Allison Transmission 3000 HS, 3500 RDS, 3000 RDS, 3000 EVS, 3000 MH Service Manual

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ALLISON 1000/2000 SERIES

INDEX

CLUTCH AND SOLENOID APPLICATION CHART ........................................................................................... 4

TRANSMISSION IDENTIFICATION TAG INFORMATION .............................................................................. 5

GENERAL DESCRIPTION AND OPERATION .................................................................................................... 6

ELECTRICAL OPERATION ................................................................................................................................... 9

THROTTLE POSITION SENSOR .............................................. ........................................................................... 10

NEUTRAL START BACK UP SWITCH ................................................................................................................. 11

TRANSMISSION CONTROL MODULE CONNECTOR IDENTIFICATION .................................................... 12

DIAGNOSTIC TROUBLE CODE IDENTIFICATION ......................................................................................... 14

SOLENOID IDENTIFICATION AND OPERATION ............................................................................................. 16

INTERNAL WIRING HARNESS SCHEMATIC AND RESISTANCE CHART ................................................... 18

EXTERNAL WIRING HARNESS SCHEMATIC AND TERMINAL IDENTIFICATION ................................... 19

PRESSURE SWITCH ASSEMBLY IDENTIFICATION AND OPERATION ....................................................... 20

RETRIEVING DIAGNOSTIC TROUBLE CODES ................................................................................................ 22

LINE PRESSURE TESTS ................................................... ................................................................................... 23

BELL HOUSING OIL PASSAGE IDENTIFICATION ......................................................................................... 24

MAIN CASE "FRONT" OIL PASSAGE IDENTIFICATION .............................................................................. 26

MAIN CASE "REAR" OIL PASSAGE IDENTIFICATION ................................................................................. 27

OIL PUMP COVER OIL PASSAGE IDENTIFICATION ..................................................................................... 29

SHIFT VALVE BODY OIL PASSAGE IDENTIFICATION ................................................................................. 31

MAIN VALVE BODY "TOP VIEW" OIL PASSAGE IDENTIFICATION .......................................................... 32

MAIN VALVE BODY "BOTTOM VIEW" OIL PASSAGE IDENTIFICATION ................................................ 33

MAIN CASE "BOTTOM VIEW" OIL PASSAGE IDENTIFICATION ............................................................... 35

TRANSMISSION DISASSEMBLY PROCESS ...................................................................................................... 36

COMPONENT REBUILD

TRANSMISSION CASE ASSEMBLY .............................................................................................................. 53

OIL PUMP AND BELLHOUSING ASSEMBLY ............................................................................................ 55

FOUR DIFFERENT BELL HOUSINGS IDENTIFICATION ...................................................................... 66

C1/C2 CLUTCH HOUSING ASSEMBLY ....................................................................................................... 68

C1/C2 CLUTCH HOUSING SNAP RING IDENTIFICATION ..................................................................... 72

VALVE BODY ASSEMBLY ............................................................................................................................. 80

SOLENOID AIR CHECKS ............................................................................................................................... 83

EXTENSION HOUSING ASSEMBLY ............................................................................................................. 91

GEAR TRAIN PARTS ....................................................................................................................................... 96

CASE CLUTCH PARTS .................................................................................................................................... 100

FINAL TRANSMISSION ASSEMBLY PROCESS ................................................................................................ 102

BOLT IDENTIFICATION CHART ........................................................................................................................ 119

TORQUE SPECIFICATION CHART .................................................................................................................... 120

CAUTION: ATSG service manuals are intended for use by professional, qualified technicians. Attempting repairs or service without the proper training, tools and equipment could cause injury to you or others and damage to the vehicle that may cause it not to operate properly.

AUTOMATIC TRANSMISSION SERVICE GROUP

18639 S.W. 107TH AVENUE

MIAMI, FLORIDA 33157

(305) 670-4161

Updated

October, 2003

INTRODUCTION

ALLISON 1000/2000 SERIES

Beginning at the start of production for the 2000 model year, General Motors introduced two new Allison automatic transmissions referred to as the 1000 Series and the 2000 Series, for light duty (8600-19850 GVW) and medium duty (19850-3000 GVW) commercial trucks.

The 1000 and 2000 Series transmissions both have helical cut planetary gear systems to minimize noise concerns and come in two different gear ratio configurations. The 1000 Series uses closer steps to improve the shift quality that we now expect from an automatic transmission. The 2000 Series uses wider steps to accommodate the greater vehicle weights associated with the 2000 Series. The gear ratios for both of the new units are shown in this Manual.

The 1000 and 2000 Series transmissions have a Park position, Reverse, Neutral and five forward speeds with 5th gear being overdrive, and are completely electronic shift controlled. Notice that the standard General Motors case connector has been utilized, and the Park/Neutral switch is exactly the same switch used currently on the THM 4L60-E transmission. Two different bottom pan configurations are also provided to make these units even more versitile. The 1000 and 2000 Series transmissions utilize five clutch packs (No Bands-No Freewheels) to obtain the five forward gears and reverse. This manual will cover the dis-assembly, rebuild of all components and re-assembly of both the 1000 and 2000 Series units.

No part of any ATSG publication may be reproduced, stored in any retrieval system or transmitted in any form or by any means, including but not limited to electronic, mechanical, photocopying, recording or otherwise, without written permission of Automatic Transmission Service Group. This includes all text illustrations, tables and charts.

"Portions of materials contained herein have been reprinted under

license from General Motors Corp, Service & Parts Operations."

The information and part numbers contained in this booklet have

been carefully compiled from industry sources known for their

reliability, but ATSG does not guarantee its accuracy.

