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

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ALLISON 1000/2000 SERIES

INDEX

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

COMPONENT REBUILD

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

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

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

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

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

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

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

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

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

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

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

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

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

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

AUTOMATIC TRANSMISSION SERVICE GROUP

18639 S.W. 107TH AVENUE

MIAMI, FLORIDA 33157

(305) 670-4161

Updated

October, 2003

INTRODUCTION

ALLISON 1000/2000 SERIES

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

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

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

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

"Portions of materials contained herein have been reprinted under

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

The information and part numbers contained in this booklet have

been carefully compiled from industry sources known for their

reliability, but ATSG does not guarantee its accuracy.

DALE ENGLAND

FIELD SERVICE CONSULTANT

WAYNE COLONNA

TECHNICAL SUPERVISOR

PETER LUBAN

TECHNICAL CONSULTANT

JON GLATSTEIN

TECHNICAL CONSULTANT

JERRY GOTT

TECHNICAL CONSULTANT

GERALD CAMPBELL

TECHNICAL CONSULTANT

JIM DIAL

TECHNICAL CONSULTANT

ED KRUSE

TECHNICAL CONSULTANT

GREGORY LIPNICK

TECHNICAL CONSULTANT

DAVID CHALKER

TECHNICAL CONSULTANT

MIKE SOUZA

TECHNICAL CONSULTANT

ROLAND ALVAREZ

TECHNICAL CONSULTANT

AUTOMATIC TRANSMISSION SERVICE GROUP

18639 S.W. 107TH AVENUE

MIAMI, FLORIDA 33157

(305) 670-4161

1

Technical Service Information

ALLISON 1000/2000 SERIES

Engine Speed

Sensor

Turbine Speed

Sensor

AllisonAllison

Output Speed

Sensor

Neutral Start

Switch

Engine Speed

Sensor

TWO WHEEL DRIVE

Turbine Speed

Sensor

AllisonAllison

Neutral Start

Switch

FOUR WHEEL DRIVE

Figure 1

AUTOMATIC TRANSMISSION SERVICE GROUP

3

Technical Service Information

ALLISON 1000/2000 SERIES TRANSMISSION

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

"C1" CLUTCH

"C5" CLUTCH

C1

Range

Park Reverse X Neutral

OD-1st

OD-2nd

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

X = Electrical Power Applied To Solenoid

= Apply Solenoid "F" To Apply Converter Clutch

*

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

**

holding pressure to the five clutch packs.

Clut

ON ON ON ON ON

4

C2

ClutC3ClutC4ClutC5Clut

ONON ON ONON

ON

AUTOMATIC TRANSMISSION SERVICE GROUP

Sol

"A"

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

Figure 2

Sol

"B"

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

**

Sol

"C"

X

X X

Sol

"D"

XXON

X X

Sol

"E"

X X X

Sol

"F"

* *

X X

* ***

Ratios

1000 2000

4.49

3.10

1.81

1.41

1.00

0.71

5.09

3.51

1.90

1.44

1.00

0.74

Technical Service Information

ALLISON IDENTIFICATION TAG LOCATION

9 .8

9

.8

9

.8

W A U

3 3 9

X

n

X

n

.

X

P

o

R

X

-

i

O

X

C

X

s

S

X

R

iso

X

s

O

l

A

i

X

T

l

O

X

AN

-

M

X

L

X

m

X

A

NDI

X

I

A

R

s

X

,

X

S

NE

I

X

E

n

L

X

G

-

O

X

P

a

X

A

OF

X

N

r

X

A

O

I

X

S

T

I

ND

X

V

X

I

-

I

X

D

X

X X X

X

-

X

L

X

E

X

X D I

X

OD

T

X

S

M

-

IE

X

R

X

E

X

E

S

T

X

0

-

DA

0

.

X

1

X

O

X

N

X

L

1

A

2

I

F

X

R

9

X

E

9

S

X

N

X

FC

X

E

X

X X

X

9 . 8

9 .

8

9 . 8

MODEL

1000 SERIES 99F21 X X

SERIAL NO.

