Allison Transmission 4000, B 500 Service Manual

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TECHNICIANS’ GUIDE

INSPECTION AND ANALYSIS OF THE

ALLISON 4000 & B500

PRODUCT FAMILIES

GN4065EN

(5/05)

INSPECTION AND ANALYSIS OF THE

ALLISON 4000/B 500 PRODUCT FAMILIES

 2005 General Motors Corporation.

ALLISON TRANSMISSION TECHNICIANS’ GUIDE

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

Introduction T o

Inspection & Analysis . . . . . . . . 3

General Inspection Guidelines for

Cast Parts & Machined

Surfaces . . . . . . . . . . . . . . . . . . 4

Gears . . . . . . . . . . . . . . . . . . . . 5

Splines . . . . . . . . . . . . . . . . . . . 6

Bearings . . . . . . . . . . . . . . . . 7-8

Bushings . . . . . . . . . . . . . . . . . 9

Retaining Rings . . . . . . . . . . 10

Thrust Washers . . . . . . . . . . . 11

Clutch Plates . . . . . . . . . . 12-13

Springs . . . . . . . . . . . . . . . . . 14

Valves and Valve Bores . . . . 15

Control Module . . . . . . . . . . 16-21

Torque Converter

Module . . . . . . . . . . . . . . . . . 22-27

Torque Converter

Housing Module . . . . . . . . . 28-30

Standard Rear Cover and

P3 Planetary Module . . . . . 31-38

Retarder Module . . . . . . . . . 39-42

Close Ratio Main

Shaft Module . . . . . . . . . . . . . . 43

Wide Ratio Main

Shaft Module . . . . . . . . . . . . . . 44

P2 Planetary Module . . . . . 45-46

P1 Planetary Module . . . . . 47-48

Front Support & Oil

Pump Module . . . . . . . . . . . 49-52

Rotating Clutch Module . . . 53-58

C3/C4 Clutch Module . . . . . 59-64

Main Housing . . . . . . . . . . . 65-66

C6 Adapter Housing . . . . . . 67-69

Wear Limits and

Spring Data . . . . . . . . . . . . . 70-77

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 T ransfer - 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

ALLISON 4000/B500 PRODUCT FAMILIES

GLOSSARY OF TERMS

 2005 General Motors Corporation.

ALLISON TRANSMISSION TECHNICIANS’ GUIDE

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.

ALLISON 4000/B500 PRODUCT FAMILIES

INTRODUCTION TO INSPECTION & ANALYSIS

 2005 General Motors Corporation.

ALLISON TRANSMISSION TECHNICIANS’ GUIDE

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.

 2005 General Motors Corporation.

ALLISON TRANSMISSION TECHNICIANS’ GUIDE

ALLISON 4000/B500 PRODUCT FAMILIES

GENERAL INSPECTION GUIDELINES FOR CAST PARTS & MACHINED SURFACES

C. Fluid

Passages

A. Cast

Part

A. Housings

D. Splines

C. Fluid

Passages

B. Machined

Surfaces

ALLISON 4000/B500 PRODUCT FAMILIES

GENERAL INSPECTION GUIDELINES FOR

GEARS

 2005 General Motors Corporation.

ALLISON TRANSMISSION TECHNICIANS’ GUIDE

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.

Check gears for damaged or missing teeth.

A. Gear

Teeth

B. Thrust Face

Surface

A. Gear

Teeth

 2005 General Motors Corporation.

ALLISON TRANSMISSION TECHNICIANS’ GUIDE

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

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.

ALLISON 4000/B500 PRODUCT FAMILIES

GENERAL INSPECTION GUIDELINES FOR SPLINES

Inspect splined parts for burrs, damage and excessive wear.

A. Splines

 2005 General Motors Corporation.

ALLISON TRANSMISSION TECHNICIANS’ GUIDE

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 are discolored from heat, lack of lubrication or debris lapping in the race. Replace the bearing if the races are worn, galled or abraded. Replace the bearing if it catches or feels rough after being thoroughly cleaned.

C. Replace the bearing if any

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

ALLISON 4000/B500 PRODUCT FAMILIES

GENERAL INSPECTION GUIDELINES FOR

BEARINGS

A. Rollers

B. Bearing

Race

C. Retainer

B. Bearing

Race

B. Bearing Race

(continued)

C. Retainer

 2005 General Motors Corporation.

ALLISON TRANSMISSION TECHNICIANS’ GUIDE

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.

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/B500 PRODUCT FAMILIES

GENERAL INSPECTION GUIDELINES FOR BEARINGS

(continued)

 2005 General Motors Corporation.

ALLISON TRANSMISSION TECHNICIANS’ GUIDE

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.

ALLISON 4000/B500 PRODUCT FAMILIES

GENERAL INSPECTION GUIDELINES FOR

BUSHINGS

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

A. Bushing

 2005 General Motors Corporation.

ALLISON TRANSMISSION TECHNICIANS’ GUIDE

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.

ALLISON 4000/B500 PRODUCT FAMILIES

GENERAL INSPECTION GUIDELINES FOR RETAINING RINGS

Examine retaining rings for damage, distortion or excessive wear.

A. Retaining

Rings

 2005 General Motors Corporation.

ALLISON TRANSMISSION TECHNICIANS’ GUIDE

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.

ALLISON 4000/B500 PRODUCT FAMILIES

GENERAL INSPECTION GUIDELINES FOR

THRUST W ASHERS

A. Thrust

Washers

Thrust Washers

 2005 General Motors Corporation.

ALLISON TRANSMISSION TECHNICIANS’ GUIDE

A. Contact

Surface

C. Oil

Groove Depth

D. Spline

Teeth

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.

ALLISON 4000/B500 PRODUCT FAMILIES

GENERAL INSPECTION GUIDELINES FOR CLUTCH PLATES

B. Clutch Plate

Thickness and Coning

Check Using Feeler Gauge

Thickness

Coned Plate

Flat Plate

(continued)

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.

 2005 General Motors Corporation.

ALLISON TRANSMISSION TECHNICIANS’ GUIDE

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

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.

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.

ALLISON 4000/B500 PRODUCT FAMILIES

GENERAL INSPECTION GUIDELINES FOR

(continued)

CLUTCH PLATES

A. Contact

Surfaces

B. Thickness

& Coning

(see prior page graphic)

C. Tangs

Acceptable discoloration reuse plates.

Excessive scoring replace plates.

Broken tangs replace plates.

 2005 General Motors Corporation.

ALLISON TRANSMISSION TECHNICIANS’ GUIDE

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.

ALLISON 4000/B500 PRODUCT FAMILIES

GENERAL INSPECTION GUIDELINES FOR SPRINGS

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

A. Springs

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

 2005 General Motors Corporation.

ALLISON TRANSMISSION TECHNICIANS’ GUIDE

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.

ALLISON 4000/B500 PRODUCT FAMILIES

GENERAL INSPECTION GUIDELINES FOR

VALVES & VALVE BORES

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

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

A. Valves

B. Valve

Bores

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.

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.

A. Channel

Plate

B. Solenoid

Separator Plate

D. Internal

Wiring Harness

C. Suction

Filter Assembly

E. Rotating

Clutch Body Assembly

F. Main Valve

Body Assembly

G. Stationary Clutch

Valve Body Assembly

H. Oil Level

Sensor

ALLISON 4000/B500 PRODUCT FAMILIES

CONTROL MODULE

 2005 General Motors Corporation.

ALLISON TRANSMISSION TECHNICIANS’ GUIDE

B. Separator Plate

Separator plate and gasket installed on channel plate.

(continued)

ALLISON 4000/B500 PRODUCT FAMILIES

(continued)

CONTROL MODULE

 2005 General Motors Corporation.

ALLISON TRANSMISSION TECHNICIANS’ GUIDE

C. Replace the suction filter

assembly during overhaul.

D. Replace or repair the control

module wiring harness if the

wires, terminals or connectors are visibly damaged. Inspect the molded harness channel for cracks or breaks. Replace the harness if the molded channel is damaged. Check sump temperature resistance following the guidelines and specifications listed in the Service Manual and Troubleshooting Manual.

NOTE: Transmissions built prior to

S/N 6610014067 used the former design sump temperature sensor. Sensor resistance specifications

differ between the former and current designs. Be sure to use the correct resistance specification chart for the sensor being checked.

Sump Temperature Sensor (TID 2, 3)

D Solenoid (C4)

C Solenoid (C3)

E Solenoid (C5)

F Solenoid (Lockup)

Oil Level Sensor

Feed Through Stand-Off

C3 Pressure Switch

A Solenoid (C1)

Feed Through Harness

B Solenoid (C2)

G Solenoid (C2 Latch)

Identification Detail:

Internal Wiring Harness

Current TID2/TID3 Harness

Former TID1 Harness

TID1 Sump Temp. Sensor

(continued)

Dust Seal

O-Ring Seal

TID 2, 3 Sump Temp. Sensor

ALLISON 4000/B500 PRODUCT FAMILIES

CONTROL MODULE

(continued)

 2005 General Motors Corporation.

ALLISON TRANSMISSION TECHNICIANS’ GUIDE

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.

Supersession Information

Oil Drain Plug Redesign SIL 5-WT-98, Rev. A

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.

Current

Former

(continued)

Replace the C3 pressure switch if it is visibly damaged. Resistance between the two switch terminals should measure 20k ohms or higher when the switch is open (and no pressure is present). Resistance between the two terminals should not exceed 2 ohms when the switch is closed (159 kPa-255 kPa or 23-37 psi present).

H. Replace the optional oil level

sensor if it is determined it is not

functioning correctly.

ALLISON 4000/B500 PRODUCT FAMILIES

(continued)

CONTROL MODULE

 2005 General Motors Corporation.

ALLISON TRANSMISSION TECHNICIANS’ GUIDE

4” Channel Plate

2” Channel Plate

Supersession Information

Suction Filter Redesign - SIL 1-WT-00

Replace the assembly during overhaul.

Current

Former

(continued)

ALLISON 4000/B500 PRODUCT FAMILIES

CONTROL MODULE

(continued)

B Solenoid (C2)

F Solenoid (Lockup)

A Solenoid (C1)

Rotating Clutch V alve Body

Solenoid Regulator Valves

C3 Pressure Switch

Solenoid Regulator Springs

Identification Detail: Rotating Clutch Valve Body Assembly

D Solenoid (C4)

C Solenoid (C3)

E Solenoid (C5)

Solenoid Regulator Valves

Solenoid Regulator Springs

Stationary Valve Body

Overdrive Knock Down V alve

Identification Detail: Stationar y Clutch Valve Body Assembly

 2005 General Motors Corporation.

ALLISON TRANSMISSION TECHNICIANS’ GUIDE

Accumulator Relay V alve

(continued)

ALLISON 4000/B500 PRODUCT FAMILIES

(continued)

CONTROL MODULE

Converter Regulator Valve

Converter Regulator Spring

Converter Regulator Valve Stop

Main Regulator Valve Stop

Control Main Valve

Control Main Valve Spring

Control Main Valve Stop

Main Regulator Valve Spring

Lube Regulator Valve

Lube Regulator Valve Spring

Lube Regulator Valve Stop

Main Regulator Valve

Lockup Valve

Lockup Valve Spring

Lockup Valve Stop

C1 Latch Valve

C2 Latch Valve

Main Valve Body

G Solenoid

C1 Latch Valve Spring

C2 Latch Valve Spring

C1 Latch Valve Stop

C2 Latch Valve Stop

Exhaust Backfill Valve Stop

Exhaust Backfill V alve

Supersession Information

Converter Regulator Valve Stop Redesign SIL 12-WT-99

 2005 General Motors Corporation.

ALLISON TRANSMISSION TECHNICIANS’ GUIDE

Identification Detail: Main Valve Body Assembly

Current Stop

Former Stop

(continued)

A. Converter

Pump Exterior

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).

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.

Inspect the pump hub tangs for cracks, impact damage and broken tangs.

B. Drive Hub

B. Drive

Hub

Model Identifiers (see chart)

Torque Converter Model Designation

Front Cover Sticker and Converter Paint Dot Color (Exterior Marker)

Engraved Letter Identifiers (Torus Ring of Converter Pump) Ink Stamped Letter (Exterior of Converter Pump)

Number of Stator Blades Paint Dot Color on Stator

TC-521

Green

None

TC-531

Pink

None

TC-541

Blue

None

TC-551

Orange

None

TC-561

Yellow

None

4000 Product Family Torque Converter Identification Chart

(continued)

ALLISON 4000/B500 PRODUCT FAMILIES

TORQUE CONVERTER MODULE

 2005 General Motors Corporation.

ALLISON TRANSMISSION TECHNICIANS’ GUIDE

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.