DALE ENGLAND

FIELD SERVICE CONSULTANT

WAYNE COLONNA

TECHNICAL SUPERVISOR

PETER LUBAN

TECHNICAL CONSULTANT

JON GLATSTEIN

TECHNICAL CONSULTANT

JERRY GOTT

TECHNICAL CONSULTANT

GERALD CAMPBELL

TECHNICAL CONSULTANT

JIM DIAL

TECHNICAL CONSULTANT

ED KRUSE

TECHNICAL CONSULTANT

GREGORY LIPNICK

TECHNICAL CONSULTANT

DAVID CHALKER

TECHNICAL CONSULTANT

MIKE SOUZA

TECHNICAL CONSULTANT

ROLAND ALVAREZ

TECHNICAL CONSULTANT

AUTOMATIC TRANSMISSION SERVICE GROUP

18639 S.W. 107TH AVENUE

MIAMI, FLORIDA 33157

(305) 670-4161

1

Technical Service Information

ALLISON 1000/2000 SERIES

Engine Speed

Sensor

Turbine Speed

Sensor

AllisonAllison

Output Speed

Sensor

Neutral Start

Switch

Engine Speed

Sensor

TWO WHEEL DRIVE

Turbine Speed

Sensor

AllisonAllison

Neutral Start

Switch

FOUR WHEEL DRIVE

Figure 1

AUTOMATIC TRANSMISSION SERVICE GROUP

3

Technical Service Information

ALLISON 1000/2000 SERIES TRANSMISSION

"C4" CLUTCH "C3" CLUTCH "C2" CLUTCH

"C1" CLUTCH

"C5" CLUTCH

C1

Range

Park Reverse X Neutral

OD-1st

OD-2nd

OD-3rd OD-4th OD-5th

X = Electrical Power Applied To Solenoid

= Apply Solenoid "F" To Apply Converter Clutch

*

= Solenoids "A" and "B" are "Trim" solenoids used to control oncoming, off-going, and

**

holding pressure to the five clutch packs.

Clut

ON ON ON ON ON

4

C2

ClutC3ClutC4ClutC5Clut

ONON ON ONON

ON

AUTOMATIC TRANSMISSION SERVICE GROUP

Sol

"A"

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

Figure 2

Sol

"B"

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

**

Sol

"C"

X

X X

Sol

"D"

XXON

X X

Sol

"E"

X X X

Sol

"F"

* *

X X

* ***

Ratios

1000 2000

4.49

3.10

1.81

1.41

1.00

0.71

5.09

3.51

1.90

1.44

1.00

0.74

Technical Service Information

ALLISON IDENTIFICATION TAG LOCATION

9 .8

9

.8

9

.8

W A U

3 3 9

X

n

X

n

.

X

P

o

R

X

-

i

O

X

C

X

s

S

X

R

iso

X

s

O

l

A

i

X

T

l

O

X

AN

-

M

X

L

X

m

X

A

NDI

X

I

A

R

s

X

,

X

S

NE

I

X

E

n

L

X

G

-

O

X

P

a

X

A

OF

X

N

r

X

A

O

I

X

S

T

I

ND

X

V

X

I

-

I

X

D

X

X X X

X

-

X

L

X

E

X

X D I

X

OD

T

X

S

M

-

IE

X

R

X

E

X

E

S

T

X

0

-

DA

0

.

X

1

X

O

X

N

X

L

1

A

2

I

F

X

R

9

X

E

9

S

X

N

X

FC

X

E

X

X X

X

9 . 8

9 .

8

9 . 8

MODEL

1000 SERIES 99F21 X X

SERIAL NO.

X X X X X X X X X X X X X X X X X X X

Allison

TransmissionTransmission

DIVISION OF GENERAL MOTORS CORP.

INDIANAPOLIS, INDIANA

X X - X X X X X X - X X X X

DATE

EFCN

X X - X X X X X X - X X X X

TID

X X - X X X X X X - X X X X X X - X X X X X X - X X X X X X - X X X X X X - X X X X

UAW

933

Figure 3

TRANSMISSION IDENTIFICATION TAG

Several different transmission configurations are available within the 1000/2000/2400 Series. The different models are identified as follows:

1000

Series

2000

Series

2400

Series

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

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

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

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

This information must be used when discussing specific service issues, or when parts replacement is necessary. The transmission identification tag also includes the date of manufacture, and also the transmission identification number used with the diagnostic systems.

Special Note:

Allison Series 1000/2000/2400 transmissions are designed and manufactured to metric standards, and metric tools are required for service.

The cooler ports and the main line pressure tap are the only non-metric fittings on the transmission case. The output flange/yoke retaining bolt is also non-metric.

AUTOMATIC TRANSMISSION SERVICE GROUP

5

Technical Service Information

GENERAL DESCRIPTION AND OPERATION

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

The spin-on filter is located externally on the converter housing at the lower left front of the transmission. Some 1000/2000/2400 Series transmissions are available with an optional extension housing that accommodates an OEM installed two shoe, expanding type, drum parking brake. The 1000/2000/2400 Series transmissions use lever type shift selectors, as shown in Figure 4. The vehicle may be equipped with one or two shift selectors, depending on the number of operator stations for driving the vehicle and/or operating a variety of chassis mounted equipment. The shift positions on the shift selector can vary according to the shift selector installed in the vehicle.

NOTE: Refer to Figure 5 for the various Shift Selector positions, and corresponding ranges that can be attained for all 1000/2000/2400 Series models.