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

Allison

TransmissionTransmission

DIVISION OF GENERAL MOTORS CORP.

INDIANAPOLIS, INDIANA

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

DATE

EFCN

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

TID

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

UAW

933

Figure 3

TRANSMISSION IDENTIFICATION TAG

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

1000

Series

2000

Series

2400

Series

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

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

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

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

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

Special Note:

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

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

AUTOMATIC TRANSMISSION SERVICE GROUP

5

Technical Service Information

GENERAL DESCRIPTION AND OPERATION

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

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

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

TYPICAL MANUAL SHIFT TOWER

DO NOT

SHIFT

P R N D 4 2 1

DO NOT

SHIFT

Figure 4

6

AUTOMATIC TRANSMISSION SERVICE GROUP

Technical Service Information

ALL 1000 AND 2400 SERIES

Shift Selector Position

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

* With Park Pawl Engaged

** 4 Speed Calibration or Trailering Mode

Gears

Available

Neutral*

Reverse

Neutral

1-5 1-4 1-3 1st

Selector

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

ALL 2000 SERIES "WITH" AUTO-APPLY PARKING BRAKE

Shift Selector Position

PB = (Park) R (Reverse)

Gears

Available

Neutral*

Reverse

Selector

Position PB = (Park) R (Reverse)

Shift

Gears

Available

Neutral*

Reverse

Neutral

1-5 1-4 1-2 1st

Gears

Available

Neutral*

Reverse

Shift Selector Position

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

Shift Selector Position

PB = (Park) R (Reverse)

Gears

Available

Neutral*

Reverse

Neutral

1-5 (1-4)**

1-3 1-2 1st

Gears

Available

Neutral*

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

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

Neutral

1-5 1-4 1-3 1st

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

ALL 2000 SERIES "WITHOUT" AUTO-APPLY PARKING BRAKE

Shift Selector Position

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

Gears

Available

Reverse

Neutral

1-5 1-4 1-3

Selector

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

Shift

Neutral

1-5 1-4 1-2 1st

Gears

Available

Reverse

Neutral

1-5 1-4 1-2

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

Shift Selector Position

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

Neutral

1-5 (1-4)**

1-3 1-2 1st

Gears

Available

Reverse

Neutral

1-5 (1-4)**

1-3 1-2

1 (First)

** 4 Speed Calibration or Trailering Mode

1st

1 (First)

AUTOMATIC TRANSMISSION SERVICE GROUP

Figure 5

1st

1 (First)

1st

7

Technical Service Information

TYPICAL TRANSMISSION CONTROL MODULE

AND VEHICLE HARNESS

TRANSMISSION CONTROL

MODULE (TCM)

TRANSMISSION (J2)

HARNESS

"J2"

CONNECTOR

(RED)

"J1"

CONNECTOR

(GRAY)

VEHICLE (J1)

HARNESS

J 1939

CONNECTOR

(OPTIONAL)

VIW "X"

CONNECTOR

VIW "Y"

CONNECTOR

GP 19

CONNECTOR

THROTTLE

POSITION

SENSOR (TPS)

Actual harness configuration may differ from this illustration.

TPS

CONNECTOR

TURBINE

SPEED SENSOR

CONNECTOR

7 PIN

4 PIN

NSBU SWITCH CONNECTORS

OUTPUT

SPEED SENSOR

CONNECTOR

ENGINE

SPEED SENSOR

CONNECTOR

Figure 6

8

AUTOMATIC TRANSMISSION SERVICE GROUP

Technical Service Information

ELECTRICAL OPERATION

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

EXTERNAL COMPONENTS

SPEED SENSORS

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

ENGINE SPEED SENSOR

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

TURBINE SPEED SENSOR

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

OUTPUT SPEED SENSOR

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

TYPICAL SPEED SENSOR

Figure 7

AUTOMATIC TRANSMISSION SERVICE GROUP

9

Technical Service Information

THROTTLE POSITION SENSOR

C

B

A

Figure 8

THROTTLE POSITION SENSOR

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

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

TPS

Throttle Position

Sensor

(TPS)

Connector

Green, Ground

A

Blue, Signal Ret.