ALLISON 4000/B500 PRODUCT FAMILIES

TORQUE CONVERTER MODULE

(continued)

 2005 General Motors Corporation.

ALLISON TRANSMISSION TECHNICIANS’ GUIDE

C. Front

Cover Mounting Face

Current Plug

E. Ring

Gear

D. Pilot

F. Flexplate

Adapter

Converter Retaining Bolt

Turbine Shaft Selective Shim

Supersession Information

Converter Plug and Front Cover Update SIL-21-WT-98

Model Identifiers (see chart previous page)

The current front cover has a threaded pilot to accept the current converter plug. Plugs are not interchangeable

(continued)

A. Inspect the converter pump

interior. Replace the assembly if

the vanes are damaged, cracked or loose.

B. Replace the converter pump

assembly if the torus ring is loose or cracked.

C. Inspect the seal surface

between the converter pump assembly and the front cover.

Light stoning is permitted to remove slight irregularities.

ALLISON 4000/B500 PRODUCT FAMILIES

TORQUE CONVERTER MODULE

(continued)

 2005 General Motors Corporation.

ALLISON TRANSMISSION TECHNICIANS’ GUIDE

A. Converter

Pump Interior Vanes

B. Torus

Ring

Replace the assembly if the vanes are damaged, cracked or loose.

C. Seal Ring

Area

C. Front Cover-to-

Converter Pump Sealing Surface

(continued)

A. Converter

Turbine Blades

B. Torus

Ring

C. Rivets

D. Turbine Hub

E. Splines

Turbine Assembly Exterior

Turbine Assembly Interior

A. Inspect the converter turbine

assembly. Replace the assembly if the blades are cracked, broken or loose.

B. Inspect the torus ring. Replace

the turbine assembly if the torus ring is loose or cracked.

C. Inspect the rivets. Replace the

turbine assembly if the rivets are loose or cracked.

D. Inspect the converter turbine

hub. Replace the converter turbine

assembly if the hub is worn beyond limits. Minimum allowable hub diameter is 66.69 mm (2.626 inches). Inspect the sealring groove for damage.

E. Inspect the hub splines for

damage and wear. Spline movment between the lockup damper and turbine hub cannot exceed 0.38 mm (0.015 inch). Replace the turbine assembly if splines are excessively worn.

F. Inspect the thrust bearing

following the “General Inspection Guidelines for Bearings” section of this manual. Replace any thrust bearing failing these inspection procedures.

ALLISON 4000/B500 PRODUCT FAMILIES

TORQUE CONVERTER MODULE

(continued)

 2005 General Motors Corporation.

ALLISON TRANSMISSION TECHNICIANS’ GUIDE

Inspect the hub splines and rivets for damage and wear.

Turbine hub sealring groove Sealring installed.

F. Thrust

Bearing

(continued)

A. Torque converter lockup

clutch components fit inside the

front cover. Install a new turbine sealring in the converter cover bore then measure the sealring inside diameter. Replace the cover assembly if diameter exceeds 61.77 mm (2.432 inch).

B. Inspect the converter cover

bushing for damage. Replace the

bushing if damage cannot be removed with crocus cloth. Maximum allowable bushing inside diameter is 66.91 mm (2.634 inch).

C. Inspect the lockup clutch

piston for damage. Minimum

allowable piston thickness is 6.53 mm (0.257 inch).

D. Inspect the lockup clutch

backplate for damage, scoring and

overheating. Minimum allowable plate thickness is 11.79 mm (0.464 inch).

NOTE: If the backplate is within

thickness limits but has surface damage due to metal transfer between the backplate and lockup damper, the plate may be reused by turning it over so that the lockup damper has a new contact surface.

E. Replace the lockup clutch

damper if the friction surfaces are

worn beyond service limits. Minimum allowable friction surface thickness is 8.51 mm (0.335 inch). Maximum allowable damper distortion is 0.51 mm (0.020 inch). Maximum allowable movement between the damper and converter turbine splines is 0.38 mm (0.015 inch). Replace the damper if any of these measurements are beyond allowable limits.

F. Inspect thrust bearing

following the “General Inspection Guidelines for Bearings” section of this manual. Replace any thrust bearing failing these inspection procedures.

ALLISON 4000/B500 PRODUCT FAMILIES

TORQUE CONVERTER MODULE

(continued)

 2005 General Motors Corporation.

ALLISON TRANSMISSION TECHNICIANS’ GUIDE

A. Sealring

Bore

D. Backplate

B. Bushing

E. Lockup

Damper

Front Cover

Supersession Information

Lockup Clutch Damper Assembly Update SIL-4-WT-00, Rev. B

Current damper is backward compatible with all torque converter assemblies. ECU recalibration is not necessary.

C. Lockup

Clutch Piston

F. Thrust

Bearing

(continued)

L. Retaining

Ring

D. Star

Plate

A. Stator

Race

F. Thrust

Bearing

E. Front Stator

Thrust Washer

G. Stator

Thrust Plate

B. Stator

Spring

C. Stator

Roller

A. Inspect the stator race for

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

B. Inspect the stator springs for

correct spring height following per the Service Manual. Replace any spring which has a free length below

17.8 mm (0.700 inch).

C. Inspect the stator rollers for

damage. Rollers should be smooth, round and defect-free. Replace damage or worn rollers.

D. Inspect the star plate for

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

E. Inspect the front stator thrust

washer for wear beyond service

limits. Replace the stator thrust washer it is worn 0.40 mm (0.010

inch) or more. If it is within service limits, the thrust washer can be turned over and the un-worn surface can be used.

F. Inspect the thrust bearings

following the “General Inspection Guidelines for Bearings” section of this manual. Replace any thrust bearings failing these inspection procedures.

G. Inspect the stator thrust plate

for damage and wear. Replace the plate if damage cannot be removed using a soft stone or crocus cloth. Minimum allowable plate thickness is 9.45 mm (0.372 inch).

H. Inspect the stator and cam

assembly for damage. Replace the

stator and cam assembly if damaged.

NOTE: Use care when cleaning the

stator and cam assembly. Hot tank

temperatures may be high enough to release the cam assembly from the stator.

I. Inspect the stator roller

pockets for wear and damage. Verify

correct spring-to-roller orientation. Inspect the bottom of the cam pocket for wear. Replace the stator and cam assembly if it is worn 0.40 mm (0.010 inch) or more in the bottom of the pocket.

J. Inspect tanged thrust bearing

race for damage. Replace any

damaged race.

K. Inspect shim for damage.

Replace any damaged shims. Use procedure for shim selection in 4000 Series Service Manual.

L. Inspect the retaining ring for

damage and distortion. Replace any distorted or damaged retaining rings.

ALLISON 4000/B500 PRODUCT FAMILIES

(continued)

TORQUE CONVERTER MODULE

 2005 General Motors Corporation.

ALLISON TRANSMISSION TECHNICIANS’ GUIDE

H. Stator Cam

and Assembly

K. Shim

J. Tanged Thrust

Bearing Race

I. Roller

Stator Pockets

A. Inspect for torque converter

housing damage. High spots may be removed with crocus cloth or a soft stone. Inspect threaded holes for debris and thread damage. Replace the torque converter housing if it is cracked, if it leaks from a damaged machined surface, or if it has thread damage which cannot be repaired.

B. Inspect the breather for

damage and obstructions. Replace the breather if it is damaged. Clean the breather if it is blocked with debris.

C. Replace the input speed sensor

if the sensor body or electrical terminals are damaged. Speed sensor resistance is 300 ohms (plus or minus 30 ohms). Replace the

speed sensor if it does not meet the service limit.

D. On PTO-equipped models,

inspect the converter housing bearing bore for wear. Maximum

allowable bearing bore inside diameter is 180.05 mm (7.088 inches). Replace the housing if damage cannot be repaired using a soft stone or crocus cloth.

E. Inspect the PTO bearing

retainer mounting face surface and threads for damage. Replace

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

ALLISON 4000/B500 PRODUCT FAMILIES

TORQUE CONVERTER HOUSING MODULE

 2005 General Motors Corporation.

ALLISON TRANSMISSION TECHNICIANS’ GUIDE

D. Bearing

Bore

E. Retainer

Mounting Surface

C. Speed

Sensor & Bore

B. Breather

A. Torque

Converter Housing (PTO)

A. Torque

Converter Housing (Non-PTO)

F. PTO Drive

Assembly Bearing Retainer

H. Oil

Pump Drive Hub

M.PTO Drive

Gear Bearings

I. PTO Gear

Teeth

J. Bearing

Surfaces

L. Splines

F. On PTO-equipped models,

inspect the PTO drive bearing retainer housing bore for damage.

Replace the retainer if damage cannot be repaired using a soft stone or crocus cloth. Replace the retainer housing if the bushing has spun in the bushing bore.

G. Inspect the retainer housing

bushing for damage and wear.

Replace the bushing if damaged. Maximum allowable bushing inside diameter is 89.19 mm (3.511 inches). Replace the bushing if it is worn beyond service limits.

H. Inspect the oil

pump drive hub.

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

I. Inspect the PTO drive gear

teeth for chips, pitting and

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

NOTE: Some axial movement of the

gear is normal, but movement should not exceed 3.175 mm (0.125 inch). Replace the PTO bearings if axial movement exceeds service limit.

NOTE: Normal operating backlash

after PTO is installed is 0.1 mm to

0.66 mm (0.004 to 0.026 inch).

ALLISON 4000/B500 PRODUCT FAMILIES

(continued)

TORQUE CONVERTER HOUSING MODULE

 2005 General Motors Corporation.

ALLISON TRANSMISSION TECHNICIANS’ GUIDE

F. Retainer

Bore

G. Bushing

(continued)

I. PTO

Gear Teeth

K. Splines

J. Inspect the PTO drive hub

tangs for step wear, deformation and cracks. Replace the drive hub if tang step wear exceeds 0.38 mm (0.015 inch) or if either tang is deformed or cracked.

NOTE: Drive 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.

K. Inspect the drive hub splines

for wear. Replace the drive hub if spline wear exceeds 0.38 mm (0.015 inch).

L. Inspect the PTO drive gear

bearings following the “General

Inspection Guidelines for Bearings” section of this manual. Replace either bearing as needed.

ALLISON 4000/B500 PRODUCT FAMILIES

TORQUE CONVERTER HOUSING MODULE

(continued)

Examine the oil pump drive tangs for excessive battering.

 2005 General Motors Corporation.

ALLISON TRANSMISSION TECHNICIANS’ GUIDE

A. Output

Speed Sensor

B. Rear Cover

C. Piston

D. Spring

Pack

E. Retaining

Ring

F. Clutch Plates

A. Inspect the output speed

sensor for damage. Replace any sensor that has body, terminal or connector seat damage. Allowable output speed sensor resistance is 300 ohms plus or minus 30 ohms.

B. Inspect the rear cover

following the “General Inspection Guidelines for Cast Parts and Machined Surfaces” section of this manual. High spots on machined surfaces can be removed using a soft stone or crocus cloth. Inspect the slot on the back side of the housing where the C5 piston tang indexes. Replace the rear cover if

damage to any machined surface cannot be repaired using a soft stone or crocus cloth. Replace the rear cover if it is cracked.

C. Inspect the C5 clutch piston

following the “General Inspection Guidelines for Cast Parts and Machined Surfaces” section of this manual. Replace the piston if it fails to meet the inspection guidelines. Inspect the C5 piston tang for excessive wear.

D. Inspect the C5 clutch spring

pack for damage due to rubbing

adjacent parts and cracked or broken pieces. Check springs for wear, breakage and damage. Reference the Spring Data Charts in the Service Manual SM2457EN for spring specifications and identification.

E. Replace the C5 retaining

ring if it is bent or distorted.

ALLISON 4000/B500 PRODUCT FAMILIES

STANDARD REAR COVER &

P3 PLANETARY MODULE

 2005 General Motors Corporation.

ALLISON TRANSMISSION TECHNICIANS’ GUIDE

(continued)

F. Clutch

Plates

F. Inspect the C5 friction clutch

plates following the “General Inspection Guidelines for Friction Plates” section of this manual. Discard any plates that do not meet the guidelines. Minimum allowable thickness for reuse is 3.48 mm (0.137 inch). Minimum oil groove depth for reuse is 0.20 mm (0.0008 inch). Maximum cone for reuse is

0.25 mm (0.010 inch).

NOTE: Battered and worn spline

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

Inspect the C5 reaction clutch plates following the “General Inspection Guidelines for Reaction Plates” section of this manual. Discard any plates that do not meet the guidelines. Minimum allowable thickness for reuse is 2.41 mm (0.095 inch). Maximum cone for reuse is 0.25 mm (0.010 inch).

NOTE: The current clutch friction

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

ALLISON 4000/B500 PRODUCT FAMILIES

STANDARD REAR COVER & P3 PLANETARY MODULE

(continued)

 2005 General Motors Corporation.

ALLISON TRANSMISSION TECHNICIANS’ GUIDE

Supersession Information

Former C5 Friction Plate - one or no missing splines.

Current C5 Friction Plate missing two splines.

C5 Friction Plate Update SIL 4-WT-00, Rev. B and SIL 12-WT-03

Clutch plate identification is made by counting the number of missing teeth.

(continued)

ALLISON 4000/B500 PRODUCT FAMILIES

STANDARD REAR COVER &

(continued)

P3 PLANETARY MODULE

 2005 General Motors Corporation.

ALLISON TRANSMISSION TECHNICIANS’ GUIDE

Supersession Information

Use C5 friction plate missing 3 internal teeth.