TYPICAL MANUAL SHIFT TOWER

DO NOT

SHIFT

P R N D 4 2 1

DO NOT

SHIFT

Figure 4

6

AUTOMATIC TRANSMISSION SERVICE GROUP

Technical Service Information

ALL 1000 AND 2400 SERIES

Shift Selector Position

P (Park) R (Reverse) N (Neutral) D (Drive) 4 (Fourth) 3 (Third) 1 (First)

* With Park Pawl Engaged

** 4 Speed Calibration or Trailering Mode

Gears

Available

Neutral*

Reverse

Neutral

1-5 1-4 1-3 1st

Selector

Position P (Park) R (Reverse) N (Neutral) D (Drive) 4 (Fourth) 2 (Second) 1 (First)

ALL 2000 SERIES "WITH" AUTO-APPLY PARKING BRAKE

Shift Selector Position

PB = (Park) R (Reverse)

Gears

Available

Neutral*

Reverse

Selector

Position PB = (Park) R (Reverse)

Shift

Gears

Available

Neutral*

Reverse

Neutral

1-5 1-4 1-2 1st

Gears

Available

Neutral*

Reverse

Shift Selector Position

P (Park) R (Reverse) N (Neutral) D (Drive) 3 (Third) 2 (Second) 1 (First)

Shift Selector Position

PB = (Park) R (Reverse)

Gears

Available

Neutral*

Reverse

Neutral

1-5 (1-4)**

1-3 1-2 1st

Gears

Available

Neutral*

Reverse N (Neutral) D (Drive) 4 (Fourth) 3 (Third) 1 (First)

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

Neutral

1-5 1-4 1-3 1st

N (Neutral) D (Drive) 4 (Fourth) 2 (Second) 1 (First)

ALL 2000 SERIES "WITHOUT" AUTO-APPLY PARKING BRAKE

Shift Selector Position

R (Reverse) N (Neutral) D (Drive) 4 (Fourth) 3 (Third)

Gears

Available

Reverse

Neutral

1-5 1-4 1-3

Selector

Position R (Reverse) N (Neutral) D (Drive) 4 (Fourth) 2 (Second)

Shift

Neutral

1-5 1-4 1-2 1st

Gears

Available

Reverse

Neutral

1-5 1-4 1-2

N (Neutral) D (Drive) 3 (Third) 2 (Second) 1 (First)

Shift Selector Position

R (Reverse) N (Neutral) D (Drive) 3 (Third) 2 (Second)

Neutral

1-5 (1-4)**

1-3 1-2 1st

Gears

Available

Reverse

Neutral

1-5 (1-4)**

1-3 1-2

1 (First)

** 4 Speed Calibration or Trailering Mode

1st

1 (First)

AUTOMATIC TRANSMISSION SERVICE GROUP

Figure 5

1st

1 (First)

1st

7

Technical Service Information

TYPICAL TRANSMISSION CONTROL MODULE

AND VEHICLE HARNESS

TRANSMISSION CONTROL

MODULE (TCM)

TRANSMISSION (J2)

HARNESS

"J2"

CONNECTOR

(RED)

"J1"

CONNECTOR

(GRAY)

VEHICLE (J1)

HARNESS

J 1939

CONNECTOR

(OPTIONAL)

VIW "X"

CONNECTOR

VIW "Y"

CONNECTOR

GP 19

CONNECTOR

THROTTLE

POSITION

SENSOR (TPS)

Actual harness configuration may differ from this illustration.

TPS

CONNECTOR

TURBINE

SPEED SENSOR

CONNECTOR

7 PIN

4 PIN

NSBU SWITCH CONNECTORS

OUTPUT

SPEED SENSOR

CONNECTOR

ENGINE

SPEED SENSOR

CONNECTOR

Figure 6

8

AUTOMATIC TRANSMISSION SERVICE GROUP

Technical Service Information

ELECTRICAL OPERATION

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

EXTERNAL COMPONENTS

SPEED SENSORS

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

ENGINE SPEED SENSOR

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

TURBINE SPEED SENSOR

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

OUTPUT SPEED SENSOR

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

TYPICAL SPEED SENSOR

Figure 7

AUTOMATIC TRANSMISSION SERVICE GROUP

9

Technical Service Information

THROTTLE POSITION SENSOR

C

B

A

Figure 8

THROTTLE POSITION SENSOR

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

0.5 volts at idle, to 5.0 volts at wide open throttle.

TPS

Throttle Position

Sensor

(TPS)

Connector

Green, Ground

A

Blue, Signal Ret.

B

Pink, 5V Supply

C

TCM "J2" (RED)

Connector

Transmission

Control Module

(TCM)

20

9

19

(TPS) Distance of Travel Versus Volts

mm/inch

0/0

1/.039" 2/.079" 3/.118" 4/.157" 5/.197" 6/.236" 7/.275" 8/.314"

9/.354" 10/.394" 11/.433" 12/.472" 13/.511"

14/.551"

15/.590" 16/.629" 17/.669" 18/.708" 19/.748" 20/.787" 21/.826" 22/.866" 23/.905" 24/.945" 25/.984"

26/1.023" 27/1.063" 28/1.102" 29/1.142" 30/1.181" 31/1.220" 32/1.260" 33/1.299" 34/1.339" 35/1.378" 36/1.417" 37/1.457" 38/1.496" 39/1.535" 40/1.575" 41/1.614" 42/1.654" 43/1.693" 44/1.732" 45/1.772"

46/1.811"

Volts

0

0.11

0.22

0.33

0.44

0.55

0.66

0.77

0.88

0.99

1.10

1.20

1.30

1.43

1.54

1.65

1.76

1.87

1.98

2.08

2.19

2.30

2.41

2.52

2.63

2.74

2.85

2.96

3.07

3.18

3.29

3.40

3.51

3.62

3.73

3.84

3.95

4.06

4.17

4.28

4.39

4.50

4.61

4.72

4.83

4.94

5.05

10

Figure 10Figure 9

AUTOMATIC TRANSMISSION SERVICE GROUP

Technical Service Information

NEUTRAL START BACK-UP SWITCH

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

NSBU SWITCH WIRE SCHEMATIC

NSBU SWITCH RANGE CHART ON SCAN TOOL

Range A B C P

P R

N D

3 2 1

OFF OFF

ON

ON OFF OFF

ON

ON ON

OFF OFF OFF

OFF

ON ON

ON

ON OFF OFF

OFF OFF

OFF

ON

OFF

ON

OFF

ON

OFF

NEUTRAL START BACK-UP SWITCH

Figure 11

Rev/Park Accessory

Battery Feed

PK/NEUT Start

Battery Feed

7-Way NSBU

Switch Receptacle

(Face View)

4-Way NSBU

Switch Receptacle

(Face View)

