TECHNICIANS’ GUIDE
INSPECTION AND ANALYSIS OF THE
ALLISON 4000 & B 500 PRODUCT FAMILIES
GN4065EN
(5/05)
INSPECTION AND ANALYSIS OF THE
ALLISON 4000 / B 500 PRODUCT FAMILIES
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.
. . . . . .Glossary Of Terms |
. . . . . 2 |
. . . . .Control Module |
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16-21 |
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Introduction To |
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Torque Converter |
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Inspection & Analysis . . . |
. . . . . 3 |
Module . . . . . . . . . . . . |
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22-27 |
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General Inspection |
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Torque Converter |
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Housing Module . . . . |
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28-30 |
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Guidelines for |
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Standard Rear Cover and |
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Cast Parts & Machined |
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P3 Planetary Module |
. . . . . 31-38 |
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Surfaces . . . . . . . . . . . . . |
. . . . . 4 |
Retarder Module |
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39-42 |
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Gears |
5 |
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Close Ratio Main |
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Splines . . . . . . . . . . . . . . . |
. . . . 6 |
Shaft Module . . . . . . . |
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. . . 43 |
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Bearings . . . . . . . . . . . . . . |
. . 7-8 |
Wide Ratio Main |
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44 |
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Bushings |
9 |
Shaft Module . . . . . . . |
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P2 Planetary Module |
. . . . . 45-46 |
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Retaining Rings |
10 |
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P1 Planetary Module |
. . . . . 47-48 |
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Thrust Washers |
11 |
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Front Support & Oil |
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Clutch Plates |
12-13 |
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Pump Module . . . . . . . |
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49-52 |
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Springs . . . . . . . . . . . . . . |
. . . 14 |
Rotating Clutch Module . . . |
53-58 |
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Valves and Valve Bores |
. . . . 15 |
C3/C4 Clutch Module |
. . . . . 59-64 |
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Main Housing . . . . . . . |
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65-66 |
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C6 Adapter Housing . . |
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67-69 |
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Wear Limits and |
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Spring Data . . . . . . . . . |
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70-77 |
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A L L I S O N T R A N S M I S S I O N T E C H N I C I A N S ’ G U I D E i
2005 General Motors Corporation.
ALLISON 4000 / B 500 PRODUCT FAMILIES
GLOSSARY OF TERMS
Abrade - Scrape off
Battering - Wear or damage due to hard usage or repeated blows
Brinelling - Permanent deformation of a bearing surface where rollers or balls contact a race; Results from excessive load or impact; Characterized by indentations
on a bearing surface
Burr - Sharp metal extending beyond normal surface
Chipped - Having a small piece broken off
Cone - A shape whose base is a circle and whose sides taper up to a point
Crimped - Pinched or pressed together tightly
Crocus cloth - Fine grit cloth
Discoloration - Change in color
Distortion - Change from original shape
Erosion - Gradual uneven removal of material
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
Metal Transfer - Metal from one component embedded in a mating component
Nick - Small notch
Pit - Local areas where material has been removed
Porosity - Porous area where air, fluid, or light may pass through
Score - Deep scratch
Scuff - Wear due to two moving parts coming together with no lubricant
Spalled - Damage characterized by metal flaking or breaking down on a wear surface; Similar to pitting damage
Stripped - Threads broken or damaged so part will not hold torque
TAN - Total Acid Number;
Oil acidity should not change by more then 3 from the new fluid TAN when oil sampling is used to determine oil change intervals
Twisted - Bent from original shape
2 A L L I S O N T R A N S M I S S I O N T E C H N I C I A N S ’ G U I D E
2005 General Motors Corporation.
ALLISON 4000 / B 500 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 4000/B 500 automatic transmissions in conjunction with the 4000/B 500 Service Manual
(SM2457EN) 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 SM2457EN. 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.
A L L I S O N T R A N S M I S S I O N T E C H N I C I A N S ’ G U I D E 3
2005 General Motors Corporation.
ALLISON 4000 / B 500 PRODUCT FAMILIES
GENERAL INSPECTION GUIDELINES FOR CAST PARTS & MACHINED SURFACES
A. Housings
B. Machined
Surfaces
A. Cast
Part
C. Fluid
Passages
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 Table (7-1) in Service Manual SM2457EN.