B

Pink, 5V Supply

C

TCM "J2" (RED)

Connector

Transmission

Control Module

(TCM)

20

9

19

(TPS) Distance of Travel Versus Volts

mm/inch

0/0

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

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

14/.551"

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

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

46/1.811"

Volts

0

0.11

0.22

0.33

0.44

0.55

0.66

0.77

0.88

0.99

1.10

1.20

1.30

1.43

1.54

1.65

1.76

1.87

1.98

2.08

2.19

2.30

2.41

2.52

2.63

2.74

2.85

2.96

3.07

3.18

3.29

3.40

3.51

3.62

3.73

3.84

3.95

4.06

4.17

4.28

4.39

4.50

4.61

4.72

4.83

4.94

5.05

10

Figure 10Figure 9

AUTOMATIC TRANSMISSION SERVICE GROUP

Technical Service Information

NEUTRAL START BACK-UP SWITCH

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

NSBU SWITCH WIRE SCHEMATIC

NSBU SWITCH RANGE CHART ON SCAN TOOL

Range A B C P

P R

N D

3 2 1

OFF OFF

ON

ON OFF OFF

ON

ON ON

OFF OFF OFF

OFF

ON ON

ON

ON OFF OFF

OFF OFF

OFF

ON

OFF

ON

OFF

ON

OFF

NEUTRAL START BACK-UP SWITCH

Figure 11

Rev/Park Accessory

Battery Feed

PK/NEUT Start

Battery Feed

7-Way NSBU

Switch Receptacle

(Face View)

4-Way NSBU

Switch Receptacle

(Face View)

Park Accessory

Back-up Lamps

Not Used

A

G

B

F

C

E

D

C

A

D

B

Harness Connectors

A

G

B

F

C

E

D

C

A

D

B

NSBU Switch

(Face View)

A

B C

E F G

D

A

B C

D

Tan

Blue

Yellow

Pink

Orange

Green

Blue Gray

White Yellow

TCM "J2" (RED)

Connector

20

5

7 8

6

Starter

Relay

Transmission

Control Module

(TCM)

Figure 12

AUTOMATIC TRANSMISSION SERVICE GROUP

11

TCM "J2" (Red)

Receptacle

Technical Service Information

RED

R

ED

G

GR

R

A

Y

TCM "J1" (Gray)

Receptacle

TRANSMISSION CONTROL MODULE (TCM)

S

IS

TO

SSI

D TO

N

ND

U

CHASS

U

CHA

E

O

E

N

L

R

RO

C

ICL

I

IO

H

T G

T

TIO

EH

O

U

OT G

VE

V

N

A

AU

N

O

C

D

1322313304295286278251023122114

TCM "J2" (Red)

Receptacle

14

13

151816

19

20

17

9

11

25

23

21

24

22

10

12

TCM "J2" (Red)

Harness Connector

(Face View)

72692411221320151816

7

26

1322313304295286278

1322313304295286278251023122114

19

17

72692411221320151816

19

17

TCM "J1" (Gray)

Receptacle

14

11

13

151816

21

19

22

20

17

7269

25

23

24

10

12

1322313304295286278

TCM "J1" (Gray)

Harness Connector

(Face View)

12

Figure 13

AUTOMATIC TRANSMISSION SERVICE GROUP

Technical Service Information

TCM CONNECTOR PIN IDENTIFICATION CHART

14

11

13

151816

21

19

22

20

17

7269

25

23

24

10

12

TCM "J2" (Red)

Harness Connector

(Face View)