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 Allison Transmission. Do not intermix both former and current friction plates in a clutch pack.

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.

C5 Pressure

Oil Passage Detail

(continued)

FORMER (NON-HARDENED)

P3 RING GEAR

HARDENED

P3 RING GEAR

IDENTIFICATION

GROOVE

Use C5 friction plate missing 2 internal teeth.

P3 Ring Gear Update SIL 12-WT-03

ALLISON 4000/B500 PRODUCT FAMILIES

STANDARD REAR COVER & P3 PLANETARY MODULE

(continued)

 2005 General Motors Corporation.

ALLISON TRANSMISSION TECHNICIANS’ GUIDE

A. P3 Carrier

Assembly (Non-Retarder)

B. Tapered

Roller Bearing

D. P3 Planetary

Spindle

E. Thrust

Washer

G. Pinion

Roller Bearing

I. Output Shaft

External Retaining Ring

H. Output

Shaft Spacer

J. Output Shaft

Verify a proper press fit between the P3 carrier and rear cover or retarder housing by

inverting the carrier over a table or workbench. If the P3 carrier falls out of the rear cover or retarder housing without using a press or mallet, the press fit between the tapered bearings and P3 carrier no longer exists and the carrier must be replaced.

Inspect the P3 carrier for spline wear. Replace the carrier if spline wear exceeds 0.38 mm (0.015 inch). Inspect the pinion spindle bores in the carrier and the pinion thrust surfaces for excessive wear and damage. Replace the P3 carrier if a

spindle has more than 0.051 mm (0.002 inch) clearance in the bore. Inspect for thread damage on the carrier hub. Replace the carrier if threads are damaged.

B. Inspect the tapered roller

bearings and races following the

“General Inspection Guidelines for Bearings” section of this manual. Replace any bearings failing to meet the inspection guidelines. Bearing races are located in the rear cover housing and should also be inspected for wear and damage.

C. Inspect the P3 indexing ring

for step wear in the area where it contacts the spindle. Replace the

indexing ring if it is broken or if it has excess step wear or damage which cannot be repaired using a soft stone or crocus cloth. Indexing rings with acceptable wear can be flipped during reassembly so that a new contact surface is used.

Bearing races located in rear cover.

F. Pinion

Gear

C. Indexing

Ring

(continued)

D. Inspect planetary spindles for

wear and damage. Discoloration is only a concern if spindle surface damage exists.

E. Inspect the pinion gear thrust

washers for damage, distortion and

signs of excessive wear. Minimum allowable thrust washer thickness is 1.39 mm (0.054 inch). Replace damaged or worn thrust washers.

F. Inspect the pinion gears

following the “General Inspection Guidelines for Gears” section of this manual. Replace any gears which fail these inspection procedures or if the damage cannot be repaired using a soft stone.

G. Inspect the pinion roller

bearings following the “General

Inspection Guidelines for Bearings” section of this manual. Replace any bearings which fail these inspection procedures.

H. Replace the output shaft

spacer if it is bent, cracked or if it

is distorted in any way. An attempt can be made to repair some minor damage using a soft stone.

I. Inspect the output shaft

external retaining ring. Replace

the retaining ring if it is distorted or fits loosely on the shaft.

ALLISON 4000/B500 PRODUCT FAMILIES

STANDARD REAR COVER &

(continued)

P3 PLANETARY MODULE

 2005 General Motors Corporation.

ALLISON TRANSMISSION TECHNICIANS’ GUIDE

Supersession Information

P3 Carrier Update SIL 25-WT-01

Current P3 carriers use a drill point hole and a Belleville spring washer.

Supersession Information

Planetary Spindle and Indexing Ring Updates SIL 10-WT-00

Planetary spindles and indexing rings are backward compatible. Current spindles are stamped with the number “2.” Indexing rings are stamped with the identifier “HD5.”

P1 P2

(continued)

 2005 General Motors Corporation.

ALLISON TRANSMISSION TECHNICIANS’ GUIDE

J. Inspect the output shaft

Inspect the output shaft bushing following the “General Inspection Guidelines for Bushings” section of this manual. Replace the bushing if it fails these inspection procedures. Maximum allowable bushing inside diameter is 36.14 mm (1.423 inch).

ALLISON 4000/B500 PRODUCT FAMILIES

STANDARD REAR COVER & P3 PLANETARY MODULE

(continued)

Supersession Information

Flange /Yoke Retaining Bolt Update - Reference SIL 1-WT-99

Single Bolt design increases clamp load.

Output spacers are not interchangeable between the former and current designs.

Supersession Information

Service Kit for Two-Bolt Ouput - SIL 15-WT-98 Kit Part Number: 29535910

J. Output Shaft

J. Inspect the output shaft

bushing for damage.

* Note: Kit contains

Belleville washers and 2 allen-head bolts to replace original locking tab and hex-head bolts.

(continued)

ALLISON 4000/B500 PRODUCT FAMILIES

STANDARD REAR COVER &

(continued)

P3 PLANETARY MODULE

 2005 General Motors Corporation.

ALLISON TRANSMISSION TECHNICIANS’ GUIDE

K. Replace the output bearing

locknut retainer whenever the

locknut is removed.

L. Inspect the Belleville spring

washer for damage. Replace the

washer if it is distorted or the tang is worn.

M. Replace the output bearing

locknut if it is cracked, distorted,

has damaged threads. The current locknuts have three buttons in the threaded area. This nut should be replaced if it does not have a minimum of 10 N.m (7.5 ft. lb.) of running torque when threading the nut.

(continued)

K. Locknut

Retainer

4000 Series Wide Ratio P3 Carrier Assembly

4000 Series Close Ratio P3 Carrier Assembly

Former output bearing locknut and retainer

M.Output

Bearing Locknut

L. Belleville

Spring

 2005 General Motors Corporation.

ALLISON TRANSMISSION TECHNICIANS’ GUIDE

Supersession Information

ALLISON 4000/B500 PRODUCT FAMILIES

STANDARD REAR COVER & P3 PLANETARY MODULE

(continued)

Supersession Information

Bearing Retainer Locknut Update - Reference SIL 25-WT-01

Current bearing retainer locknuts include three locking buttons.

Supersession Information

Output Yoke/Flange Update Reference SIL 4-WT-03

Not all yoke / slinger combinations can be used with all transmissions. Rear cover design determines yoke / slinger combination.

Supersession Information

Rear Cover Update - Reference SIL 4-WT-03

Current rear cover has interior cut relief to accommodate 5-ridge output seal. Former rear cover has interior cut relief to accommodate 4-ridge output seal

(reference Output Seal Update

Supersession Information)

Former: No cut relief Current: Cut relief on

the exterior for a wrap around slinger.

Former Output Seal

Current Output Seal

(former

standard/ retarder housing)

for S/N prior to 6610116108

Current Output Seal

(current

standard/ retarder housing)

for

S/N starting with 6610116108

Output Seal Update Reference SIL 4-WT-03

Two seals are currently available to fit former and current rear covers. They are NOT interchangeable.

ALLISON 4000/B500 PRODUCT FAMILIES

RETARDER MODULE

 2005 General Motors Corporation.

ALLISON TRANSMISSION TECHNICIANS’ GUIDE

A. Inspect the retarder housing

following the “General Inspection Guidelines for Cast Parts and Machined Surfaces” section of this manual. High spots on machined surfaces can be removed using a soft stone or crocus cloth. Replace the retarder housing if it is cracked or if machined surface damage cannot be removed using a soft stone or crocus cloth.

Install a “known good” rotor sealring in the retarder housing and measure sealring inside diameter. If the retarder housing is slightly grooved or worn, place the sealring directly in the grooved or worn area. Replace the housing if sealring

inside diameter is greater than

139.72 mm (5.501 inches). A bearing race fits into the housing and should be inspected for damage.

B. Inspect the stator housing

following the “General Inspection Guidelines for Cast Parts and Machined Surfaces” section of this manual. Some light housing imperfections can be removed using a soft stone. Discard and replace the housing if damage is excessive.

NOTE: Transmissions built prior to

January 1998 included two small check balls and retainers located in the retarder stator housing. Minimum allowable check ball movement is 0.50 mm (0.020 inch).

Inspect the slot on the back side of the housing where the C5 piston tang indexes for excessive wear. Replace the stator housing if damage to any machined surface cannot be repaired using a soft stone or crocus cloth. Replace the stator housing if it is cracked.

C. Inspect the retarder rotor

following the “General Inspection Guidelines for Cast Parts and Machined Surfaces” section of this manual. Check for loose, cracked or broken rivets. Replace the rotor if movement exists between the center hub and the vaned assembly. Inspect the rotor splines for wear.

B. Retarder Stator

Housing

E. Autoflow V alve,

Spring & Plug

C. Retarder

Rotor

F. Retarder Temp

Sensor Assembly

A. Retarder

Housing

G. Output Speed

Sensor

(continued)

D. P3 Carrier

Assembly (Retarder)

Supersession Information

Retarder Exhaust Backfill Valve Update Reference SIL 14-WT-02

The current stop is backward compatible with all 4000/B500 retarder equipped transmissions.

Current Retarder Exhaust Backfill Valve Stop

Former Retarder Exhaust Backfill Valve Stop

 2005 General Motors Corporation.

ALLISON TRANSMISSION TECHNICIANS’ GUIDE

Fluid Flow Detail

ALLISON 4000/B500 PRODUCT FAMILIES

RETARDER MODULE

(continued)

Spline wear cannot exceed 0.38 mm (0.015 inch). Replace the rotor if it exceeds this wear limit.

D. Reference the “Inspection and

Analysis of the Standard Rear Cover” section of this manual for P3 planetary carrier assembly details.

NOTE: Inspect retarder P3 carriers

for excessive step wear on the splines of the P3 carrier hub. Replace those P3 carriers that exhibit step wear.

E. Inspect the retarder autoflow

valve for wear and damage. The

autoflow valve must move freely in its bore, when dry, under its own

weight. Replace or repair the autoflow valve and/or retarder housing as necessary. Crocus cloth can be used to remove slight high spots.

Inspect the autoflow valve spring for defects and permanent set. Reference the Spring Data Charts in Service Manual SM2457 for spring specifications and identification. Replace the spring if it fails any inspection procedures.

F. Inspect the retarder

temperature sensor exterior for

defects. Replace the temperature sensor if it is damaged. There are two temperature sensor types - TID

1 and post-TID 1 (TID 2 and TID 3). Resistance specifications vary between the two sensor types. Be sure to use the correct Troubleshooting Manual chart for the sensor being tested. Replace the temperature sensor if its measured resistance is not within Troubleshooting Manual specifications.

G. Inspect the output speed

sensor for damage. Replace the

sensor if it has body, terminal or connector seat damage. Allowable output speed sensor resistance is 300 ohms plus or minus 30 ohms.

Supersession Information

Retarder Sump Cooling Feature - Reference SIL 25-WT-00, Rev. A

The sump cooling feature provides additional cooling when the retarder is active through either an additional auxiliary cooler or the direct mount cooler for retarder transmissions.The direct mount cooler for retarder transmissions works as both the main cooler and auxiliary cooler.

(continued)

Main

Control Main

From Cooler

To Cooler

C5 Pressure

Exhaust

Retarder Out

Accumulator

Converter Out (To Cooler)

Lube Pressure

From Cooler

To Retarder

Control Main

Main

No Sump Cooling Feature

Sump Cooling Provision

ALLISON 4000/B500 PRODUCT FAMILIES

(continued)

RETARDER MODULE

 2005 General Motors Corporation.

ALLISON TRANSMISSION TECHNICIANS’ GUIDE

A. Inspect the retarder control

valve body following the “General

Inspection Guidelines for Cast Parts and Machined Surfaces” section of this manual. All passages must be clean and debris free. Valve bores must be free of nicks, burrs and scoring. Crocus cloth or a soft stone can be used to attempt removal of slight irregularities, however no honing of any kind is permitted.

B & H. Inspect the retarder

control valve and exhaust backfill

valve for nicks, burrs, scoring and other damage. A soft stone or crocus cloth can be used to attempt

removal of slight irregularities. Valves must move freely in their bores, when dry, under their own weight.

C & I. Replace the retarder

control valve spring or exhaust backfill spring for damage or

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

D. Inspect the valve plug for

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

E. Inspect the channel plate

following the “General Inspection Guidelines for Cast Parts and Machined Surfaces” section of this manual. Replace the channel plate if it fails any of these inspection procedures or if it has damage which cannot be repaired using a soft stone or crocus cloth. All passages must be clean and debris free.