NOTE: Some parts have Spiralock® threaded holes . A standard tap will eliminate the locking feature requiring the reworked part to be replaced. For repair, use a Spiralock® tap to repair Spiralock® threaded holes. As of this printing, the following parts have Spiralock® threaded holes:
Torque converter front cover flexplate adapter bolt holes and lockup clutch backplate bolt holes.
Output shafts using a single bolt for flange or yoke retention.
4 A L L I S O N T R A N S M I S S I O N T E C H N I C I A N S ’ G U I D E
2005 General Motors Corporation.
D. Splines
C.Fluid Passages
ALLISON 4000 / B 500 PRODUCT FAMILIES
GENERAL INSPECTION GUIDELINES FOR GEARS
A. Gear 
Teeth
Check gears for
damaged or
missing teeth. B. Thrust Face Surface
A. Gear
Teeth
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 for damage. If these defects cannot be removed with a soft stone, replace the gear.
A L L I S O N T R A N S M I S S I O N T E C H N I C I A N S ’ G U I D E 5
2005 General Motors Corporation.
ALLISON 4000 / B 500 PRODUCT FAMILIES
GENERAL INSPECTION GUIDELINES FOR SPLINES
A. Splines
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
Inspect splined parts for burrs, damage and excessive wear.
0.38 mm (0.015 inches) if not otherwise listed in Wear Limits Table 7-1 in Service Manual SM2457EN. 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.
6 A L L I S O N T R A N S M I S S I O N T E C H N I C I A N S ’ G U I D E
2005 General Motors Corporation.
ALLISON 4000 / B 500 PRODUCT FAMILIES
GENERAL INSPECTION GUIDELINES FOR BEARINGS
C. Retainer
B. Bearing
Race
C. Retainer
A. Rollers 
C. Retainer 
B. Bearing 
Race
A.Replace the bearing if any rollers/balls 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 are discolored from heat, lack of lubrication or debris lapping in the balls/rollers. Replace the bearing if the balls/rollers are worn, galled or abraded. Replace the bearing if it catches or feels rough after being thoroughly cleaned.
B.Replace the bearing if any races are rusted. Replace the
bearing if the bearing balls/rollers have a feeling of looseness in the raceway compared to a new
bearing. Replace the bearing if races |
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are discolored from heat, lack of |
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lubrication or debris lapping in the |
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race. Replace the bearing if the |
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races are worn, galled or abraded. |
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Replace the bearing if it catches or |
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feels rough after being thoroughly |
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cleaned. |
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C. Replace the bearing if any |
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retainer or retainer clip is |
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fractured, bent, dented or missing. |
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Replace the bearing if any retainer |
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B. Bearing Race |
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is rusted. Replace the bearing if |
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there is a feeling of looseness |
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between the retainer and ball/roller |
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compared to a new bearing. Replace |
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the bearing if it catches or feels |
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rough after being thoroughly |
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cleaned. |
(continued) |
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A L L I S O N T R A N S M I S S I O N T E C H N I C I A N S ’ G U I D E 7 |
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2005 General Motors Corporation. |
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ALLISON 4000 / B 500 PRODUCT FAMILIES
GENERAL INSPECTION GUIDELINES FOR BEARINGS
(continued)
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.
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.
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.
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 to avoid rust.
NOTE: Wear eye protection and follow the appropriate safety guidelines when using solvents to clean components.
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.
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.
8 A L L I S O N T R A N S M I S S I O N T E C H N I C I A N S ’ G U I D E
2005 General Motors Corporation.
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 4000 / B 500 PRODUCT FAMILIES
GENERAL INSPECTION GUIDELINES FOR BUSHINGS
Bushing wear is strongly influenced by the quantity and condition of the lubricant.
A. Bushing
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.
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.
A L L I S O N T R A N S M I S S I O N T E C H N I C I A N S ’ G U I D E 9
2005 General Motors Corporation.
ALLISON 4000 / B 500 PRODUCT FAMILIES
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.
Examine retaining rings for damage, distortion or excessive wear.