Park Accessory

Back-up Lamps

Not Used

A

G

B

F

C

E

D

C

A

D

B

Harness Connectors

A

G

B

F

C

E

D

C

A

D

B

NSBU Switch

(Face View)

A

B C

E F G

D

A

B C

D

Tan

Blue

Yellow

Pink

Orange

Green

Blue Gray

White Yellow

TCM "J2" (RED)

Connector

20

5

7 8

6

Starter

Relay

Transmission

Control Module

(TCM)

Figure 12

AUTOMATIC TRANSMISSION SERVICE GROUP

11

TCM "J2" (Red)

Receptacle

Technical Service Information

RED

R

ED

G

GR

R

A

Y

TCM "J1" (Gray)

Receptacle

TRANSMISSION CONTROL MODULE (TCM)

S

IS

TO

SSI

D TO

N

ND

U

CHASS

U

CHA

E

O

E

N

L

R

RO

C

ICL

I

IO

H

T G

T

TIO

EH

O

U

OT G

VE

V

N

A

AU

N

O

C

D

1322313304295286278251023122114

TCM "J2" (Red)

Receptacle

14

13

151816

19

20

17

9

11

25

23

21

24

22

10

12

TCM "J2" (Red)

Harness Connector

(Face View)

72692411221320151816

7

26

1322313304295286278

1322313304295286278251023122114

19

17

72692411221320151816

19

17

TCM "J1" (Gray)

Receptacle

14

11

13

151816

21

19

22

20

17

7269

25

23

24

10

12

1322313304295286278

TCM "J1" (Gray)

Harness Connector

(Face View)

12

Figure 13

AUTOMATIC TRANSMISSION SERVICE GROUP

Technical Service Information

TCM CONNECTOR PIN IDENTIFICATION CHART

14

11

13

151816

21

19

22

20

17

7269

25

23

24

10

12

TCM "J2" (Red)

Harness Connector

(Face View)

Term. Term.Color ColorCircuit Ends Circuit Ends

Blue Trans-D Vehicle System

1 1 2 2

Pink

3 3

White

4 4

Green

Blue

5 5

Yellow

6 6

Gray

7 7

White

8 8

Blue

9 9

10 10

Orange

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

21 22 23 24 25 26 27 28 29 30 31 32

Blue

Orange

Blue Yellow Green

Orange

Pink Green

Yellow Yellow White

Pink

Orange

Green

Blue

Gray

White

Orange

Green

Circuit Function Circuit Function

PSA Input Battery Ground PSA Input PSA Input PSA Input NSBU Input NSBU Input NSBU Input NSBU Input Throttle Position Sensor

Tan

Trans Sump Temp Input Retarder Temp Input (Opt) Engine Coolant Temp Turbine Speed Sensor (High) Turbine Speed Sensor (Low) Output Speed Sensor (High) Output Speed Sensor (Low) Engine Speed Sensor (High) Engine Speed Sensor (Low) TPS Voltage Supply Analog Ground

TRANS ID Trim Solenoid A (High) Trim Solenoid A (Low) Trim Solenoid B (High) Trim Solenoid B (Low) C Solenoid Ground (On/Off) D Solenoid Ground (On/Off) E Solenoid Ground (On/Off) F Solenoid Low (PWM) G Solenoid Low (PWM)(Opt) C, D, E Solenoid V Supply F Solenoid High (PWM)

1322313304295286278

Trans-F Trans-E

Trans-K NSBU-4A NSBU-4D NSBU-4B NSBU-4C

TPS-B

Trans-G

R Temp-A

ECTS-A

TSS-A TSS-B OSS-A OSS-B ESS-A ESS-B TPS-C

Trans-H, ECTS-A,

Temp-B, NSBU-7D

R-Temp-B, TPS-A

Trans-T

Trans-L

Trans-M Trans-N

Trans-P

Trans-A

Trans-B

Trans-W

Trans-J

Trans-J Trans-C Trans-S

21 22 23 24 25 26 27 28 29 30 31 32

Gray

Yellow

Pink

Yellow

Gray

Blue

Orange

Green White

Yellow

Green

Blue Pink

Orange

Yellow

White

Pink

Green

Tan

Orange

White

Blue

Pink White Green

Tan

Pink

Yellow

Red

Blue Green

Black

14

11

13

151816

21

19

22

20

17

7269

25

23

24

10

12

TCM "J1" (Gray)

Harness Connector

(Face View)

Ignition Power Battery Power Ignition Power Battery Ground GPI 1 GPI 2 GPI 3 GPI 4 GPI 5 GPI 6 GPI 7 GPI 8 GPI 9 Retarder Mod. Reg. (Opt) PWM Throttle Sensor Power Analog Ground GPO 1 GPO 2 GPO 3 GPO 4 Range Inhibit Indicator GPO 6 CHECK TRANS Vehicle Speed Vehicle Speed Digital Ground CAN High ISO 9141 CAN Shield CAN Low

1322313304295286278

Vehicle System Vehicle System Vehicle System Vehicle System Vehicle System Vehicle System Vehicle System Vehicle System Vehicle System Vehicle System Vehicle System Vehicle System Vehicle System

RMR-B

Vehicle System

RMR-C

RMR-A Vehicle System Vehicle System Vehicle System Vehicle System Vehicle System Vehicle System Vehicle System Vehicle System Vehicle System Vehicle System

J 1939 A or H

Vehicle System

J 1939 C or S J 1939 B or L

Figure 14

AUTOMATIC TRANSMISSION SERVICE GROUP

13

DTC Description

Technical Service Information

DIAGNOSTIC TROUBLE CODE (DTC) CHART

"Check Trans"

Light

P0117

P0118

P0121

P0122

P0123

P0218

P0561

P0562 P0563

P0602

P0606

P0700

P0703

P0705

P0706

P0708

P0711

P0712

P0713

P0716

P0717

P0721

P0722

P0726

P0727

P0731

P0732

P0733

P0734

P0735

P0736

P0741

P0742

P0746

P0747 YES

P0763

P0768

P0776 YES

P0777 YES

Engine Coolant Temperature Circuit Low Voltage (High Temperature)