Term. Term.Color ColorCircuit Ends Circuit Ends

Blue Trans-D Vehicle System

1 1 2 2

Pink

3 3

White

4 4

Green

Blue

5 5

Yellow

6 6

Gray

7 7

White

8 8

Blue

9 9

10 10

Orange

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

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

Blue

Orange

Blue Yellow Green

Orange

Pink Green

Yellow Yellow White

Pink

Orange

Green

Blue

Gray

White

Orange

Green

Circuit Function Circuit Function

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

Tan

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

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

1322313304295286278

Trans-F Trans-E

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

TPS-B

Trans-G

R Temp-A

ECTS-A

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

Trans-H, ECTS-A,

Temp-B, NSBU-7D

R-Temp-B, TPS-A

Trans-T

Trans-L

Trans-M Trans-N

Trans-P

Trans-A

Trans-B

Trans-W

Trans-J

Trans-J Trans-C Trans-S

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

Gray

Yellow

Pink

Yellow

Gray

Blue

Orange

Green White

Yellow

Green

Blue Pink

Orange

Yellow

White

Pink

Green

Tan

Orange

White

Blue

Pink White Green

Tan

Pink

Yellow

Red

Blue Green

Black

14

11

13

151816

21

19

22

20

17

7269

25

23

24

10

12

TCM "J1" (Gray)

Harness Connector

(Face View)

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

1322313304295286278

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

RMR-B

Vehicle System

RMR-C

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

J 1939 A or H

Vehicle System

J 1939 C or S J 1939 B or L

Figure 14

AUTOMATIC TRANSMISSION SERVICE GROUP

13

DTC Description

Technical Service Information

DIAGNOSTIC TROUBLE CODE (DTC) CHART

"Check Trans"

Light

P0117

P0118

P0121

P0122

P0123

P0218

P0561

P0562 P0563

P0602

P0606

P0700

P0703

P0705

P0706

P0708

P0711

P0712

P0713

P0716

P0717

P0721

P0722

P0726

P0727

P0731

P0732

P0733

P0734

P0735

P0736

P0741

P0742

P0746

P0747 YES

P0763

P0768

P0776 YES

P0777 YES

Engine Coolant Temperature Circuit Low Voltage (High Temperature)

Engine Coolant Temperature Circuit High Voltage (Low Temperature)

Throttle Position Sensor Performance Problem

Throttle Position Sensor Circuit Low Voltage

Throttle Position Sensor Circuit High Voltage

Transmission Fluid Over Temperature

Urealistic variations in vehicle system voltage

System Voltage Low System Voltage High

TCM Not Programmed

Transmission Control Module Internal Performance

MIL Illumination requested

Brake Switch Circuit

Transmission Range Sensor Circuit (PRNDL Input)

Transmission Range Sensor Circuit Performance

Transmission Range Sensor Circuit High Input

Transmission Fluid Temperature Circuit Performance

Transmission Fluid Temperature Circuit Low Voltage (High Temperature)

Transmission Fluid Temperature Circuit High Voltage (Low Temperature)

Turbine Speed Sensor Circuit Performance

Turbine Speed Sensor Circuit No Signal

Output Speed Sensor Circuit Performance

Output Speed Sensor Circuit No Signal

Engine Speed Sensor Circuit Performance

Engine Speed Sensor Circuit No Signal

Incorrect 1st Gear Ratio

Incorrect 2nd Gear Ratio

Incorrect 3rd Gear Ratio

Incorrect 4th Gear Ratio

Incorrect 5th Gear Ratio

Incorrect Reverse Gear Ratio

Torque Converter Clutch System Stuck Off

Torque Converter Clutch System Stuck On

Torque Converter Clutch Solenoid ElectricalP0742 YES

Solenoid A controlled Clutch Stuck Off

Solenoid A controlled Clutch Stuck On

Pressure Control Trim Solenoid "A" ElectricalP0748 YES

Shift Solenoid "C" Electrical

Shift Solenoid "D" Electrical

Shift Solenoid "E" ElectricalP0773 YES

Solenoid B controlled Clutch Stuck Off

Solenoid B controlled Clutch Stuck On

NO

YES

YES YES

YES

NO

YES

14

Figure 15

AUTOMATIC TRANSMISSION SERVICE GROUP

DTC Description

Technical Service Information

DIAGNOSTIC TROUBLE CODE (DTC) CHART

"Check Trans"