1 0 A L L I S O N T R A N S M I S S I O N T E C H N I C I A N S ’ G U I D E
2005 General Motors Corporation.
ALLISON 4000 / B 500 PRODUCT FAMILIES
GENERAL INSPECTION GUIDELINES FOR THRUST WASHERS
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.
A L L I S O N T R A N S M I S S I O N T E C H N I C I A N S ’ G U I D E 1 1
2005 General Motors Corporation.
ALLISON 4000 / B 500 PRODUCT FAMILIES
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
A.Contact Surface
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.
B.Measure friction plate thickness and coning. Reference the Service Manual 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.
C.Measure friction plate oil groove depth. Replace any plates that are not within Service Manual minimum groove depth specification.
D.Inspect spline teeth for excessive wear and battering. Replace the clutch plate if damage cannot be repaired using a soft
stone or crocus cloth. Replace the clutch plate if spline teeth are broken or missing.
NOTE: Anti-freeze (glycol) and/or water can 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.
(continued)
B. Clutch Plate |
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Thickness and |
Coned Plate |
Coning |
Check Using
Feeler Gauge
Flat Plate
Thickness
1 2 A L L I S O N T R A N S M I S S I O N T E C H N I C I A N S ’ G U I D E
2005 General Motors Corporation.
ALLISON 4000 / B 500 PRODUCT FAMILIES
GENERAL INSPECTION GUIDELINES FOR (continued) CLUTCH PLATES
A.Contact Surfaces 
C. Tangs
NOTE: The current clutch friction plates were implemented April of 2000 starting with s/n 6610062126. Current clutch friction plates will have two or more missing splines. Former friction plates will either have one spline missing or none missing. Any 4000/B 500 model transmission may be updated from former C5 friction plates to current C5 frictions without recalibrating the transmission ECU. The rest of the clutches in the main housing (C1 through C4) must be updated with current friction plates if any other individual clutch besides C5 is updated from former to current friction plates. Any update from former frictions to current frictions in C1 through C4 for a 4000 Series or B500 with a WTEC II ECU will require a new ECU calibration from Allison Transmission. Any update from former frictions to current frictions in C1 through C4 for a 4000 Series or B500 with a WTEC III ECU with a calibration prior to October 25, 1999 will require an updated ECU calibration from
B.Thickness & Coning
(see prior page graphic)
Allison Transmission. Do not intermix both former and current friction plates in a clutch pack.
The P3 ring gear changed to a harder ring gear on s/n 6610027070. The current P3 ring gear identifier is a groove machined around the outer diameter of the gear. The P3 ring gear with a groove identifier requires the C5 friction with two missing splines if updating from former C5 frictions. If any 4000/B500 series model without the harder ring gear (no groove on O.D.) is being updated with current C5 frictions, then it will require the C5 friction that has three missing internal splines. The C5 friction plate missing three splines will exhibit spline wear if used with the current P3 ring gear with a groove identifier on the O.D. The former P3 ring gear (no groove on O.D.) will exhibit premature wear if used with the current C5 friction with two missing internal splines. No ECU calibration is necessary for updating C5 clutch plates.
Acceptable discoloration - reuse plates.
Excessive scoring - replace plates.
Broken tangs - replace plates.
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..
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.
A L L I S O N T R A N S M I S S I O N T E C H N I C I A N S ’ G U I D E 1 3
2005 General Motors Corporation.
ALLISON 4000 / B 500 PRODUCT FAMILIES
GENERAL INSPECTION GUIDELINES FOR SPRINGS
A. Springs
Reference the Service Manual Spring Data Charts for spring identification and specifications.
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 Spring Data Charts in Service Manual SM2457EN for spring identification and service limit specifications.
Inspect springs for signs of overheating, permanent set or wear due to rubbing adjacent parts.
1 4 A L L I S O N T R A N S M I S S I O N T E C H N I C I A N S ’ G U I D E
2005 General Motors Corporation.
ALLISON 4000 / B 500 PRODUCT FAMILIES
GENERAL INSPECTION GUIDELINES FOR VALVES & VALVE BORES
A. Valves
A.Valves must be free of nicks, 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.
B.Valve bores must be free of 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.