Engine Coolant Temperature Circuit High Voltage (Low Temperature)

Throttle Position Sensor Performance Problem

Throttle Position Sensor Circuit Low Voltage

Throttle Position Sensor Circuit High Voltage

Transmission Fluid Over Temperature

Urealistic variations in vehicle system voltage

System Voltage Low System Voltage High

TCM Not Programmed

Transmission Control Module Internal Performance

MIL Illumination requested

Brake Switch Circuit

Transmission Range Sensor Circuit (PRNDL Input)

Transmission Range Sensor Circuit Performance

Transmission Range Sensor Circuit High Input

Transmission Fluid Temperature Circuit Performance

Transmission Fluid Temperature Circuit Low Voltage (High Temperature)

Transmission Fluid Temperature Circuit High Voltage (Low Temperature)

Turbine Speed Sensor Circuit Performance

Turbine Speed Sensor Circuit No Signal

Output Speed Sensor Circuit Performance

Output Speed Sensor Circuit No Signal

Engine Speed Sensor Circuit Performance

Engine Speed Sensor Circuit No Signal

Incorrect 1st Gear Ratio

Incorrect 2nd Gear Ratio

Incorrect 3rd Gear Ratio

Incorrect 4th Gear Ratio

Incorrect 5th Gear Ratio

Incorrect Reverse Gear Ratio

Torque Converter Clutch System Stuck Off

Torque Converter Clutch System Stuck On

Torque Converter Clutch Solenoid ElectricalP0742 YES

Solenoid A controlled Clutch Stuck Off

Solenoid A controlled Clutch Stuck On

Pressure Control Trim Solenoid "A" ElectricalP0748 YES

Shift Solenoid "C" Electrical

Shift Solenoid "D" Electrical

Shift Solenoid "E" ElectricalP0773 YES

Solenoid B controlled Clutch Stuck Off

Solenoid B controlled Clutch Stuck On

NO

YES

YES YES

YES

NO

YES

14

Figure 15

AUTOMATIC TRANSMISSION SERVICE GROUP

DTC Description

Technical Service Information

DIAGNOSTIC TROUBLE CODE (DTC) CHART

"Check Trans"

Light

P0778

P0836

P0840

P0841 P0842

P0843

P0845

P0846

P0847

P0848

P1688 P1709 P1710 P1711

P1712 P1713

P1714

P1715

P1716 P1720 P1721 P1723

P1724 P1726

P1727 P1760

P1835

P1860

P1891

Pressure Control Trim Solenoid "B" Electrical

4 Wheel Drive Low Switch Circuit Malfunction (may also be listed as P1875)

Transmission Pressure Switch, Solenoid C Circuit

Transmission Pressure Switch, Solenoid C Circuit Stuck Open Transmission Pressure Switch, Solenoid C Circuit Stuck Closed

Transmission Pressure Switch, Solenoid C Circuit High

Transmission Pressure Switch, Solenoid D Circuit

Transmission Pressure Switch, Solenoid D Circuit Stuck Open

Transmission Pressure Switch, Solenoid D Circuit Stuck Closed

Transmission Pressure Switch, Solenoid D Circuit High

Transmission Pressure Switch, Solenoid E Circuit HighP0870 YES

Transmission Pressure Switch, Solenoid E Circuit Stuck OpenP0871 YES

Transmission Pressure Switch, Solenoid E Circuit Stuck ClosedP0872 YES Transmission Pressure Switch, Solenoid E Circuit HighP0873 YES

Reverse Pressure Switch MalfunctionP0875 YES

Reverse Pressure Switch Circuit Stuck OpenP0876 YES

TCM Power Input SignalP0880 YES

Unmanaged Engine Torque Delivered To TCM Transmission Pressure Switch, Solenoid E Circuit Transmission Pressure Switch, Solenoid E Circuit Stuck Open Transmission Pressure Switch, Solenoid E Circuit Stuck Closed

Transmission Pressure Switch, Solenoid E Circuit High Transmission Pressure Switch, Reverse Circuit

Transmission Pressure Switch, Reverse Circuit Stuck Open

Transmission Pressure Switch, Reverse Circuit Stuck Closed

Transmission Pressure Switch, Reverse Circuit High Trim Solenoid "A" Controlled Clutch Not Engaged Trim Solenoid "B" Controlled Clutch Not Engaged Trim Solenoid "A" Controlled Clutch Not Engaged

Trim Solenoid "B" Controlled Clutch Not Engaged Shift Solenoid "D" Controlled Clutch Not Engaged

Shift Solenoid "E" Controlled Clutch Not Engaged TCM Supply Voltage Engine Torque Delivered to TCMP1779 NO

Kickdown Circuit

TCC (PWM) Solenoid Circuit-Electrical

Throttle Position Sensor Clutch PWM Signal Low Input

YES

YES YES

YES

YES YES YES YES

YES YES

YES

YES YES YES YES

YES YES

YES

NO

YES

NO

P1892

U1016

U1300

U1301

U2105

Throttle Position Sensor Clutch PWM Signal High Input

Class 2 Powertrain Controller State Of Health

Serial Data Communication Link Low (Class 2)

Serial Data Communication Link High (Class 2)

CAN Bus Error ECM

Figure 16

AUTOMATIC TRANSMISSION SERVICE GROUP

NO

15

Technical Service Information

SOLENOID LOCATIONS

Shift Solenoid "E"

(Normally Closed)

Shift Solenoid "C"

(Normally Closed)

Trim Solenoid "A"

(Normally Closed)

Trim Solenoid "B"

(Normally Open)

PRESSURE SWITCH

ASSEMBLY

TCC (PWM) Solenoid "F"

(Normally Closed)

Figure 17

Shift Solenoid "D"

(Normally Closed)

16

Internal Wiring Harness And

Case Connector Assembly

Figure 18

AUTOMATIC TRANSMISSION SERVICE GROUP

Technical Service Information

INTERNAL COMPONENTS

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

SOLENOIDS

The 1000/2000/2400 Series solenoid locations are shown in Figure 17. The solenoids may be normally closed or normally open. A normally closed solenoid remains closed until a signal from the TCM energizes the solenoid. A normally open solenoid remains open until the TCM energizes the solenoid. TCC (PWM) Solenoid F - This solenoid a normally closed, pulse width modulated, and operates at a frequency of 100 Hz (cycles per second) during a shift. The percentage of time the voltage is ON during each 100th of a second is called the solenoid

duty cycle.