Light

P0778

P0836

P0840

P0841 P0842

P0843

P0845

P0846

P0847

P0848

P1688 P1709 P1710 P1711

P1712 P1713

P1714

P1715

P1716 P1720 P1721 P1723

P1724 P1726

P1727 P1760

P1835

P1860

P1891

Pressure Control Trim Solenoid "B" Electrical

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

Transmission Pressure Switch, Solenoid C Circuit

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

Transmission Pressure Switch, Solenoid C Circuit High

Transmission Pressure Switch, Solenoid D Circuit

Transmission Pressure Switch, Solenoid D Circuit Stuck Open

Transmission Pressure Switch, Solenoid D Circuit Stuck Closed

Transmission Pressure Switch, Solenoid D Circuit High

Transmission Pressure Switch, Solenoid E Circuit HighP0870 YES

Transmission Pressure Switch, Solenoid E Circuit Stuck OpenP0871 YES

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

Reverse Pressure Switch MalfunctionP0875 YES

Reverse Pressure Switch Circuit Stuck OpenP0876 YES

TCM Power Input SignalP0880 YES

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

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

Transmission Pressure Switch, Reverse Circuit Stuck Open

Transmission Pressure Switch, Reverse Circuit Stuck Closed

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

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

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

Kickdown Circuit

TCC (PWM) Solenoid Circuit-Electrical

Throttle Position Sensor Clutch PWM Signal Low Input

YES

YES YES

YES

YES YES YES YES

YES YES

YES

YES YES YES YES

YES YES

YES

NO

YES

NO

P1892

U1016

U1300

U1301

U2105

Throttle Position Sensor Clutch PWM Signal High Input

Class 2 Powertrain Controller State Of Health

Serial Data Communication Link Low (Class 2)

Serial Data Communication Link High (Class 2)

CAN Bus Error ECM

Figure 16

AUTOMATIC TRANSMISSION SERVICE GROUP

NO

15

Technical Service Information

SOLENOID LOCATIONS

Shift Solenoid "E"

(Normally Closed)

Shift Solenoid "C"

(Normally Closed)

Trim Solenoid "A"

(Normally Closed)

Trim Solenoid "B"

(Normally Open)

PRESSURE SWITCH

ASSEMBLY

TCC (PWM) Solenoid "F"

(Normally Closed)

Figure 17

Shift Solenoid "D"

(Normally Closed)

16

Internal Wiring Harness And

Case Connector Assembly

Figure 18

AUTOMATIC TRANSMISSION SERVICE GROUP

Technical Service Information

INTERNAL COMPONENTS

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

SOLENOIDS

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

duty cycle.

INTERNAL WIRING HARNESS ASSEMBLY

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

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

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

Serviced as an assembly under

Allison Part Number 15321154.

Figure 19

AUTOMATIC TRANSMISSION SERVICE GROUP

INTERNAL WIRING HARNESS

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

Continued on Page 18.

17

Technical Service Information

INTERNAL WIRING SCHEMATIC

A

B

M

G

F

N

T

UCV

E L

D

HPJRK

S

W

PED 4

TRANSMISSION EXTERNAL

CONNECTOR FACE VIEW

Dark Green

A

Orange/Black

B

Pink

C

Light Green

D

Red

E

Blue

F

Orange

G

Black

H

Brown

J

Tan

K

Red/Black

L

Light Blue

M

N P R S T U V

W

Gray Purple

N/A Black

Tan Green Green

Black/Tan

TRIM (N/C) SOLENOID

"A"

TRIM (N/0)

SOLENOID

"B"

Solenoid Terminals

Resistance In

Ohms @ 72°F

TRIM "A" 5.5 - 8.0 W

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

TCC "F"

TEMP

SENSOR

SHIFT

SOLENOID

"E"

SHIFT

SOLENOID

"D"

L and M

N and P

C and A

C and B

C and W

J and S

H and G

SHIFT

SOLENOID

"C"

To Pressure

Switch Assembly

5.5 - 8.0 W

TCC

SOLENOID

"F"

A B C D E F

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

8 - 15 W

2.8K W

@ 72° F

18

Figure 20

AUTOMATIC TRANSMISSION SERVICE GROUP

Technical Service Information

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

CHECK TRANS

LIGHT

IGNITION POWER IGNITION POWER

BATTERY POWER

TCM GROUND

10A

IGNITION

SWITCH

10A

OPTIONAL SPEEDO

SIGNAL RETURN

TCM "J1" (Gray)