K. Wiring

Harness

A. Retarder

Valve Body

G. Retarder

Solenoid

H. Exhaust

Backfill Valve

I. Exhaust

Backfill Valve Spring

L. Solenoid

Cover

E. Channel

Plate

C. Retarder Control

Valve Spring

F. Separator

Plate

J. Exhaust

Backfill V alve Stop & Pin

D. Valve

Plug & Retaining Ring

B. Retarder

Control Valve

(continued)

 2005 General Motors Corporation.

ALLISON TRANSMISSION TECHNICIANS’ GUIDE

ALLISON 4000/B500 PRODUCT FAMILIES

RETARDER MODULE

(continued)

F. Inspect the separator plate for

nicks, burrs, scoring and distortion (flatness). Replace the plate if damage cannot be repaired using a soft stone or crocus cloth.

G. Replace the retarder solenoid

if the body, connector or terminals show visible signs of damage. Solenoid resistance should be 3 to 4 ohms measured between the two solenoid terminals. Check resistance between each solenoid terminal and the solenoid body. Replace the solenoid if either reading is less than 100k ohms resistance.

J. Inspect the exhaust backfill

valve stop for damage. Replace the

stop if damage cannot be repaired using a soft stone or crocus cloth. Inspect the exhaust backfill valve pin for damage. Replace the pin if it is bent or has damage.

K. Replace or repair the wiring

harness if the wires, terminals or

connectors are visibly damaged. Check the installed harness for tight bends or crimps which might damage harness wires.

L. Inspect the solenoid cover

following the “General Inspection Guidelines for Cast Parts and Machined Surfaces” section of this manual. Replace the housing if it fails any of these inspection procedures.

Exhaust Pressure

Retarder Pressure

Pocket

Main Pressure

Control Main

Retarder Pressure

Exhaust Pressure

Pocket

Retarder Pressure

Main Pressure

Exhaust Pressure

Exhaust Backfill Pressure

Exhaust Pressure

Retarder Pressure

Main Pressure (to Flow Valve)

Main Pressure (Feed)

Control Main Pressure

ALLISON 4000/B500 PRODUCT FAMILIES

CLOSE RATIO MAIN SHAFT MODULE

 2005 General Motors Corporation.

ALLISON TRANSMISSION TECHNICIANS’ GUIDE

A. Main Shaft

H. P3

Sun Gear

D. Thrust

Bearing

F. Bearing

Spacer

G. Selective

Shim

E. P2 Sun

Gear

I. Spiral

Retaining Ring

B. Main

Shaft Pilots

C. Journal

B. Main

Shaft Pilots

A. Inspect the main shaft

following the “General Inspection Guidelines for Gears” and “General Inspection Guidelines for Splines” sections of this manual. Replace the main shaft if it fails any of these inspection procedures.

B. Inspect the front and rear

main shaft pilots for damage. The

front main shaft pilot fits inside the turbine shaft. The rear main shaft pilot fits inside the output shaft. Replace the main shaft if pilot outside diameter is less than 35.92 mm (1.414 inch).

C. Inspect the P2 bushing journal

area for damage. Replace the main

shaft if P2 planetary bushing

journal diameter is less than 52.98 mm (2.085 inch).

D. Inspect the thrust bearings

following the “General Inspection Guidelines for Bearings” section of this manual. Replace any bearing that fails any of these inspection procedures.

E. Inspect the P2 sun gear

following the “General Inspection Guidelines for Gears” and “General Inspection Guidelines for Splines” sections of this manual. Replace the gear if it fails any of these inspection procedures.

F. Inspect the main shaft bearing

spacer following the “General

Inspection Guidelines for Cast Parts

and Machined Surfaces” and “General Inspection Guidelines for Splines” sections of this manual. Replace the spacer if it fails any of these inspection procedures.

G. Inspect the selective shim for

damage. Replace the shim if it is distorted or if damage cannot be removed by light stoning.

H. Inspect the P3 sun gear

I. Replace the spiral retaining

ring if it is removed.

Close Ratio Main Shaft Module

 2005 General Motors Corporation.

ALLISON TRANSMISSION TECHNICIANS’ GUIDE

ALLISON 4000/B500 PRODUCT FAMILIES

WIDE RATIO MAIN SHAFT MODULE

A. Main

Shaft

D. P2 Sun

Gear

E. Thrust

Bearing

F. Bearing

Spacer

G. Selective

Shim

H. Spiral

Retaining Ring

B. Main Shaft

Pilots

C. Journal

B. Main Shaft Pilots

A. Inspect the main shaft

B. Inspect the front and rear main

shaft pilots for damage. The front

main shaft pilot fits inside the turbine shaft. The rear main shaft pilot fits inside the output shaft. Replace the main shaft if pilot outside diameter is less than 35.92 mm (1.414 inch).

C. “Inspect the P2 bushing

journal for damage. Replace the

main shaft if P2 planetary bushing journal diameter is less than 52.98 mm (2.085 inch).

D. Inspect the P2 sun gear

E. Inspect the thrust bearings

following the “General Inspection Guidelines for Bearings” section of this manual. Replace any bearing that fails any of these inspection procedures.

F. Inspect the main shaft bearing

spacer following the “General

Inspection Guidelines for Cast Parts and Machined Surfaces” “General Inspection Guidelines for Splines” sections of this manual. Replace the spacer if it fails any of these inspection procedures.

G. Inspect the selective shim for

damage. Replace the shim if it is distorted or if damage cannot be removed by light stoning.

H. Replace the spiral retaining

ring if it is removed.

Wide Ratio Main Shaft Module

D. P3 Ring

Gear

A. P2 Planetary

Carrier

E. Index

Ring

F. Pinion Thrust

Washers

G. Pinion

Spindle

H. Pinion

Roller Bearings

I. Pinion

Gear

J. Retaining

Rings

A. Inspect the P2 carrier

B. Inspect the P2 carrier bushing

for damage. Replace the bushing if damaged. Replace the bushing if inside diameter exceeds 53.23 mm (2.096 inches).

C. Inspect the carrier hub for

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

D. Inspect the P3 ring gear

following the “General Inspection Guidelines for Gears” and “General Inspection Guidelines for Splines” sections of this manual. Replace the ring gear if it fails any of these inspection procedures.

E. Inspect the P2 indexing ring for

step wear in the area where it contacts the spindle. Replace the indexing ring if it is broken or if it has excessive step wear or damage. Indexing rings with acceptable wear can be flipped during reassembly so that a new contact surface is used.

F. Replace the pinion gear thrust

washers if they are damaged, distorted, galled or showing signs of

excessive wear. Minimum allowable thrust washer thickness is 1.40 mm (0.055 inch). Maximum allowable thrust washer step wear is 0.12 mm (0.005 inch).

G. Replace planetary spindles if

they are worn or damaged. Discoloration is only a concern if spindle surface damage exists.

ALLISON 4000/B500 PRODUCT FAMILIES

P2 PLANETARY MODULE

 2005 General Motors Corporation.

ALLISON TRANSMISSION TECHNICIANS’ GUIDE

B. Carrier

Bushing

C. Carrier

Hub

(continued)

 2005 General Motors Corporation.

ALLISON TRANSMISSION TECHNICIANS’ GUIDE

ALLISON 4000/B500 PRODUCT FAMILIES

P2 PLANETARY MODULE

(continued)

H. Inspect the pinion roller

bearings following the “General Inspection Guidelines for Bearings” section of this manual. Replace any bearing failing these inspection procedures.

I. Inspect the P2 pinion gears

following the “General Inspection Guidelines for Gears” section of this manual. Replace any gear that fails these inspection procedures or if damage cannot be removed using a soft stone.

J. Inspect the P2 carrier

retaining rings for damage or

distortion. Replace any retaining rings with damage that cannot be removed using a soft stone.

NOTE: Current P3 ring gears are

hardened. Former P3 ring gears were non-hardened. Each ring gear requires a specific C5 clutch plate. There are two current versions of C5 clutch plates. Plates which are missing two splined teeth must be used with the hardened P3 ring gear (identified by the groove on the gear’s outside diameter). Plates missing three splined teeth must be used with the non-hardened P3 ring gear (no identification groove). Reference the C5 clutch plate “Supersession Information” in this section and SILs 12-WT-03 and 4-WT-00, Revision B. The correct current C5 clutch plate must be used with each ring gear to avoid transmission damage.

Supersession Information

Planetary Spindle and Indexing Ring Updates - Reference SIL 10-WT-00

Planetary spindles and indexing rings are backward compatible. Current spindles are stamped with the number “2.” Indexing rings are stamped with the identifier “HD5.”

FORMER (NON-HARDENED)

P3 RING GEAR

HARDENED

P3 RING GEAR

IDENTIFICATION

GROOVE

Supersession Information

P3 Ring Gear Update SIL 12-WT-03

Use C5 friction plate missing 2 internal teeth.

Use C5 friction plate missing 3 internal teeth.

4000 Series Close Ratio P2 Carrier Assembly

4000 Series Wide Ratio P2 Carrier Assembly

A. P1

Planetary Carrier

B. P2

Ring Gear

C. Index

Ring

D. Pinion

Thrust Washers

E. Pinion

Spindle

G. Pinion Roller

Bearings

F. Pinion

Gear

H. Retaining

Ring

A. Inspect the P1 carrier following

the “General Inspection Guidelines for Cast Parts and Machined Surfaces” and the “General Inspection Guidelines for Splines” sections of this manual. Replace the carrier if any spindle has more than

0.051 mm (0.002 inch) clearance in its bore.

Thrust bearings fit on both sides of the P1 carrier. Inspect the thrust bearings following the “General Inspection Guidelines for Bearings” section of this manual. Replace any bearing that fails any of these inspection procedures.

B. Inspect the P2 ring gear

following the “General Inspection Guidelines for Gears” and the “General Inspection Guidelines for Splines” sections of this manual. Replace the ring gear if it fails any of these inspection procedures.

C. Inspect the P1 indexing ring

for step wear in the area where it contacts the spindle. Replace the indexing ring if it is broken or if it has excessive step wear or damage. Indexing rings with acceptable wear can be flipped during reassembly so that a new contact surface is used.

ALLISON 4000/B500 PRODUCT FAMILIES

P1 PLANETARY MODULE

 2005 General Motors Corporation.

ALLISON TRANSMISSION TECHNICIANS’ GUIDE

Thrust bearing inspection.

(continued)

 2005 General Motors Corporation.

ALLISON TRANSMISSION TECHNICIANS’ GUIDE

ALLISON 4000/B500 PRODUCT FAMILIES

P1 PLANETARY MODULE

(continued)

D. Replace the pinion gear thrust

washers if they are damaged, distorted, galled or showing signs of excessive wear. Minimum allowable thrust washer thickness is 1.39 mm (0.054 inch).

E. Replace planetary spindles if

they are worn or damaged. Discoloration is only a concern if spindle surface damage exists.

F. Inspect the P1 pinion gears

following the “General Inspection Guidelines for Gears” section of this manual. Replace any gear that fails these inspection procedures or if damage cannot be removed using a soft stone.

G. Inspect the pinion roller

bearings following the “General

Inspection Guidelines for Bearings” section of this manual. Replace any bearing failing these inspection procedures.

H. Inspect the P1 carrier retaining

rings for damage or distortion.

Replace any retaining rings with damage that cannot be removed using a soft stone.

Supersession Information

Planetary Spindle and Indexing Ring Updates SIL 10-WT-00

Planetary spindles and indexing rings are backward compatible. Current spindles are stamped with the number “2.” Indexing rings are stamped with the identifier “HD5.”

P1 P2

A. Front Support

Assembly

D. PTO-Model

Ground Sleeve

F. Charging

Pump Housing (PTO Model)

H. Roller

Bearing

G. Main

Pressure Relief Ball & Spring

J. Wear

Plate

D. Non-PTO Model

Ground Sleeve

E. Bushing

Journal

I. Charging Pump

Gear Set

A. Inspect the front support

assembly following the “General Inspection Guidelines for Cast Parts and Machined Parts” section of this manual. Replace the assembly if it fails any of these inspection procedures. If the ground sleeve has rotated in the front support, replace both components (the ground sleeve and the front support assembly). If the ground sleeve is replaced, check the front support for flatness after ground sleeve installation. Replace the front support if it is more than

0.051 mm (0.002 inch) from flat.

B. Replace the front support if

the sleeve has damage that cannot be repaired using a soft stone or crocus cloth. Minimum allowable front support sleeve diameter is

119.81 mm (4.717 inches).

C. Inspect the three sealring

grooves on the front support

assembly hub for nicks, burrs, cracks and other damage.

ALLISON 4000/B500 PRODUCT FAMILIES

FRONT SUPPORT &

OIL PUMP MODULE

 2005 General Motors Corporation.

ALLISON TRANSMISSION TECHNICIANS’ GUIDE

Supersession Information

Redesigned Charging Pump Gear Set - SIL 13-WT-04

Orange bushing identifies current gear set.

C. Sealring Grooves

B. Front

Support Sleeve

B. Front

Support Sleeve

Former

Current

(continued)

 2005 General Motors Corporation.

ALLISON TRANSMISSION TECHNICIANS’ GUIDE

ALLISON 4000/B500 PRODUCT FAMILIES

FRONT SUPPORT & OIL PUMP MODULE

(continued)

Oil Passage Detail

Lube Pressure

Main Pressure

Lockup Pressure

Converter Out

Converter In

Pump Suction

C1 Pressure

Inspect the ground sleeve following the “General Inspection Guidelines for Splines” section of this manual. Replace the shaft if it fails any of these inspection procedures.