Valves should move freely in their bores, when dry, under their own weight.
B. Valve
Bores
Valve bores must be free of nicks, burrs and scoring.
A L L I S O N T R A N S M I S S I O N T E C H N I C I A N S ’ G U I D E 1 5
2005 General Motors Corporation.
ALLISON 4000 / B 500 PRODUCT FAMILIES
CONTROL MODULE
A. Channel
Plate
H. Oil Level
Sensor
G. Stationary Clutch
Valve Body Assembly
A. Inspect the channel plate for damage. All passages must be clear of debris. Inspect all machined surfaces for burrs, nicks or scoring. Light stoning and crocus cloth may be used to eliminate minor high spots. If a channel plate cannot be repaired so that all machined surfaces can seal correctly to their mating parts, or if thread damage cannot be repaired, replace the channel plate.
NOTE: Do not use impact guns (air wrenches, electric impact wrenches, etc.) when working with aluminum threads or when torque sequencing bolts.
F. Main Valve
Body Assembly
B. Inspect both separator plates for dents, nicks, burrs and other damage or distortion. Replace the plate if it has damage which cannot be repaired using a soft stone or crocus cloth. All passages must be clean and debris free.
(continued)
B. Solenoid
Separator Plate
C.Suction Filter Assembly
D. Internal
Wiring
Harness
E. Rotating
Clutch Body
Assembly
B. Separator Plate
Separator plate and gasket installed on channel plate.
1 6 A L L I S O N T R A N S M I S S I O N T E C H N I C I A N S ’ G U I D E
2005 General Motors Corporation.
ALLISON 4000 / B 500 PRODUCT FAMILIES
(continued) CONTROL MODULE
Identification Detail:
Internal Wiring Harness
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Feed |
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Through |
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Stand-Off |
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Sump Temperature |
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Dust |
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Sensor (TID 2, 3) |
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Seal |
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O-Ring |
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C3 Pressure |
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Seal |
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Feed |
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Switch |
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Through |
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A Solenoid |
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Harness |
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(C1) |
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F Solenoid |
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G Solenoid |
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(Lockup) |
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B Solenoid |
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D Solenoid (C4) |
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C Solenoid (C3) |
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E Solenoid |
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Oil Level |
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Sensor |
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(C5) |
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C. Replace the suction filter |
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NOTE: Transmissions built prior to |
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differ between the former and |
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assembly during overhaul. |
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S/N 6610014067 used the former |
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current designs. Be sure to use the |
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D. Replace or repair the control |
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design sump temperature sensor. |
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correct resistance specification |
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Sensor resistance specifications |
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chart for the sensor being checked. |
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module wiring harness if the |
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(continued) |
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wires, terminals or |
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connectors are visibly |
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Current TID2 / TID3 |
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Former TID1 |
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damaged. Inspect the |
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Harness |
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Harness |
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molded harness channel |
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for cracks or breaks. |
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TID 2, 3 |
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Replace the harness if |
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Sump Temp. |
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the molded channel is |
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Sensor |
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damaged. Check sump |
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temperature resistance |
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following the guidelines |
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and specifications listed |
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TID1 Sump |
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in the Service Manual |
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Temp. Sensor |
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and Troubleshooting |
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Manual. |
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A L L I S O N T R A N S M I S S I O N T E C H N I C I A N S ’ G U I D E 1 7 |
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2005 General Motors Corporation. |
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ALLISON 4000 / B 500 PRODUCT FAMILIES
CONTROL MODULE (continued)
Supersession Information
Oil Drain Plug Redesign -
SIL 5-WT-98, Rev. A
Current
Former
Current plug is backward compatible with all control modules.
Supersession Information
Oil Level Sensor Redesign -
SIL 19-WT-99
Kit must be used when replacing former sensor with current sensor.
E, F, G. Valves, valve body bores and oil passages must be free of debris, nicks, burrs, scoring and galling. Valves should move freely in their bores, when dry, under their own weight. Repair or replace valves and/or valve bodies failing to meet these requirements.
Valve body machined surfaces must be free of debris, nicks, burrs and scoring. Light stoning of these machined surfaces is permitted to correct minor defects. Replace any valve body that cannot be repaired.