Yellow Yellow

Pink Gray Gray

Green

Red

Black

Green

CONNECTOR

25

CONTROL MODULE

2 4 3

1 5

GRAYGRAY

31

+

29

_

32

DO NOT GROUND TO

EXTERNAL WIRE SCHEMATIC

TCM "J2" (Red)

TRANSMISSION

(TCM)

CAN 2.08

J=1939

DATA LINK

CAUTIONCAUTION

VEHICLE CHASSIS

TCM "J2" (Red)

CONNECTOR

15 16

13 14

17 18

23 22 24 25

31 26 27 28 29

REDRED

30 32

21

1 2

3 4

10

5V

19

9

12 20

5 6 7 88

RECOMMENDED

WIRE COLORS

Yellow Green

Orange Blue

Tan Orange

White Yellow Pink Orange

Tan Green Blue Gray White

Green Yellow

Blue Pink White Green

Tan Pink Blue

Green Blue Yellow

Gray White

ALLISON

TRANS ID

A

B

A

B

A

B

Lt Blue

M

Red/Black

L

Gray

N

Purple

P

Pink

C

Dk Green

A

Orange/Black

B

Black/Tan

W

Brown

J

Green

U V

Black

S

Orange

R

T

D

NOT USED

Tan

Lt Green

Blue Red Tan

Orange

Black

TRANSMISSION CASE CONNECTORTRANSMISSION CASE CONNECTOR

A BF

CE DK

EG FH

OUTPUT SPEED

SENSOR

TURBINE SPEED

SENSOR

ENGINE SPEED

SENSOR

SOL "A"

SOL "B"

SOL "C" SOL "D"

SOL "E" SOL "F"

C

NOT USED

D

E

NOT USED

R

PRESSURE SWITCH

ASSEMBLY

C

THROTTLE

B

POSITION

SENSOR

A

TEMP

SENSOR

12V OR 24V12V OR 24V

SAE J-1939 BACKBONESAE J-1939 BACKBONE

ENGINE

INTERFACE

SAE STANDARD 9-PIN

DIAGNOSTIC CONNECTOR

AUTOMATIC TRANSMISSION SERVICE GROUP

TRANSMISSION

NSBU SWITCH

P

C

B

A

Figure 21

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

STARTER

RELAY

Orange

Yellow

Pink

Blue

Tan

RELAY

REVERSE LAMPSREVERSE LAMPS

ACCESSORY

PK/NEUT

VOLT FEED

REV & PARK

VOLT FEED

PARK

19

NOT USED (N/O)

Terminal Identification

Cast In Connector Here

Technical Service Information

PRESSURE SWITCH ASSEMBLY

NOT USED (N/O)

"E" SHIFT (N/O)

"D" SHIFT (N/O)

"C" SHIFT (N/O)

REVERSE (N/C)

TEMP SENSOR

(THERMISTER)

Figure 22

PRESSURE SWITCH CONNECTOR

PIN FUNCTION AND IDENTIFICATION

A

B

C

D

E

F

A B C D E F

Pressure Switch Assembly

Receptacle (Face View)

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

20

Figure 23

AUTOMATIC TRANSMISSION SERVICE GROUP

Technical Service Information

PRESSURE SWITCH CONNECTOR

PIN FUNCTION AND IDENTIFICATION

TCM "J2" (Red)

Connector

21

1 2

3 4

10 20

Yellow TRANS ID Blue Pink White Green

Tan

Green

Transmission

Case Connector

Figure 24

PRESSURE SWITCH ASSEMBLY

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

Pressure Switch

Connector

Tan

T

Lt Green

D

Blue Red Ta n

Orange

Black

C

A

NOT USED

D

BF

E

CE

NOT USED

R

DK

EG FH

PRESSURE SWITCH

ASSEMBLY

TEMP

SENSOR

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

Pressure Switch Logic State Chart

Range

Park

Rev

Neut

OD

4 3 2 1

"C"