INTERNAL WIRING HARNESS ASSEMBLY

A 100 percent duty cycle indicates a maximum signal to the solenoid. A zero percent duty signal indicates a minimum or no signal to the solenoid. The TCM, using pulse width modulation programming, varies the percentage of voltage ON time during a cycle. As the pulse width, or duty cycle is increased, the solenoid is ON longer.

Shift Solenoids C, D, E - Shift Solenoids C, D, & E are normally closed solenoids that provide the necessary logic to distribute fluid to the correct clutch packs in the transmission. The shift solenoids provide either full control line pressure, or exhaust, to the lands of each of the corresponding Shift V alves C, D, and E. Shift Solenoids C, D, and E may operate in the open or closed state with no modulation capability at all.

Trim Solenoids A and B - Trim Solenoid A and B are used to control oncoming, off-going, and holding pressure to the five clutch packs. These solenoids are reffered to as Pressure Proportional to Current (PPC) solenoids, since the output hydraulic pressure supplied by these solenoids is proportional to the current commanded. Trim Solenoids A and B operate using a frequency of 1000 Hz. The current causes a force on the armature and shaft assembly, which is balanced by fluid pressure acting on the end of the shaft. The trim solenoids operate using battery voltage. Trim Solenoid A is a Normally Closed solenoid, providing 86 psi (590 kpa) at zero current, and no trim pressure at full current. Trim Solenoid A allows for limp-home capability in the event of a power or TCM failure. Trim Solenoid B is a Normally Open solenoid, and prrovides zero pressure at zero current.

Serviced as an assembly under

Allison Part Number 15321154.

Figure 19

AUTOMATIC TRANSMISSION SERVICE GROUP

INTERNAL WIRING HARNESS

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

Continued on Page 18.

17

Technical Service Information

INTERNAL WIRING SCHEMATIC

A

B

M

G

F

N

T

UCV

E L

D

HPJRK

S

W

PED 4

TRANSMISSION EXTERNAL

CONNECTOR FACE VIEW

Dark Green

A

Orange/Black

B

Pink

C

Light Green

D

Red

E

Blue

F

Orange

G

Black

H

Brown

J

Tan

K

Red/Black

L

Light Blue

M

N P R S T U V

W

Gray Purple

N/A Black

Tan Green Green

Black/Tan

TRIM (N/C) SOLENOID

"A"

TRIM (N/0)

SOLENOID

"B"

Solenoid Terminals

Resistance In

Ohms @ 72°F

TRIM "A" 5.5 - 8.0 W

TRIM "B" SHIFT "C" SHIFT "D" SHIFT "E"

TCC "F"

TEMP

SENSOR

SHIFT

SOLENOID

"E"

SHIFT

SOLENOID

"D"

L and M

N and P

C and A

C and B

C and W

J and S

H and G

SHIFT

SOLENOID

"C"

To Pressure

Switch Assembly

5.5 - 8.0 W

TCC

SOLENOID

"F"

A B C D E F

20 -30 W 20 -30 W 20 -30 W

8 - 15 W

2.8K W

@ 72° F

18

Figure 20

AUTOMATIC TRANSMISSION SERVICE GROUP

Technical Service Information

See Pages 12 and 13 For TCM Connector Pin I.D.

CHECK TRANS

LIGHT

IGNITION POWER IGNITION POWER

BATTERY POWER

TCM GROUND

10A

IGNITION

SWITCH

10A

OPTIONAL SPEEDO

SIGNAL RETURN

TCM "J1" (Gray)

Yellow Yellow

Pink Gray Gray

Green

Red

Black

Green

CONNECTOR

25

CONTROL MODULE

2 4 3

1 5

GRAYGRAY

31

+

29

_

32

DO NOT GROUND TO

EXTERNAL WIRE SCHEMATIC

TCM "J2" (Red)

TRANSMISSION

(TCM)

CAN 2.08

J=1939

DATA LINK

CAUTIONCAUTION

VEHICLE CHASSIS

TCM "J2" (Red)

CONNECTOR

15 16

13 14

17 18

23 22 24 25

31 26 27 28 29

REDRED

30 32

21

1 2

3 4

10

5V

19

9

12 20

5 6 7 88

RECOMMENDED

WIRE COLORS

Yellow Green

Orange Blue

Tan Orange

White Yellow Pink Orange

Tan Green Blue Gray White

Green Yellow

Blue Pink White Green

Tan Pink Blue

Green Blue Yellow

Gray White

ALLISON

TRANS ID

A

B

A

B

A

B

Lt Blue

M

Red/Black

L

Gray

N

Purple

P

Pink

C

Dk Green

A

Orange/Black

B

Black/Tan

W

Brown

J

Green

U V

Black

S

Orange

R

T

D

NOT USED

Tan

Lt Green

Blue Red Tan

Orange

Black

TRANSMISSION CASE CONNECTORTRANSMISSION CASE CONNECTOR

A BF

CE DK

EG FH

OUTPUT SPEED

SENSOR

TURBINE SPEED

SENSOR

ENGINE SPEED

SENSOR

SOL "A"

SOL "B"

SOL "C" SOL "D"

SOL "E" SOL "F"