E. Inspect the journal area where

the charging pump driven gear bushing rides. Replace the shaft if

the journal is damaged or galled. Minimum allowable journal diameter is 66.67 mm (2.265 inches).

NOTE: Ground sleeve galling is

typically an indicator of poor transmission fluid condition due to improper maintenance intervals. Observation of proper fluid change

intervals is key to optimum transmission life.

Inspect the area in the ground sleeve where the turbine shaft sealrings ride for grooves, scoring and other wear or damage. Install new sealrings in the ground sleeve and measure the end gap. If the ground sleeve is grooved or worn, place the sealrings directly in the grooved or worn area. Maximum allowable sealring end gap is 1.01 mm (0.039 inches). Replace the ground sleeve if any of the seal ring end gaps exceeds this specification.

NOTE: When replacing the ground

sleeve, total shaft runout cannot exceed 0.30 mm (0.012 inch) once it is pressed into the front support.

C2 Pressure

(continued)

C1 Pressure C2 Pressure

Front support oil passage detail - outside hub.

F. Inspect the charging pump

housing following the “General Inspection Guidelines for Cast Parts and Machined Parts” section of this manual. Replace the housing if it fails any of these inspection procedures. Replace the charging pump housing if gear cavity depth exceeds 19.04 mm (0.750 inches). Replace the charging pump housing if gear cavity diameter exceeds

150.25 mm (5.915 inches).

G. Replace the main pressure

relief ball if it is damaged. Inspect

the main pressure relief spring following the “General Inspection Guidelines for Springs” section of this manual. Replace the spring if it is bent, broken, distorted or shows signs of wear from rubbing adjacent parts. Reference the Spring Data Charts in the Service Manual for spring identification and specifications.

H. The roller bearing fits inside

the back of the front support hub. Inspect this bearing following the “General Guidelines for Bearings” section of this manual. Replace the bearing if it fails any of these inspection procedures.

ALLISON 4000/B500 PRODUCT FAMILIES

(continued)

FRONT SUPPORT & OIL PUMP MODULE

 2005 General Motors Corporation.

ALLISON TRANSMISSION TECHNICIANS’ GUIDE

(continued)

Oil passage detail -

inside hub.

Lube

Lockup

Converter Out

C1 Pressure

C2 Pressure

Indexing Alignment Arrow

Flat on Ground Sleeve

 2005 General Motors Corporation.

ALLISON TRANSMISSION TECHNICIANS’ GUIDE

Ground sleeve oil passage detail.

ALLISON 4000/B500 PRODUCT FAMILIES

FRONT SUPPORT & OIL PUMP MODULE

(continued)

Lube

Lockup

Converter Out

C2 Pressure

C1 Pressure

I. Replace the charging pump

gear set if the sides, faces or gear teeth are damaged. Replace the gear set if the inside gear shows damage or battering at the point where the torque converter drive tangs (or the PTO drive hub tangs) index into the gear. Replace the gear set if the bushing inside diameter exceeds

57.30 mm (2.256 inch). Minimum allowable outside diameter of the outer gear is 149.94 mm (5.903 inch).

NOTE: Install the pump gear set in

the oil pump housing to perform the following inspections and measurements.

Maximum allowable clearance between the installed gear set and mounting face of the pump housing is 0.10 mm (0.004 inch). This is often referred to as pump gear side clearance. Maximum allowable gear tooth tip clearance (the gap between a tooth on the outer gear and a tooth on the inner gear) is

0.15 mm (0.006 inch). The maximum allowable clearance between the outer gear and the pump housing is 0.30 mm (0.012 inch).

J. Replace the wear plate if it is

galled or moderately scored. Pay particular attention to the area where the charging pump gear set rides. Minimum allowable wear plate thickness is 4.70 mm (0.0185 inch). Replace the wear plate if it is worn past service limits or if it has damage that cannot be repaired using a soft stone or crocus cloth.

A. Inspect the turbine shaft

following the “General Inspection Guidelines for Cast Parts and Machined Surfaces” section of this manual. Replace the turbine shaft if it fails any of these inspection procedures. Maximum allowable spline wear is 0.38 mm (0.015 inch).

B. Inspect the turbine shaft

bushing following the “General

Inspection Guidelines for Bushings” section of this manual. Replace the bushing if it fails any of these inspection procedures. Maximum allowable bushing inside diameter is 36.14 mm (1.423 inch).

C. Inspect the bearing

journal area for damage.

Replace the turbine shaft if damage cannot be repaired with a light stone or crocus cloth.

D. Inspect the three sealring

grooves for damage. Replace the

turbine shaft if damage cannot be repaired with a light stone or crocus cloth. Install three new sealrings and check end gap. Minimum end gap allowed is 0.65 mm (0.026 inch). Replace turbine shaft if end gap is below minimum.

E. Inspect the rotating drum

following the “General Inspection Guidelines for Cast Parts and

Machined Surfaces” and “General Inspection Guidelines for Splines” sections of this manual. Replace the drum if it fails any of these inspection procedures. Maximum allowable spline wear is 0.38 mm

0.015 inch).

F. Inspect the rotating clutch

hub following the “General

Inspection Guidelines for Cast Parts and Machined Surfaces” and

ALLISON 4000/B500 PRODUCT FAMILIES

ROTATING CLUTCH MODULE

 2005 General Motors Corporation.

ALLISON TRANSMISSION TECHNICIANS’ GUIDE

A. Turbine Shaft

(PTO Model)

G. P1 Sun

Gear Assembly

H. Thrust

Bearing

F. Rotating

Clutch Hub

E. Rotating

Drum

A. Turbine Shaft

(Non-PTO Model)

H. Thrust

Bearing

(continued)

J. Sealring

Bore

K. Bushing

C. Journal

B. Bushing

D. Sealring

Grooves

I. Retaining Ring

 2005 General Motors Corporation.

ALLISON TRANSMISSION TECHNICIANS’ GUIDE

“General Inspection Guidelines for Splines” sections of this manual. Replace the hub if it fails any of these inspection procedures.

G. Inspect the P1 sun gear

assembly following the “General

Inspection Guidelines for Gears and “General Inspection Guidelines for Splines” sections of this manual. Replace the assembly if it fails any of these inspection procedures or if it has damage which cannot be repaired using a soft stone or crocus cloth.

H. Inspect the thrust bearings

following the “General Inspection Guidelines for Bearings” section of

this manual. Replace any bearings which fail any of these inspection procedures.

I. Inspect the turbine shaft

retaining ring following the

“General Inspection Guidelines for Retaining Rings” section of this manual. Replace the retaining ring if it fails any of these inspection procedures or if the ring is bent, distorted or shows other signs of damage.

J. Inspect the area inside the hub

where the front support sealrings ride for grooves and damage. Replace the hub if damage cannot be repaired using a soft stone or

crocus cloth. Install three new sealrings in the wear area of the bore and check each seal’s end gap. Replace the rotating clutch hub if end gap exceeeds 1.44 mm (0.056 inch).

K. Inspect the rotating hub

bushing following the “General

Inspection Guidelines for Bushings” section of this manual. Replace the bushing if it fails any of these inspection procedures or if it has damage which cannot be repaired using a soft stone or crocus cloth. Maximum allowable bushing inside diameter is 120.27 mm (4.735 inch).

ALLISON 4000/B500 PRODUCT FAMILIES

ROTATING CLUTCH MODULE

(continued)

C1 Pressure

C2 Pressure

Rotating clutch hub oil passage detail.

C1 Pressure

C2 Pressure

Supersession Information

Turbine Shaft Update Reference SIL 19-WT-94

Former turbine shaft and current ground sleeve are NOT compatible.

Supersession Information

Rotating Clutch Hub Update Reference SIL 8-WT-99, Rev. A

Supersession Information

Turbine Shaft Update Reference SIL 19-WT-94 & 22-WT-94

Former turbine shafts include a raised area toward the torque converter end of the shaft.

Former Turbine Shaft

Current Turbine Shaft

Former (No Weld)

Current (Weld)

Turbine Shaft

Ground Sleeve

(continued)

Note:The rotating clutch hub was

updated beginning with serial number

6610037353.The former rotating clutch hub is not welded in the area shown. The current rotating hub is welded and machined in the area shown.

H. Thrust

Bearings

F. C1 Apply

Plate

A. C1

Drive Hub

G. C1 Clutch

Pack

B. C1 Piston

E. C1 Backing

Plate

D. C1

Return Spring

C1 Clutch Components

A. Inspect the C1 drive hub

following the “General Inspection Guidelines for Cast Parts and Machined Surfaces” and the “General Inspection Guidelines for Splines” sections of this manual. Replace the hub if it fails any of these inspection procedures. Maximum allowable spline wear is

0.38 mm (0.015 inch).

B & C. Inspect the C1 clutch

piston and C1 balance piston

following the “General Inspection Guidelines for Cast Parts and Machined Surfaces” section of this manual. Replace any component if it fails any of these inspection procedures.

NOTE: Aluminum castings (like

clutch housings) can be etched by caustic parts cleaners and solvents. Etched components are identified by a dull to dark gray color - not the bright finish of a normal machined aluminum part. Etched components are also identified by roughness in the piston seal surface which can cause piston seals to abrade and result in low clutch apply pressure and transmission damage. Replace etched or damaged components.

D. Replace the C1 return spring

assembly if it has permanent spring

set, wear due to rubbing adjacent parts or if springs are cracked or broken in any way. Reference the

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

E & F. Inspect the C1 pressure

plate and C1 backplate for flatness, galling and other damage. Replace any plate with damage which cannot be removed using a soft stone or crocus cloth. Former C1 pressure plate minimum allowable thickness is 7.90 mm (0.311 inch). Current C1 apply plate minimum allowable thickness is 5.90 mm (0.232 inch). Current C1 backplate minimum allowable thickness is

9.90 mm (0.390 inch). Maximum allowable distortion of all plates is

0.15 mm (0.006 inch).

ALLISON 4000/B500 PRODUCT FAMILIES

(continued)

ROTATING CLUTCH MODULE

 2005 General Motors Corporation.

ALLISON TRANSMISSION TECHNICIANS’ GUIDE

(continued)

Housing in good condition - reuse.

Etched housing - do NOT use.

C. C1 Balance

Piston

 2005 General Motors Corporation.

ALLISON TRANSMISSION TECHNICIANS’ GUIDE

NOTE: Transmissions built prior to

S/N 6610032320 used two identical C1 pressure plates. Transmissions built after that used different plates. The current C1 apply pressure plate (next to the C1 piston) is approximately 2 mm thinner and has a different shape than the current C1 backplate (opposite end of the C1 clutch pack). When replacing the former pressure plates in a transmission with the current plate, both current plates must be used. Mixing former and current plates will result in C1 clutch failure.

G. Inspect the C1 clutch friction

plates following the “General

Inspection Guidelines for Friction

Plates” section of this manual. Replace any plates failing these inspection procedures. Minimum allowable friction plate thickness is

2.92 mm (0.115 inch). Minimum allowable oil groove depth is 0.20 mm (0.008 inch). Maximum allowable plate coning is 0.25 mm (0.010 inch).

NOTE: Battered and worn spline

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

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

ALLISON 4000/B500 PRODUCT FAMILIES

ROTATING CLUTCH MODULE

(continued)

Supersession Information

C1 Drive Hub Update - Reference SIL 26-WT-04

Drill point identifies the current hub which is backward compatible.

Supersession Information

C1 Clutch Piston and Balance Piston Re-design - Reference SIL 30-WT-04

Former and current components can NOT be mixed.

Former: C1 Drive Hub

Current: C1 Drive Hub

Drill Point Identifier

(continued)

ALLISON 4000/B500 PRODUCT FAMILIES

(continued)

ROTATING CLUTCH MODULE

 2005 General Motors Corporation.

ALLISON TRANSMISSION TECHNICIANS’ GUIDE

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.

Inspect the C1 clutch reaction plates following the “General Inspection Guidelines for Reaction Plates” section of this manual. Replace any plates failing these inspection procedures. Minimum allowable reaction plate thickness is 2.41 mm (0.095 inch). Maximum allowable reaction plate coning is

0.25 mm (0.010 inch).

H. Inspect the thrust bearings

following the “General Inspection Guidelines for Bearings” section of this manual. Replace any bearings which fail any of these inspection procedures.

Supersession Information

C1 Backing and Apply Plate Updates Reference SIL 22-WT-98, Rev. A

Former and current components can NOT be mixed

(continued)

5.90 mm

9.90 mm

 2005 General Motors Corporation.

ALLISON TRANSMISSION TECHNICIANS’ GUIDE

ALLISON 4000/B500 PRODUCT FAMILIES

ROTATING CLUTCH MODULE

(continued)

A. Inspect the C2 drive hub

0.38 mm (0.015 inch).

B. Inspect the C2 clutch piston

following the “General Inspection Guidelines for Cast Parts and Machined Surfaces” section of this manual. Replace the piston if it fails any of these inspection procedures.