On On On

Off

On

On Off Off

"D"

On On On Off Off Off Off On

"E"

On On On On On Off Off Off

Reverse

Off On Off Off Off Off Off Off

Figure 25

AUTOMATIC TRANSMISSION SERVICE GROUP

21

Technical Service Information

RETRIEVING DIAGNOSTIC CODES

A or H

Pause

Break

Scroll

Lock

Print

Home

Scrn

Backspace

F12

F11

_

-

F10

F9

0

F8

9

F7

F6

7

F5

6

F4

5

F3

F2

3

F1

2

ESC

1

W

~

`

Q

b

Ta

A

ps Lock

Ca

Shift

rl

Ct

Fn

Y

4

T

R

G

E

F

D

V

S

C

X

Z

Alt

n

Wi

P

8

O

I

L

U

K

<

J

,

H

M

N

B

PgUp

+

|

=

\

}

PgDn

]

r

{

Ente

[

:

;

>

.

Alt

End

"

ift

'

Sh

?

/

Del

Ins

C or SB or L

J-1939 Connector

Figure 26

CHECK TRANS LIGHT

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

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

RETRIEVING DIAGNOSTIC CODES

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

22

AUTOMATIC TRANSMISSION SERVICE GROUP

Technical Service Information

Allison TransPro

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

TYPICAL TransPro® DISPLAY

Transmission

Demo Mode ON

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

DTCs RetrievedDTCs Retrieved

Allison TransProStartStart

Figure 27

?

MAIN PRESSURE TAP LOCATION AND SPECIFICATIONS

ActiveDescriptionCode

Y Y Y Y Y Y

MIL

10:45 AM

LINE PRESSURE TEST

Check transmission fluid level. All transmission

XX

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

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

MAIN PRESSURE TEST SPECIFICATIONS

Pressure @ 600 RPM

900-1655 kpa (130-240 psi)

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

Main Pressure Tap

TO COOLERTO COOLER

FROM COOLERFROM COOLER

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

1000-1170 kpa (145-170 psi)

Figure 28

AUTOMATIC TRANSMISSION SERVICE GROUP

23

Technical Service Information

BELL HOUSING OIL PASSAGE IDENTIFICATION

16

9

15 16

16

29536810

3

2

1

13

2

9

14

2

10

3

16

3

1

8 1

16

7

1

6

11

1. PUMP SUCTION

2. LINE PRESSURE

3. OVERAGE (CONV RELEASE)

4. CONVERTER IN

5. CONVERTER OUT

6. TO COOLER

7. FROM COOLER

8. LUBE OIL

9. LOCK-UP APPLY

10. C1 CLUTCH

11. C2 CLUTCH

12. LOCK-UP SIGNAL

13. CUT-BACK (5TH GEAR)

14. LINE - TO FILTER

15. LINE - FROM FILTER

16. EXHAUST

24

15 14

16

2

16

6

BOTTOM BELL HOUSING COOLER MANIFOLD SURFACE

Figure 29

AUTOMATIC TRANSMISSION SERVICE GROUP

7

16

Technical Service Information

PUMP COVER SPACER PLATE OIL PASSAGE I.D.

16

3

2

8

1

2

7

6

1

16

2

16

3

2

16

9

16

9

1. PUMP SUCTION

2. LINE PRESSURE

3. OVERAGE (CONV RELEASE)

4. CONVERTER IN

5. CONVERTER OUT

6. TO COOLER

7. FROM COOLER

8. LUBE OIL

9. LOCK-UP APPLY

10. C1 CLUTCH

11. C2 CLUTCH

12. LOCK-UP SIGNAL

13. CUT-BACK (5TH GEAR)

14. LINE - TO FILTER

15. LINE - FROM FILTER

16. EXHAUST

11

10

1

2

13

Figure 30

AUTOMATIC TRANSMISSION SERVICE GROUP

15

14

25

Technical Service Information

MAIN CASE "FRONT" PASSAGE I.D.

