00 (0.433)

15.20 (0.598)

9.80 (0.386)

12.60 (0.496)

14.00 (0.551)

9.17* (0.361)

10.05* (0.396)

11.25 (0.443)

11.70 (0.464)

16.10 (0.634)

13.46 (0.529)

22.61 (0.890)

Spring OD mm (in.)

12.00* (0.472)

29.55 (1.161)

31.40** (1.236)

29.29 (1.153)

23.25 (0.915)

20.15 (0.793)

22.54 (0.887)

40.62 (1.599)

19.49** (0.767)

19.60** (0.772)

27.25 (1.073)

39.22 (1.544)

31.43 (1.237)

44.85 (1.766)

73.74 (2.903)

Approx. Free Length mm (in.)

31.89** (1.256)

41.75 (1.644)

21.60** (0.850)

14.26 (0.561)

13.37 (0.526)

9.44 (0.372)

16.16 (0.636)

22.11 (0.870)

15.62** (0.615)

15.90** (0.626)

11.05 (0.435)

24.05 (0.946)

17.05 (0.671)

22.84 (0.899)

41.50 (1.634)

mm (in.)

24.81** (0.977)

11.3–14.9 (2.5–3.3)

1454.6–1620.2** (327.0–364.2)

14.61–16.59 (3.28–3.73)

18.69–21.35 (4.20–4.80)

8.14– 9.70 (1.83–2.18)

2.537–3.003 (0.570–0.675)

45.86–50.68 (10.31–11.39)

941.2–1126.4** (211.6–253.2)

652.5–770.9** (146.7–173.3)

10.41–13.09 (2.34–2.94)

55.99–72.00 (12.59–16.19)

54.23–73.89 (12.19–16.61)

45.10–55.44 (10.14–12.46)

231.56–255.94 (52.06–57.54)

N (lb) min.

162.00–187.60** (36.42–42.17)

Length Under Load

(continued) WEAR

19C

Ref. 12, 4

Foldout 6, 13

Color Code No code

Table 7–2. Spring Data

ALLISON 1000 & 2000 PRODUCT FAMILIES

LIMITS AND SPRING DATA

63

ALLISON 1000 & 2000 PRODUCT FAMILIES

NOTES

64

ALLISON

TRANSMISSION

 2005 General Motors Corporation.

TECHNICIANS’

GUIDE

GENERAL INSPECTION GUIDELINES FOR

TORQUE CONVERTER MODULE

Allison Transmission General Motors Corporation Indianapolis, IN 46206-0894 1-800-252-5283 www.allisontransmission.com

66

ALLISON

TRANSMISSION

 2005

General Motors Corporation. (5/05) GUIDE GN4062EN

TECHNICIANS’

TECH GUIDE

INSPECTION AND ANALYSIS OF THE

ALLISON 1000 & 2000 PRODUCT FAMILIES

GN4062EN (5/05)