NOTE: Aluminum castings (like

C. Replace the C2 return spring

assembly if it has permanent spring

set, wear due to rubbing adjacent parts or if springs are cracked or broken in any way. Reference the

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

D. Replace the C2 spring plate if

it is cracked, broken or showing any signs of distortion or wear.

E. Inspect the C2 backplate for

damage. Replace the plate if damage cannot be removed using a soft stone or crocus cloth. C2 backplate minimum allowable thickness is

7.90 mm (0.311 inch) when measured at the backing plate wear area. Maximum allowable distortion from flat is 0.015 mm (0.006 inch).

G. Thrust

Bearing

B. C2 Piston

A. C2

Drive Hub

E. C2 Backplate

C. C2 Return

Spring

D. C2 Spring

Plate

C2 Clutch Components

(continued)

Housing in good condition - reuse.

Etched housing - do NOT use.

F. C2

Clutch Pack

ALLISON 4000/B500 PRODUCT FAMILIES

(continued)

ROTATING CLUTCH MODULE

 2005 General Motors Corporation.

ALLISON TRANSMISSION TECHNICIANS’ GUIDE

Supersession Information

C2 Return Spring Assembly Update Reference SIL 4-WT-00, Rev. B

Currently assembly is backward compatible with all transmissions.

Former Current

F. Inspect the C2 clutch friction

plates following the “General Inspection Guidelines for Friction Plates” section of this manual. Replace any plates failing these inspection procedures. Minimum allowable friction plate thickness is

2.92 mm (0.115 inch). Minimum allowable oil groove depth is 0.20 mm (0.008 inch). Maximum allowable plate coning is 0.25 mm (0.010 inch).

NOTE: Battered and worn spline

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

NOTE: The current clutch friction

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 Allison Transmission. Do not intermix both former and current friction plates in a clutch pack.

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.

Inspect the C2 clutch reaction plates following the “General Inspection Guidelines for Reaction Plates” section of this manual. Replace any plates failing these inspection procedures. Minimum allowable reaction plate thickness is 2.41 mm (0.095 inch). Maximum allowable reaction plate coning is

0.25 mm (0.010 inch).

G. Inspect thrust bearings

following the “General Inspection Guidelines for Bearings” section of this manual. Replace any bearings which fail any of these inspection procedures.

A. C3 Clutch

Housing

E. P1 Ring Gear

D. Piston Return

Plate and Spring Assembly

B. Spring Retainer

Assembly

C. C3 Clutch

Pack

Wear Plates

 2005 General Motors Corporation.

ALLISON TRANSMISSION TECHNICIANS’ GUIDE

ALLISON 4000/B500 PRODUCT FAMILIES

C3/C4 CLUTCH MODULE

A. Inspect the C3 clutch housing

following the “General Inspection Guidelines for Cast Parts and Machined Surfaces” section of this manual. Replace the housing if it fails any of these inspection procedures. Check for C3 housing spline wear. Maximum allowable spline wear is 1.15 mm (0.045 inch). Replace the C3 housing if excessive spline wear exists. Check the C3 housing wear plates for flatness. Maximum allowable distortion is

0.15 mm (0.006 inch). Minimum allowable wear plate thickness is

2.82 mm (0.111 inch).

NOTE: Aluminum castings (like

clutch housings) can be etched by caustic parts cleaners and solvents. Etched components are identified by a dull to dark gray color - not the bright finish of a normal machined aluminum part. Etched components are also identified by roughness in the piston seals to abrade and result in low clutch apply pressure and transmission damage. Replace etched or damaged components.

B. Inspect the C3 spring retainer

assembly following the “General

Inspection Guidelines for Cast Parts and Machined Surfaces” section of this manual. Inspect the assembly for wear due to rubbing adjacent parts and cracked, broken or

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

NOTE: The C3/C4 spring retainer

assemblies (sometimes referred to as clutch apply spring assemblies) and the C3/C4 piston return plate were updated starting with S/N

6610137389. Do not mix former and current parts in the same clutch pack. The identifier for the current return plate is a letter “V” stamped in the face with an additional external spline on the outside diameter. The identifier for the current apply spring assembly is the letter “B” stamped in the spring retainer. Reference SIL 9-WT-04.

C3 Clutch Components

Housing in good condition - reuse.

Etched housing - do NOT use.

F. Clutch

Backplate Assembly

(continued)

ALLISON 4000/B500 PRODUCT FAMILIES

(continued)

C3/C4 CLUTCH MODULE

 2005 General Motors Corporation.

ALLISON TRANSMISSION TECHNICIANS’ GUIDE

C. Inspect the C3 clutch friction

plates following the “General

Inspection Guidelines for Friction Plates” section of this manual. Replace any plates failing these inspection procedures. Minimum allowable friction plate thickness is

3.485 mm (0.137 inch). Maximum allowable plate coning is 0.25 mm (0.010 inch).

NOTE: Battered and worn spline

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

NOTE: The current clutch friction

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 Allison Transmission. Do not intermix both former and current friction plates in a clutch pack.

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.

Inspect the C3 clutch reaction plates following the “General Inspection Guidelines for Reaction Plates” section of this manual. Replace any plates failing these inspection procedures. Minimum allowable reaction plate thickness is

2.41 mm (0.010 inch). Maximum allowable reaction plate coning is

0.25 mm (0.010 inch).

(continued)

Supersession Information

C3/C4 Return Plate and C3/C4 Apply Spring Assembly Update - SIL 9-WT-04

Former and current components can NOT be mixed in the same clutch pack.

 2005 General Motors Corporation.

ALLISON TRANSMISSION TECHNICIANS’ GUIDE

ALLISON 4000/B500 PRODUCT FAMILIES

C3/C4 CLUTCH MODULE

(continued)

D. Inspect the C3 piston return

plate and spring assembly following the “General Inspection Guidelines for Reaction Plates” section of this manual. Minimum allowable plate thickness is 4.91 mm (0.193 inch). Replace springs which are cracked, broken or permanently set. Reference the Spring Data Charts in the Service Manual for spring specifications and identification.

NOTE: The C3/C4 spring retainer

assemblies (sometimes referred to as clutch apply spring assemblies) and the C3/C4 piston return plate were updated starting with S/N

letter “B” stamped in the spring retainer. Reference SIL 9-WT-04.

E. Inspect the P1 ring gear

following the “General Inspection Guidelines for Gears” and General Inspection Guidelines for Splines” sections of this manual. Replace the ring gear if it fails any of these inspection procedures.

NOTE: The P1 ring gear end face

grind operation was eliminated starting with S/N 6610136125. The former P1 ring gear identifier is a groove machined on the outside diameter of the gear. The current P1 ring gear does not have a groove on the O.D. The current P1 ring gear is not compatible with aluminum wear plates riveted to the C3 housing and the clutch backplate. If the former P1 ring gear is replaced with the current P1 ring gear and the unit has aluminum wear plates, then the

wear plates will have to be updated to the current wear plates that are black in color. The former P1 ring gear (with the O.D. groove identifier) is compatible with the black wear plates. Do not replace the former P1 ring gear just because a unit has the black wear plates installed. Reference SIL 18-WT-04.

F. Inspect the clutch backplate

assembly following the “General

Inspection Guidelines for Cast Parts and Machined Surfaces” section of this manual. Replace the assembly if it fails any of these inspection procedures. Check the backplate and wear plates for flatness. Maximum allowable distortion is

0.15 mm (0.006 inch). Minimum allowable wear plate thickness is

2.82 mm (0.111 inch).

Stampings identify current components.

Housing in good condition - reuse.

Etched housing - do NOT use.

(continued)

 2005 General Motors Corporation.

ALLISON TRANSMISSION TECHNICIANS’ GUIDE

A. Inspect the C4 clutch housing

following the “General Inspection Guidelines for Cast Parts and Machined Surfaces” section of this manual. Replace the housing if it fails any of these inspection procedures. Check for C4 housing spline wear. Maximum allowable spline wear is 1.15 mm (0.045 inch). Replace the C4 housing if excessive spline wear exists.

NOTE: Aluminum castings (like

clutch housings) can be etched by caustic parts cleaners and solvents. Etched components are identified by a dull to dark gray color - not the bright finish of a normal machined aluminum part. Etched components are also identified by roughness in the piston seals to abrade and result in low clutch apply pressure and transmission damage. Replace etched or damaged components.

B. Inspect the C4 spring retainer

assembly following the “General

Inspection Guidelines for Cast Parts and Machined Surfaces” section of this manual. Inspect the assembly for wear due to rubbing adjacent parts and cracked, broken or permanently set springs. Reference the Spring Data Charts in the Service Manual for spring specifications and identification.

NOTE: The C3/C4 spring retainer

assemblies (sometimes referred to as clutch apply spring assemblies) and the C3/C4 piston return plate were updated starting with S/N

C. Inspect the C4 clutch friction

plates following the “General

Inspection Guidelines for Friction Plates” section of this manual. Replace any plates failing these inspection procedures. Minimum allowable friction plate thickness is

3.485 mm (0.137 inch). Maximum allowable plate coning is 0.25 mm (0.010 inch).

NOTE: Battered and worn spline

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

Inspect the C4 clutch reaction plates following the “General Inspection Guidelines for Reaction Plates” section of this manual. Replace any plates failing these inspection procedures. Minimum allowable reaction plate thickness is 2.41 mm (0.095 inch). Maximum allowable reaction plate coning is

0.25 mm (0.010 inch).

A. C4 Clutch

Housing

D. Piston

Return Plate and Spring Assembly

B. Spring

Retainer Assembly

C. C4

Clutch Pack

C4 Clutch Components

(continued)

Housing in good condition - reuse.

Etched housing - do NOT use.

ALLISON 4000/B500 PRODUCT FAMILIES

C3/C4 CLUTCH MODULE

(continued)

 2005 General Motors Corporation.

ALLISON TRANSMISSION TECHNICIANS’ GUIDE

ALLISON 4000/B500 PRODUCT FAMILIES

C3/C4 CLUTCH MODULE

(continued)

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 Allison Transmission. Do not intermix both former and current friction plates in a clutch pack.

Inspect the C4 piston return

plate and spring assembly

following the “General Inspection Guidelines for Reaction Plates” section of this manual. Minimum allowable plate thickness is 4.91 mm (0.193 inch). Replace springs which are cracked, broken or permanently set. Reference the Spring Data Charts in the Service Manual for spring specifications and identification.

NOTE: The C3/C4 spring retainer

assemblies (sometimes referred to as clutch apply spring assemblies) and the C3/C4 piston return plate were updated starting with S/N 6610137389. Do not mix former and current parts in the same clutch pack. The identifier for the current return plate is a letter “V” stamped in the face with an additional external spline on the outside diameter. The identifier for the current apply spring assembly is the letter “B” stamped in the spring retainer. Reference SIL 9-WT-04.

Supersession Information

C3/C4 Return Plate and C3/C4 Clutch Apply Spring Assembly Update SIL 9-WT-04

Former and current components can NOT be mixed in the same clutch pack.

ALLISON 4000/B500 PRODUCT FAMILIES

MAIN HOUSING

 2005 General Motors Corporation.

ALLISON TRANSMISSION TECHNICIANS’ GUIDE

A. Main Housing

(rear view)

Check for spline wear.

B. Splines

C. Fluid

Passages

A.Inspect the main housing

assembly following the “General Inspection Guidelines for Cast Parts and Machined Surfaces” and “General Inspection Guidelines for Splines” sections of this manual. Replace the housing if it fails any of these inspection procedures or if the damage cannot be repaired using a soft stone or crocus cloth.

B. Maximum C5 clutch spline

wear is 1.15mm (0.045 inch).

C. Inspect all fluid passages for

obstructions, porosity and cracks. Inspect bolt holes for stripped or damaged thread. Replace the housing if damage cannot be repaired.

(continued)

Oil Passage Detail: Main Housing (bottom view)

C6 Pressure C5 Pressure

C4 Pressure

C3 Pressure

Lube Pressure

Lock-up Pressure

Converter Out

C2 Pressure

C1 Pressure

Converter In

To Cooler

Main Pressure

From Cooler

Oil Passage Detail Main Housing Front View

Lube Pressure

Pump Suction

Lock-up Pressure

Converter Out

C2 Pressure

C1 Pressure

Converter In

Main Pressure

Control Main

Main Pressure

Lube Pressure

Suction

Wiring Harness Feedthrough

Oil Passage Detail Main Housing Back View

From Cooler

To Cooler

Exhaust

Control Main

Main C6 Pressure

C5 Pressure

 2005 General Motors Corporation.

ALLISON TRANSMISSION TECHNICIANS’ GUIDE

ALLISON 4000/B500 PRODUCT FAMILIES

MAIN HOUSING

(continued)

J. C6 Piston

Return Spring Assembly

I. C6

Clutch Piston

E. P4 Shaft

Flange

L. Output

Shaft

K. P4 Planetary

Assembly

G. P4 Ring

Gear

B. C6

Clutch Pack

F. P4 Sun

Gear

C. C6

Backplate

D. P4

Ring Gear Hub

H. C6 Clutch

Hub

A. Adapter

Housing

 2005 General Motors Corporation.

ALLISON TRANSMISSION TECHNICIANS’ GUIDE

A. Inspect the adapter housing

following the “General Inspection Guidelines for Cast Parts and Machined Surfaces” and “General Inspection Guidelines for Splines” section of this manual. Replace the housing if it fails any of these inspection procedures or if the damage cannot be repaired using a soft stone or crocus cloth. Maximum clutch spline wear is

1.15mm (0.045 inch). Inspect all fluid passages for obstructions, porosity and cracks. Inspect bolt holes for stripped or damage threads. Replace the housing if damage cannot be repaired.