C

NOT USED

D

E

NOT USED

R

PRESSURE SWITCH

ASSEMBLY

C

THROTTLE

B

POSITION

SENSOR

A

TEMP

SENSOR

12V OR 24V12V OR 24V

SAE J-1939 BACKBONESAE J-1939 BACKBONE

ENGINE

INTERFACE

SAE STANDARD 9-PIN

DIAGNOSTIC CONNECTOR

AUTOMATIC TRANSMISSION SERVICE GROUP

TRANSMISSION

NSBU SWITCH

P

C

B

A

Figure 21

4C 4B 4D 4A 7D 7A 7G 7E 7F 7C 7B

STARTER

RELAY

Orange

Yellow

Pink

Blue

Tan

RELAY

REVERSE LAMPSREVERSE LAMPS

ACCESSORY

PK/NEUT

VOLT FEED

REV & PARK

VOLT FEED

PARK

19

NOT USED (N/O)

Terminal Identification

Cast In Connector Here

Technical Service Information

PRESSURE SWITCH ASSEMBLY

NOT USED (N/O)

"E" SHIFT (N/O)

"D" SHIFT (N/O)

"C" SHIFT (N/O)

REVERSE (N/C)

TEMP SENSOR

(THERMISTER)

Figure 22

PRESSURE SWITCH CONNECTOR

PIN FUNCTION AND IDENTIFICATION

A

B

C

D

E

F

A B C D E F

Pressure Switch Assembly

Receptacle (Face View)

(A) SHIFT "C" SIGNAL TO PCM (CASE CONNECTOR TERMINAL "D") (B) SHIFT "D" SIGNAL TO PCM (CASE CONNECTOR TERMINAL "F") (C) SHIFT "E" SIGNAL TO PCM (CASE CONNECTOR TERMINAL "E") (D) REVERSE SWITCH TO PCM (CASE CONNECTOR TERMINAL "K") (E) TEMP SENSOR HIGH (CASE CONNECTOR TERMINAL "G") (F) TEMP SENSOR LOW (CASE CONNECTOR TERMINAL "H")

20

Figure 23

AUTOMATIC TRANSMISSION SERVICE GROUP

Technical Service Information

PRESSURE SWITCH CONNECTOR

PIN FUNCTION AND IDENTIFICATION

TCM "J2" (Red)

Connector

21

1 2

3 4

10 20

Yellow TRANS ID Blue Pink White Green

Tan

Green

Transmission

Case Connector

Figure 24

PRESSURE SWITCH ASSEMBLY

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

Pressure Switch

Connector

Tan

T

Lt Green

D

Blue Red Ta n

Orange

Black

C

A

NOT USED

D

BF

E

CE

NOT USED

R

DK

EG FH

PRESSURE SWITCH

ASSEMBLY

TEMP

SENSOR

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

Pressure Switch Logic State Chart

Range

Park

Rev

Neut

OD

4 3 2 1

"C"

On On On

Off

On

On Off Off

"D"

On On On Off Off Off Off On

"E"

On On On On On Off Off Off

Reverse

Off On Off Off Off Off Off Off

Figure 25

AUTOMATIC TRANSMISSION SERVICE GROUP

21

Technical Service Information

RETRIEVING DIAGNOSTIC CODES

A or H

Pause

Break

Scroll

Lock

Print

Home

Scrn

Backspace

F12

F11

_

-

F10

F9

0

F8

9

F7

F6

7

F5

6

F4

5

F3

F2

3

F1

2

ESC

1

W

~

`

Q

b

Ta

A

ps Lock

Ca

Shift

rl

Ct

Fn

Y

4

T

R

G

E

F

D

V

S

C

X

Z

Alt

n

Wi

P

8

O

I

L

U

K

<

J

,

H

M

N

B

PgUp

+

|

=

\

}

PgDn

]

r

{

Ente

[

:

;

>

.

Alt

End

"

ift

'

Sh

?

/

Del

Ins

C or SB or L

J-1939 Connector

Figure 26

CHECK TRANS LIGHT

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

The operator may turn off and restart the engine, and the manual selector lever will provide reverse when in R, Neutral when in P/N, and 3rd Gear when in any forward range, regardless of the range where the failure occured.

RETRIEVING DIAGNOSTIC CODES

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

22

AUTOMATIC TRANSMISSION SERVICE GROUP

Technical Service Information

Allison TransPro

3 4 6 9 1 2 6 0 5 8 1 3 6 5 2 2 6 4 5 4 8 9 1 0 4 3 3 6 7 3 3 8

TYPICAL TransPro® DISPLAY

Transmission

Demo Mode ON

P0713 Trans Fluid Temp Sensor Circuit High Input Y Y P0722 Output Speed Sensor Circuit No Signal P0748 Pressure Control Trim Solenoid A Electrical P0763 Shift Solenoid C Electrical

DTCs RetrievedDTCs Retrieved

Allison TransProStartStart

Figure 27

?

MAIN PRESSURE TAP LOCATION AND SPECIFICATIONS

ActiveDescriptionCode

Y Y Y Y Y Y

MIL

10:45 AM

LINE PRESSURE TEST

Check transmission fluid level. All transmission

XX

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

Range PARK/NEUTRAL REVERSE FORWARD (TCC Off) FORWARD (TCC On)

MAIN PRESSURE TEST SPECIFICATIONS

Pressure @ 600 RPM

900-1655 kpa (130-240 psi)

800-1380 kpa (115-200 psi) 800-1380 kpa (115-200 psi)

Main Pressure Tap

TO COOLERTO COOLER

FROM COOLERFROM COOLER

Pressure @ 1200 RPM 1515-1795 kpa (220-260 psi) 1515-1795 kpa (220-260 psi) 1515-1795 kpa (220-260 psi)

1000-1170 kpa (145-170 psi)

Figure 28

AUTOMATIC TRANSMISSION SERVICE GROUP

23

Technical Service Information

BELL HOUSING OIL PASSAGE IDENTIFICATION

16

9

15 16

16

29536810

3

2

1

13

2

9

14

2

10

3

16

3

1

8 1

16

7

1

6

11

1. PUMP SUCTION

2. LINE PRESSURE

3. OVERAGE (CONV RELEASE)

4. CONVERTER IN

5. CONVERTER OUT

6. TO COOLER

7. FROM COOLER

8. LUBE OIL

9. LOCK-UP APPLY

10. C1 CLUTCH

11. C2 CLUTCH

12. LOCK-UP SIGNAL

13. CUT-BACK (5TH GEAR)

14. LINE - TO FILTER

15. LINE - FROM FILTER

16. EXHAUST

24

15 14

16

2

16

6

BOTTOM BELL HOUSING COOLER MANIFOLD SURFACE

Figure 29

AUTOMATIC TRANSMISSION SERVICE GROUP

7

16

Technical Service Information

PUMP COVER SPACER PLATE OIL PASSAGE I.D.