Inspect all threaded holes for damage and debris. Replace the valve body if the thread damage cannot be repaired.
NOTE: Do not use impact guns (air wrenches, electric impact wrenches, etc.) when working with aluminum threads or when torque sequencing bolts.
Replace valve springs which are broken, permanently set or worn due to rubbing adjacent parts.
Reference the Spring Data Charts in the Service Manual for spring specifications and identification.
Valve stops and retention pins must not be damaged or battered. Replace valve stops or pins which have damage that cannot be removed using a soft stone or crocus cloth.
Replace solenoids if they are visibly damaged. Proper solenoid resistance is 3 to 4 ohms measured between the two solenoid terminals. Check resistance between each solenoid terminal and the solenoid body. Replace the solenoid if resistance measures less than 100k ohms.
(continued)
1 8 A L L I S O N T R A N S M I S S I O N T E C H N I C I A N S ’ G U I D E
2005 General Motors Corporation.
ALLISON 4000 / B 500 PRODUCT FAMILIES
(continued) CONTROL MODULE
2” Channel
Plate
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4” Channel |
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Plate |
Supersession Information |
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Suction Filter Redesign - SIL 1-WT-00 |
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Replace the |
Replace the C3 pressure switch if |
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it is visibly damaged. Resistance |
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assembly |
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between the two switch terminals |
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during |
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should measure 20k ohms or higher |
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overhaul. |
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when the switch is open (and no |
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pressure is present). Resistance |
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between the two terminals should |
Former |
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not exceed 2 ohms when the switch |
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is closed (159 kPa-255 kPa or 23-37 |
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Current |
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psi present). |
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H. Replace the optional oil level |
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sensor if it is determined it is not |
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functioning correctly. |
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(continued) |
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A L L I S O N T R A N S M I S S I O N T E C H N I C I A N S ’ G U I D E 1 9 |
|
2005 General Motors Corporation.
ALLISON 4000 / B 500 PRODUCT FAMILIES
CONTROL MODULE (continued)
Identification Detail: Rotating Clutch Valve Body Assembly
Solenoid |
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Solenoid |
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Regulator |
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Regulator |
Rotating |
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Valves |
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Springs |
Clutch Valve |
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Body |
B Solenoid |
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(C2) |
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Accumulator
Relay Valve
F Solenoid |
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C3 |
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(Lockup) |
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Pressure |
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Switch |
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A Solenoid |
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(C1) |
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Identification Detail: Stationary Clutch Valve Body Assembly
Overdrive Knock
Down Valve 
Stationary
Valve Body
D Solenoid (C4) 
C Solenoid |
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(C3) |
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Solenoid |
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Solenoid |
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Regulator |
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Regulator |
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Valves |
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Springs |
E Solenoid |
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(C5) |
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(continued) |
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2 0 A L L I S O N T R A N S M I S S I O N T E C H N I C I A N S ’ G U I D E |
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||
2005 General Motors Corporation. |
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||
ALLISON 4000 / B 500 PRODUCT FAMILIES
(continued) CONTROL MODULE
Identification Detail: Main Valve Body Assembly
Converter
Regulator
Valve Stop
C1 Latch
Valve Spring
C1 Latch
Valve Stop 
Exhaust
Backfill Valve
Exhaust
Backfill
Valve Stop
C2 Latch
Valve Stop
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Lube Regulator |
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Valve Spring |
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Lockup |
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Lube Regulator |
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Valve Spring |
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Converter |
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Valve |
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Converter |
Lockup |
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Lube Regulator |
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Regulator |
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Regulator |
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Valve Stop |
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Spring |
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Valve |
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Valve |
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Lockup |
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Valve Stop |
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Main
Regulator
Valve Stop
C1 Latch Valve |
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Main Regulator Valve |
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Main Regulator |
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Valve Spring |
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Control Main |
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Valve Stop |
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C2 Latch |
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Main Valve |
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Control Main |
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Valve |
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C2 Latch |
Body |
Control |
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Valve Spring |
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Spring |
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Valve |
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Main Valve |
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G Solenoid |
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Supersession Information
Converter Regulator Valve Stop Redesign -
SIL 12-WT-99
Current |
Former |
Stop |
Stop |
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(continued) |
A L L I S O N T R A N S M I S S I O N T E C H N I C I A N S ’ G U I D E 2 1 |
|
2005 General Motors Corporation.
ALLISON 4000 / B 500 PRODUCT FAMILIES
TORQUE CONVERTER MODULE
A.Converter Pump Exterior 
Model Identifiers (see chart) 
A.Inspect the converter pump exterior for dents and sealing surface damage. Replace the converter pump if damage cannot be remove with a soft stone or crocus cloth.