B. Inspect the C6 clutch friction

plates following the “General

Inspection Guidelines for Friction Plates” section of this manual. Replace any plates failing these inspection procedures. Minimum allowable friction plate thickness is

3.68 mm (0.145 inch). Maximum allowable plate coning is 0.25 mm (0.010 inch).

NOTE: Battered and worn spline

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

Inspect the C6 clutch reaction plates following the “General

Inspection Guidelines for Reaction Plates” section of this manual. Replace any plates failing these inspection procedures. Minimum allowable reaction plate thickness is 3.24 mm (0.128 inch). Maximum allowable reaction plate coning is

0.25 mm (0.010 inch).

C. Inspect the clutch backplate

assembly following the “General

Inspection Guidelines for Cast Parts and Machined Surfaces” section of this manual. Replace the assembly if it fails any of these inspection procedures.

ALLISON 4000/B500 PRODUCT FAMILIES

C6 ADAPTER HOUSING MODULE

(continued)

 2005 General Motors Corporation.

ALLISON TRANSMISSION TECHNICIANS’ GUIDE

D. E. F. G. & H. Inspect the P4 ring

gear hub, P4 shaft flange, P4 sun gear, P4 ring gear and C6 clutch hub following the “General

Inspection Guidelines for Gears” and General Inspection Guidelines for Splines” sections of this manual. Replace any components failing any of these inspection procedures. Replace any components with damage which cannot be repaired using a soft stone or crocus cloth.

I. Inspect the C6 clutch piston

following the “General Inspection Guidelines for Cast Parts and Machined Surfaces” section of this manual. Replace the piston if it fails any of these inspection procedures.

NOTE: Aluminum castings (like

J. Replace the C6 return spring

assembly if it has permanent spring

set, wear due to rubbing adjacent parts or if springs are cracked or broken. Reference the Spring Data Charts in the Service Manual for

spring specifications and identification.

K. Inspect the P4 carrier

following the “General Inspection Guidelines for Cast Parts and Machined Surfaces” and the “General Inspection Guidelines for Splines” sections of this manual. Replace the carrier if it fails any of these inspection procedures. Replace the carrier if it fails any of these inspection procedures. Replace the carrier and spindles if the spindle bores are worn, out-ofround or otherwise damaged. Maximum allowable movement between the P4 carrier and P4 ring gear is 0.38mm (0.015 inch).

ALLISON 4000/B500 PRODUCT FAMILIES

C6 ADAPTER HOUSING MODULE

(continued)

Supersession Information

4070 Output Shaft Update Reference SIL 25-WT-01

Current output shaft requires current bearing retainer locknut and Belleville washer.

(continued)

Housing in good condition - reuse.

Etched housing - do NOT use.

J. C6 Piston

Return Spring Assembly

I. C6

Clutch Piston

E. P4 Shaft

Flange

L. Output

Shaft

K. P4 Planetary

Assembly

G. P4 Ring

Gear

B. C6

Clutch Pack

F. P4 Sun

Gear

C. C6

Backplate

D. P4

Ring Gear Hub

H. C6 Clutch

Hub

A. Adapter

Housing

 2005 General Motors Corporation.

ALLISON TRANSMISSION TECHNICIANS’ GUIDE

Inspect the P4 carrier indexing ring for wear and damage,

especially where the spindles make contact with the ring. Replace the indexing ring if it shows signs of spindle battering or has damage which cannot be repaired using a light stone.

Replace the pinion gear thrust washers if they are damaged, distorted or showing signs of overheating. Minimum allowable thrust washer thickness is 1.40 mm (0.055 inch).

Replace pinion spindles if they are damage or showing signs of overheating.

Inspect the P4 pinion gears following the “General Inspection Guidelines for Gears” section of this manual. Replace any gear that fails these inspection procedures or if damage cannot be repaired using a soft stone or crocus cloth.

Inspect the pinion roller bearings following the “General Inspection Guidelines for Bearings” section of this manual. Replace any bearing failing these inspection procedures.

L. Inspect the output shaft

following the “General Inspection Guidelines for Cast Parts and Machined Surfaces” and the “General Inspection Guidelines for Splines” sections of this manual. Replace the output shaft if it fails any of these inspection procedures. Inspect the output shaft bushing following the “General Inspection Guidelines for Bushings” section of this manual. Replace the bushing if it fails these inspection procedures. Maximum allowable bushing inside diameter is 36.14 mm (1.423 inch).

ALLISON 4000/B500 PRODUCT FAMILIES

(continued)

C6 ADAPTER HOUSING MODULE

ALLISON 4000/B500 PRODUCT FAMILIES

WEAR LIMITS AND SPRING DATA

 2005 General Motors Corporation.

ALLISON TRANSMISSION TECHNICIANS’ GUIDE

7–1. WEAR LIMITS DATA

A. Maximum Variations. Wear limit information in

this Section shows the maximum wear at which components are expected to function satisfactorily. Table 7–1 lists the Wear Limits Data and is referenced to the exploded views (Foldouts 4 through 12) in the back of this manual.

B. Cleaning and Inspection. Parts must be clean to

permit effective inspection for wear or damage. Refer to Section 3.

7–2. SPRING DATA

A. Spring Replacement. Springs should be replaced

if there are signs of overheating, wear due to rubbing

Table 7–1. Wear Limits Data Wear Limit

Illustration Description mm (inches)

Foldout 4,B TORQUE CONVERTER MODULE

10 Converter Cover Bushing, Maximum ID 66.91 2.634

adjacent parts, or permanent set. Discard springs which do not meet the load height speciÞcations according to Table 7–2, Spring Data.

B. Inspection. Inspection criteria (load vs. height)

and identiÞcation characteristics of the springs are presented in Table 7–2. The Spring Data are keyed to the exploded views (Foldouts 4 through 12) in the back of this manual.

NOTE:

When more than one spring part number is listed for the same location, refer to the HD/B 500/T 400 Series Parts Catalog PC2456EN to determine which spring is used in your specific assembly number.

12 Lockup Piston Assembly, Minimum Thickness 6.53 0.257

14 Damper Assembly Plate, Maximum Distortion 0.51 0.020

14 Damper Assembly Plate, Minimum Thickness 8.51 0.335

14, 18 Turbine-To-Damper, Maximum Spline Wear 0.38 0.015

15 Backplate, Maximum Distortion 0.15 0.006

15 Backplate, Minimum Wear Surface Thickness 11.79 0.464

18 Turbine Hub, Minimum OD 66.69 2.626

19 Turbine Hub Sealring, Maximum ID 61.77 2.432

24 Stator Thrust Plate, Minimum Thickness 9.45 0.372

36 Converter Pump Hub, Minimum OD 88.99 3.504

Foldout 5,B

6 Bearing Retainer Bushing, Maximum ID 89.19 3.511

8, 14 Oil Pump Drive Hub Seal, Minimum End Gap 1.18 0.047

8, 14 Oil Pump Drive Hub Seal, Maximum End Gap 1.66 0.065

13 Oil Pump Drive Hub, Maximum Tang Wear 0.31 0.012

TORQUE CONVERTER HOUSING MODULE — PTO EQUIPPED

ALLISON 4000/B500 PRODUCT FAMILIES

(continued)

WEAR LIMITS AND SPRING DATA

 2005 General Motors Corporation.

ALLISON TRANSMISSION TECHNICIANS’ GUIDE

Table 7–1. Wear Limits Data (cont’d) Wear Limit

Illustration Description mm (inches)

Foldout 6,A FRONT SUPPORT AND CHARGING PUMP MODULE

8 Pump Housing Bushing, Maximum ID 89.19 3.511

9, 10 Pump Housing Gear, Maximum Cavity Depth 19.04 0.750

9, 10 Pump Housing Gear, Maximum Cavity Diameter 150.25 5.915

9, 10, 11 Driven Gear-To-Pump Housing, Maximum Diametric Clearance 0.30 0.012

9, 10, 13 Gear-To-Plate, Maximum Side Clearance 0.10 0.004

11 Gear Set, Maximum Gear Tooth Tip Clearance 0.15 0.006

12 Pump Gear Bushing, Maximum ID 66.93 2.635

16, 17 Ground Sleeve, Minimum OD In Bushing Area 66.67 2.625

16, 17, 20 Spline OD, Maximum Total Runout 0.13 0.005

20 Front Support, Minimum OD 119.81 4.717

25 Front Support Seal, Minimum End Gap 1.00 0.040

25 Front Support Seal, Maximum End Gap 1.44 0.056

Foldout 6,B

5 Turbine Shaft Bushing, Maximum ID 36.14 1.423

8 Turbine Seal, Minimum End Gap 0.65 0.026

8 Turbine Seal, Maximum End Gap 1.01 0.039

9 Drum Spline, Maximum Wear 0.38 0.015

12 Rotating Clutch Hub Bushing, Maximum ID 120.27 4.735

29 C1 Clutch Apply Plate, Minimum Thickness 5.90 0.232

29, 39 C1 Clutch Apply Plate or C2 Backplate, Maximum Distortion 0.15 0.006

30, 38 C1, C2 Friction Plate, Maximum Cone 0.25 0.010

30, 38 C1, C2 Friction Plate, Minimum Thickness 2.92 0.115

30, 38 C1, C2 Friction Plate, Minimum Oil Groove Depth 0.20 0.008

31, 37 C1, C2 Reaction Steel Plate, Maximum Cone 0.25 0.010

31, 37 C1, C2 Reaction Steel Plate, Minimum Thickness 2.41 0.095

ROTATING CLUTCH MODULE

32 C1 Clutch Backplate, Minimum Thickness @ ID 9.90 0.390

34, 36 C1, C2 Drive Hub, Maximum Spline Wear 0.38 0.015

39 C2 Backplate, Minimum Thickness 7.90 0.311

39 C2 Backplate, Maximum Distortion 0.15 0.006

ALLISON 4000/B500 PRODUCT FAMILIES

WEAR LIMITS AND SPRING DATA

(continued)

 2005 General Motors Corporation.

ALLISON TRANSMISSION TECHNICIANS’ GUIDE

Table 7–1. Wear Limits Data (cont’d) Wear Limit

Illustration Description mm (inches)

Foldout 7 MAIN HOUSING MODULE

4 Backplate, Maximum Step Wear 0.13 0.005

4 Backplate, Maximum Distortion 0.15 0.006

5, 18 P1 Ring Thrust Plate, Minimum Thickness At Wear Point 2.82 0.111

7 P1 Ring Gear Spline, Maximum Wear 0.38 0.015

8, 21, 29 C3, C4, C5 Friction Plate, Maximum Cone 0.25 0.010

8, 21, 29 C3, C4, C5 Friction Plate, Minimum Thickness 3.485 0.137

9, 20, 30 C3, C4, C5 Reaction (Steel) Plate, Maximum Cone 0.25 0.010

9, 20, 30 C3, C4, C5 Reaction (Steel) Plate, Minimum Thickness 2.41 0.095

11, 23 C3, C4 Piston Return Plate, Minimum Thickness 4.91 0.193

19, 28 C3, C4 Clutch Housings, Maximum Spline Wear 1.15 0.045

43 Main Housing, Maximum Spline Wear 1.15 0.045

Foldout 8

7, 8 Main Shaft Bearing Journal, Minimum OD 52.98 2.085

7, 8 Main Shaft Pilots (both ends), Minimum OD 35.92 1.414

Foldout 9,A P1 PLANETARY MODULE

3 P1 Planetary Carrier Assembly, Maximum Pinion End Play 0.94 0.037

9 P1 Carrier Bushing, Maximum ID 89.32 3.516

10, 13 P1 Pinion Thrust Washer, Minimum Thickness 1.40 0.055

10, 13 P1 Pinion Thrust Washer, Maximum Step Wear 0.12 0.005

15 P2 Ring Gear Spline, Maximum Wear 0.38 0.015

Foldout 9,B P2 PLANETARY MODULE

1 P2 Planetary Carrier Assembly, Maximum Pinion End Play 0.94 0.037

8 P2 Carrier Bushing, Maximum ID 53.23 2.096

9, 12 P2 Pinion Thrust Washer, Minimum Thickness 1.40 0.055

9, 12 P2 Pinion Thrust Washer, Maximum Step Wear 0.12 0.005

MAIN SHAFT MODULE — WIDE RATIO AND CLOSE RATIO

15 P3 Ring Gear Spline, Maximum Wear 0.38 0.015

Foldout 9,C P3 PLANETARY AND C6 ADAPTER HOUSING MODULE

(HD 4070/4076 MODELS)