16

3

2

8

1

2

7

6

1

16

2

16

3

2

16

9

16

9

1. PUMP SUCTION

2. LINE PRESSURE

3. OVERAGE (CONV RELEASE)

4. CONVERTER IN

5. CONVERTER OUT

6. TO COOLER

7. FROM COOLER

8. LUBE OIL

9. LOCK-UP APPLY

10. C1 CLUTCH

11. C2 CLUTCH

12. LOCK-UP SIGNAL

13. CUT-BACK (5TH GEAR)

14. LINE - TO FILTER

15. LINE - FROM FILTER

16. EXHAUST

11

10

1

2

13

Figure 30

AUTOMATIC TRANSMISSION SERVICE GROUP

15

14

25

Technical Service Information

MAIN CASE "FRONT" PASSAGE I.D.

16

1. PUMP SUCTION

2. LINE PRESSURE

3. OVERAGE (CONV RELEASE)

4. CONVERTER IN

5. CONVERTER OUT

6. TO COOLER

7. FROM COOLER

8. LUBE OIL

9. LOCK-UP APPLY

10. C1 CLUTCH

11. C2 CLUTCH

12. LOCK-UP SIGNAL

13. CUT-BACK (5TH GEAR)

14. LINE - TO FILTER

15. LINE - FROM FILTER

16. EXHAUST

16

11

16

N/A

9

13

2

1

10

14

15

26

Figure 31

AUTOMATIC TRANSMISSION SERVICE GROUP

Technical Service Information

MAIN CASE "REAR" PASSAGE I.D.

15

14

C5 CLUTCH

Figure 32

COOLER MANIFOLD PASSAGE I.D.

MAIN LINE

PRESSURE TAP

TO

CLR

FROM

76

FROM

CLR

6. TO COOLER

7. FROM COOLER

14. LINE - TO FILTER

Figure 33

AUTOMATIC TRANSMISSION SERVICE GROUP

27

Technical Service Information

PUMP COVER OIL PASSAGE I.D.

9

3

16

9

5

6

3

8

6

8

1

11

4

16

12

9

2

1

16

2

10

12

2

13

3

16

9

28

7

1. PUMP SUCTION

2. LINE PRESSURE

3. OVERAGE (CONV RELEASE)

4. CONVERTER IN

5. CONVERTER OUT

6. TO COOLER

7. FROM COOLER

8. LUBE OIL

9. LOCK-UP APPLY

10. C1 CLUTCH

11. C2 CLUTCH

12. LOCK-UP SIGNAL

13. CUT-BACK (5TH GEAR)

16. EXHAUST

AUTOMATIC TRANSMISSION SERVICE GROUP

6

1

10

16

Figure 34

Technical Service Information

OIL PUMP PASSAGE I.D.

2

14

1. PUMP SUCTION

2. LINE PRESSURE

14. EXHAUST

14

1

Figure 35

SHIFT VALVE BODY "TOP VIEW" PASSAGE I.D.

Exhaust

Figure 36

AUTOMATIC TRANSMISSION SERVICE GROUP

29

Technical Service Information

LEGEND FOR FIGURES 38, 39, AND 41.

Passage No.

1 2 9

10

11 12 13 14 16 15 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48 49 50 51 52 53 54 55 56 57

Reverse Park/Neut 1st 2nd

Pump Suction

Main Line Pressure

TCC Apply

Exhaust Backfill/ C-1 Clutch

C-2 Clutch/Exhaust Backfill C-2 Clutch

Lock-Up Signal

Cut-Back (5th Gear)

Control Main Line Pressure To Filter

Exhaust To Sump

Control Main Line Pressure From Filter

Reverse Pressure Switch "D" Shift Valve Pressure Switch "E" Shift Valve Pressure Switch "C" Shift Valve Pressure Switch

C-3 Clutch C-3 Clutch C-3 Clutch

Exhaust Backfill

Main Line Pressure

Exhaust Backfill

C-3/B Trim

Exhaust Backfill

C-3/B Trim OD/B TrimC-4/B Trim

C-1/B Trim

"D" Signal TCC Interlock

Exhaust Backfill/ C-3 Clutch EBF/C-3 Clutch

C-4 Clutch C-5 Clutch

Exhaust Backfill "A" Trim Solenoid Signal "B" Trim Solenoid Signal

"A" Clutch Trim

"B" Clutch Trim "A" Clutch Trim Feedback "B" Clutch Trim Feedback

"D" Solenoid Signal "E" Solenoid Signal "C" Solenoid Signal

C-1/Main

Control Main After "B" Solenoid Screen

B Trim

"E" Shift Valve Interlock

C-2/EBF

Exhaust Backfill/C-5 Clutch (Power Off State)

C-3/EBF

C-2/EBF

Thermister

Exhaust Backfill

C-1/Main

3rd 4th 5th

EBF/ C-1 ClutchC-1 Clutch

C-1/B Trim

C-2/B Trim

C-1/B TrimC-1/B Trim

C-2/B Trim

C-4/EBF OD/EBF

C-2/Main

Exhaust

C-2/Main

C-1/EBF

Cut-BackC-3/EBF

C-1/EBFC-1/EBF

30

Figure 37

AUTOMATIC TRANSMISSION SERVICE GROUP