B.Inspect the converter pump hub for damage and excessive wear. Minimum pump hub diameter is 88.99 mm (3.504 inch). Inspect the pump hub tangs for cracks, impact damage or broken tangs. Maximum allowable tang step wear is 0.31 mm (0.012 inch). On PTO-equipped models, check the splines inside the hub for wear and damage. Maximum spline wear is 0.38 mm (0.015 inch).
B.Drive Hub
B. Drive Hub
Inspect the pump hub tangs for cracks, impact damage and broken tangs.
NOTE: Do not use crocus cloth on the converter pump hub. Polishing the hub with crocus cloth can cause improper input seal performance resulting in fluid leakage.
NOTE: Pump hub tang breakage or deformity accompanied by charging
pump bushing failure and ground sleeve wear is often caused by poor transmission fluid condition due to improper maintenance intervals. Observation of proper fluid change intervals is key to optimum
transmission life. |
(continued) |
|
4000 Product Family Torque Converter Identification Chart
Torque Converter Model |
TC-521 |
TC-531 |
TC-541 |
TC-551 |
TC-561 |
Designation |
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Front Cover Sticker and |
Green |
Pink |
Blue |
Orange |
Yellow |
Converter Paint Dot Color |
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(Exterior Marker) |
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Engraved Letter Identifiers |
E |
D |
C |
B |
A |
(Torus Ring of Converter |
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Pump) Ink Stamped Letter |
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(Exterior of Converter Pump) |
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Number of Stator Blades |
19 |
19 |
19 |
19 |
19 |
Paint Dot Color on Stator |
None |
None |
None |
None |
None |
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2 2 A L L I S O N T R A N S M I S S I O N T E C H N I C I A N S ’ G U I D E
2005 General Motors Corporation.
|
|
ALLISON 4000 / B 500 PRODUCT FAMILIES |
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Supersession Information |
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TORQUE CONVERTER MODULE |
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Converter Plug and Front |
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Cover Update SIL-21-WT-98 |
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(continued) |
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Current |
Converter |
Turbine Shaft |
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The current front cover has a |
Plug |
Retaining Bolt |
Selective Shim |
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threaded pilot to accept the |
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current converter plug. Plugs |
E. Ring |
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are not interchangeable |
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Gear |
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Model Identifiers (see |
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chart previous page) |
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D. Pilot |
F. Flexplate |
Adapter |
C. Front
Cover
Mounting
Face
C.Inspect the torque converter front cover mounting faces for damage. Inspect the flexplate adapter bolt holes for stripped or damaged threads.
D.Inspect the front cover pilot for damage and wear. Maximum pilot diameter is 61.77 mm (2.432 inches). Inspect the torque converter end plug and the retaining bolt for stripped or damaged threads. Verify that the correct turbine shaft selective shim is installed following the Service Manual procedures.
E.Inspect the engine starter ring gear for chipped, worn or broken teeth.
F.Inspect the flexplate adapter mounting faces for surface damage. Replace the adapter if damage cannot be repaired using a soft stone or crocus cloth. Inspect the flexplate adapter bolt holes fro stripped or damaged threads. Clean damaged threads using the correct size tap. Replace the adapter if damage cannot be repaired.
NOTE: The flexplate adapter bolt holes use Spiralock® threads. A Spiralock® tap must be used when repairing damaged threads. Using a standard tap will destroy the locking feature. If this occurs, the torque converter front cover must
be replaced.
(continued)
A L L I S O N T R A N S M I S S I O N T E C H N I C I A N S ’ G U I D E 2 3
2005 General Motors Corporation.
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