1 P3 Carrier Module, Maximum Pinion End Play 0.94 0.037

8 P3 Pinion Thrust Washer, Minimum Thickness 1.40 0.055

8 P3 Pinion Thrust Washer, Maximum Step Wear 0.12 0.005

27 C6 Reaction Plate, Minimum Thickness 3.24 0.128

27, 28 C6 Friction and Reaction Plate, Maximum cone 0.25 0.010

28 C6 Friction Plate, Minimum Thickness 3.68 0.145

32 P4 Carrier Assembly, Maximum Pinion End Play 0.94 0.037

38 P4 Carrier Bushing, Maximum ID 113.33 4.462

40 P4 Planetary Thrust Washer, Minimum Thickness 1.40 0.055

40 P4 Planetary Thrust Washer, Maximum Step Wear 0.12 0.005

Foldout 10,A

RETARDER AND P3 MODULE (HD PRODUCT LINE MODELS PRIOR TO S/N 6610066447)

3 P3 Planetary Carrier Assembly, Maximum Pinion End Play 0.94 0.037

5 Output Shaft Bushing, Maximum ID 36.14 1.423

13, 16 P3 Pinion Thrust Washer, Minimum Thickness 1.40 0.055

13, 16 P3 Pinion Thrust Washer, Maximum Step Wear 0.12 0.005

27, 30 Retarder Rotor Sealring, Maximum ID 139.72 5.501

29 Rotor Hub, Maximum Spline Wear 0.38 0.015

Foldout 10,B REAR COVER AND P3 MODULE

5 P3 Planetary Carrier Assembly, Maximum End Play 0.94 0.037

7 Output Shaft Bushing, Maximum ID 36.14 1.423

8 Output Shaft, Maximum Spline Wear 0.38 0.015

15, 18 P3 Pinion Thrust Washer, Minimum Thickness 1.40 0.055

15, 18 P3 Pinion Thrust Washer, Maximum Step Wear 0.12 0.005

Table 7–1. Wear Limits Data (cont’d) Wear Limit

Illustration Description mm (inches)

(EXCEPT HD 4070/4076 MODELS)

ALLISON 4000/B500 PRODUCT FAMILIES

(continued)

WEAR LIMITS AND SPRING DATA

 2005 General Motors Corporation.

ALLISON TRANSMISSION TECHNICIANS’ GUIDE

ALLISON 4000/B500 PRODUCT FAMILIES

WEAR LIMITS AND SPRING DATA

(continued)

 2005 General Motors Corporation.

ALLISON TRANSMISSION TECHNICIANS’ GUIDE

Table 7–1. Wear Limits Data (cont’d) Wear Limit

Illustration Description mm (inches)

Foldout 10,C RETARDER AND OUTPUT SHAFT MODULE

(HD 4070/4076 MODELS

4 Output Shaft Bushing, Maximum ID 36.14 1.423

5 Output Shaft, Maximum Spline Wear 0.38 0.015

16, 19 Retarder Rotor Sealring, Maximum ID 139.72 5.501

18 Rotor Assembly 0.38 0.015

Foldout 10,D REAR COVER & OUTPUT SHAFT MODULE

(HD 4070/4076 MODELS)

7 Output Shaft Bushing, Maximum ID 36.14 1.423

8 Output Shaft, Maximum Spline Wear 0.38 0.015

Foldout 10,E RETARDER AND P3 MODULE (ALL MODELS

EXCEPT HD 4070/4076

PRIOR TO S/N 6610066447)

STARTING WITH S/N 6610066447)

3 P3 Planetary Carrier Assembly, Maximum Pinion End Play 0.94 0.037

5 Output Shaft Bushing, Maximum ID 36.14 1.423

13, 16 P3 Pinion Thrust Washer, Minimum Thickness 1.40 0.055

13, 16 P3 Pinion Thrust Washer, Maximum Step Wear 0.12 0.005

27, 30 Retarder Rotor Sealring, Maximum ID 139.72 5.501

29 Rotor Hub, Maximum Spline Wear 0.38 0.015

Foldout 10,F RETARDER AND OUTPUT SHAFT MODULE

(HD 4070/4076 MODELS

4 Output Shaft Bushing, Maximum ID 36.14 1.423

5 Output Shaft, Maximum Spline Wear 0.38 0.015

16, 19 Retarder Rotor Sealring, Maximum ID 139.72 5.501

18 Rotor Assembly 0.38 0.015

Foldout 12,A OUTPUT FLANGE AND YOKE

1, 2, 8 Output Seal Journal, Minimum OD 85.0 3.346

STARTING WITH S/N 6610066447)

Table 7–1. Spring Data

Approx.

Free

Length

mm (in.)

Length under load

Foldout Ref. Spring Part No. Color Code

No. of

Coils

Wire Dia

mm (in.)

Spring

mm (in.)

(in.)

(lb)

4,B 27 Stator 29501300 No Code N/A N/A N/A 17.8

(0.70)

5.7 (0.224)

0.9 (0.2)

6,A 22 Main Relief 29507709 No Code 10 3.25

(0.128)

17.96 (0.707)

52.4 (2.06)

40.7 (1.60)

474

(106.5)

6,B 20 C2 Return 29505719 No Code 11.5* 2.04*

(0.080)

19.06*

(0.750)

70.76*

(2.786)

28.2 (1.110)

5185**

(1165.6)

6,B 25 C1 Return 29509453 No Code 12* 2.10*

(0.083)

16.0* (0.630)

57.53*

(2.265)

34.8 (1.37)

4649**

(1045.4)

6,B 25 C1 Return 29537301 No Code 11.8* 2.17*

(0.085)

16.8* (0.661)

52.89*

(2.082)

34.5 (1.358)

4893**

(1100.0)

7 10 C3 Return 29506206 No Code 13* 2.10*

(0.083)

15.0* (0.590)

52.3*

(2.06)

35.4 (1.39)

274.4**

(61.69)

7 12 C3 Retainer 29507882 No Code 4* 2.36*

(0.093)

12.62*

(0.497)

11.2*

(0.44)

9.3 (0.37)

16 408**

(3689)

7 12 C3 Retainer 29515628 No Code 4* 2.36*

(0.093)

12.62*

(0.497)

11.1*

(0.44)

10.40

(0.41)

15 403**

(3463)

7 22 C4 Return 29506206 No Code 13* 2.10*

(0.083)

15.0* (0.590)

52.3*

(2.06)

35.4 (1.39)

274.4**

(61.69)

7 24 C4 Retainer 29507882 No Code 4* 2.36*

(0.093)

12.62*

(0.497)

11.2*

(0.44)

9.3 (0.37)

16 408**

(3689)

7 24 C4 Retainer 29515628 No Code 4* 2.36*

(0.093)

12.62*

(0.497)

11.1*

(0.44)

10.40

(0.41)

15 403**

(3463)

9,C 17 C5 Return 29530488 No Code 11.6* 2.03*

(0.080)

17.00*

(0.669)

53.80

(2.11)

37.7 (1.48)

3611**

(811.8)

10,A

through F

20, 22, 9, 12,

20, 9

C5 Return 29503036 No Code 12* 2.10*

(0.083)

17.00* 57.3*

(2.26)

37.6 (1.48)

3086**

(693.8)

10,A 35 Retarder Flow Valve 29512751 Silver (End) 10.5 2.16

(0.085)

19.05 (0.750)

61.5 (2.42)

25.9 (1.020)

186.9 (42.02)

* Individual springs

** For the complete spring assembly

ALLISON 4000/B500 PRODUCT FAMILIES

(continued)

WEAR LIMITS AND SPRING DATA

 2005 General Motors Corporation.

ALLISON TRANSMISSION TECHNICIANS’ GUIDE

ALLISON 4000/B500 PRODUCT FAMILIES

WEAR LIMITS AND SPRING DATA

(continued)

 2005 General Motors Corporation.

ALLISON TRANSMISSION TECHNICIANS’ GUIDE

(lb)

133.4 (29.99)

(in.)

73.66

Length under load

Free

Length

Approx.

Spring

Wire Dia

(2.900)

106.68

(4.200)

mm (in.)

36.58 (1.440)

mm (in.)

(0.149)

mm (in.)

213.3 (47.95)

91.1 (3.587)

114.3 (4.500)

36.17 (1.424)

(0.162)

2.67

18.2

29.2

8.00

(0.60)

18.0

(0.716)

30.8

(1.15)

15.1

(0.315)

(0.024)

(7.42)

18.0

(0.71)

33.69

(1.212)

15.09

(0.594)

(0.055)

(9.0)

(0.71)

(1.326)

(0.594)

(0.055)

(9.9)

18.0 (0.71)

27.8 (1.09)

15.50 (0.610)

(0.063)

(0.7)

3.45 (0.14)

6.5 (0.26)

11.05†

(0.440)

(0.026)

49.8 (11.2)

20.0 (0.79)

43.6 (1.72)

11.68 (0.460)

(0.050)

49.8 (11.2)

20.0 (0.79)

43.6 (1.72)

11.68 (0.460)

(0.050)

12.0

12.5

26.6

7.75

(2.7)

17.0

(0.49)

42.1

(1.05)

14.1

(0.305)

(0.030)

(11.0)

3.5

(0.67)

46.3

(1.66)

11.1

(0.555)

(0.054)

305

(10.6)

(68.6)

54.6

(0.93)

(2.15)

98.5

(1.82)

(3.88)

22.00

(0.437)

(0.866)

(0.048)

(0.113)

Table 7–1. Spring Data (cont’d)

Coils

No. of

Retarder Flow Valve 29515692 No Code 11.4 4.12

Exhaust BackÞll 23049391 No Code 20.4 0.61

35, 25, 35,

76, 56, 75,

7.5 1.40

(on end)

Retarder Control 29512792 Lt. Green

81, 65, 80,

Solenoid Regulator 29502195 No Code 4 0.67

152, 167

101, 120,

10,A 35 Retarder Flow Valve 29515101 Green 16 3.78

Foldout Ref. Spring Part No. Color Code

and F

10,A, C, E,

10,A 81 Retarder Control 29510495 Silver 7.5 1.40

and F

10,A, C, E,

10,A 81 Retarder Control 29510494 Orange 7 1.60

and F

10,A, C, E,

11,A 112 Accumulator Relay 29507455 Silver 12.8 1.28

11,A and

Fig. 5–31

11,A 112 Accumulator Relay 28537452 Dark Blue 12.8 1.275

11,A 127 Overdrive 23049332 Orange 12 0.76

11,B 134 Lockup 23049326 Yellow 10 1.37

11,B 138 Lube Regulator 23049327 Red 13 1.22

11,B 142 Main Regulator 29500963 Lt. Blue 15 2.87

ALLISON 4000/B500 PRODUCT FAMILIES

(continued)

WEAR LIMITS AND SPRING DATA

 2005 General Motors Corporation.

ALLISON TRANSMISSION TECHNICIANS’ GUIDE

131

(lb)

(29.5)

24.0

(in.)

Length under load

Free

Length

Approx.

Spring

Wire Dia

(0.95)

44.6 (1.76)

mm (in.)

14.8 (0.583)

mm (in.)

(0.072)

mm (in.)

71.0 (16.0)

19.0 (0.75)

41.3 (1.63)

11.43 (0.450)

(0.052)

18.2

29.2

7.80

(0.5)

29.2

(0.72)

46.2

(1.14)

16.26

(0.307)

(0.024)

(4.0)

22.8

(1.15)

30.3

(1.82)

11.00

(0.640)

(0.054)

(12.1)

(0.90)

(1.19)

(0.433)

(0.060)

Table 7–1. Spring Data (cont’d)

Coils

No. of

Foldout Ref. Spring Part No. Color Code

11,B 146 Control Main 23049325 Orange 10 1.83

11,B 156 C2 Latch 29501071 Lt. Green 11 1.32

11,B 160 Exh. Back 23049391 No Code 17 0.61

11,B 164 C1 Latch 6885065 Blue 12 1.37

11,B 168 Converter Regulator 29507456 Pink 10.2 1.53

ALLISON 4000/B500 PRODUCT FAMILIES

NOTES

 2005 General Motors Corporation.

ALLISON TRANSMISSION TECHNICIANS’ GUIDE

GENERAL INSPECTION GUIDELINES FOR

TORQUE CONVERTER MODULE

80 ALLISON TRANSMISSION TECHNICIANS’ GUIDE

Allison T ransmission

General Motors Corporation

Indianapolis, IN 46206-0894

1-800-252-5283

www.allisontransmission.com

 2005 General Motors Corporation.

(5/05)

GN4065EN

INSPECTION AND ANALYSIS OF THE

ALLISON 4000 & B500 PRODUCT FAMILIES

TECH

GUIDE

GN4065EN

(5/05)

Allison Transmission 4000, B 500 Service Manual

Specifications and Main Features

Frequently Asked Questions

User Manual