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. 34
ALLISON
TRANSMISSION
2005 General Motors Corporation.
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