16

1. PUMP SUCTION

2. LINE PRESSURE

3. OVERAGE (CONV RELEASE)

4. CONVERTER IN

5. CONVERTER OUT

6. TO COOLER

7. FROM COOLER

8. LUBE OIL

9. LOCK-UP APPLY

10. C1 CLUTCH

11. C2 CLUTCH

12. LOCK-UP SIGNAL

13. CUT-BACK (5TH GEAR)

14. LINE - TO FILTER

15. LINE - FROM FILTER

16. EXHAUST

16

11

16

N/A

9

13

2

1

10

14

15

26

Figure 31

AUTOMATIC TRANSMISSION SERVICE GROUP

Technical Service Information

MAIN CASE "REAR" PASSAGE I.D.

15

14

C5 CLUTCH

Figure 32

COOLER MANIFOLD PASSAGE I.D.

MAIN LINE

PRESSURE TAP

TO

CLR

FROM

76

FROM

CLR

6. TO COOLER

7. FROM COOLER

14. LINE - TO FILTER

Figure 33

AUTOMATIC TRANSMISSION SERVICE GROUP

27

Technical Service Information

PUMP COVER OIL PASSAGE I.D.

9

3

16

9

5

6

3

8

6

8

1

11

4

16

12

9

2

1

16

2

10

12

2

13

3

16

9

28

7

1. PUMP SUCTION

2. LINE PRESSURE

3. OVERAGE (CONV RELEASE)

4. CONVERTER IN

5. CONVERTER OUT

6. TO COOLER

7. FROM COOLER

8. LUBE OIL

9. LOCK-UP APPLY

10. C1 CLUTCH

11. C2 CLUTCH

12. LOCK-UP SIGNAL

13. CUT-BACK (5TH GEAR)

16. EXHAUST

AUTOMATIC TRANSMISSION SERVICE GROUP

6

1

10

16

Figure 34

Technical Service Information

OIL PUMP PASSAGE I.D.

2

14

1. PUMP SUCTION

2. LINE PRESSURE

14. EXHAUST

14

1

Figure 35

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

Exhaust

Figure 36

AUTOMATIC TRANSMISSION SERVICE GROUP

29

Technical Service Information

LEGEND FOR FIGURES 38, 39, AND 41.

Passage No.

1 2 9

10

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

Reverse Park/Neut 1st 2nd

Pump Suction

Main Line Pressure

TCC Apply

Exhaust Backfill/ C-1 Clutch

C-2 Clutch/Exhaust Backfill C-2 Clutch

Lock-Up Signal

Cut-Back (5th Gear)

Control Main Line Pressure To Filter

Exhaust To Sump

Control Main Line Pressure From Filter

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

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

Exhaust Backfill

Main Line Pressure

Exhaust Backfill

C-3/B Trim

Exhaust Backfill

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

C-1/B Trim

"D" Signal TCC Interlock

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

C-4 Clutch C-5 Clutch

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

"A" Clutch Trim

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

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

C-1/Main

Control Main After "B" Solenoid Screen

B Trim

"E" Shift Valve Interlock

C-2/EBF

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

C-3/EBF

C-2/EBF

Thermister

Exhaust Backfill

C-1/Main

3rd 4th 5th

EBF/ C-1 ClutchC-1 Clutch

C-1/B Trim

C-2/B Trim

C-1/B TrimC-1/B Trim

C-2/B Trim

C-4/EBF OD/EBF

C-2/Main

Exhaust

C-2/Main

C-1/EBF

Cut-BackC-3/EBF

C-1/EBFC-1/EBF

30

Figure 37

AUTOMATIC TRANSMISSION SERVICE GROUP

56

37

30

37

47

10

37

10

30

55

11

16

Technical Service Information

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

56

37

47

13

37

11

16

37

31

56

31

13

34

40 36 56

37

16

31

37

53

49

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31

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49

54

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35

57

2

51

37

52

45

44

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2

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31 44 53

54 41

57

33 15

52

46

44

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37

14

32

15

40

16

LEGEND FOUND ON PAGE 30.

15

46

16

41

37

2

15

40

15

48

Figure 38

AUTOMATIC TRANSMISSION SERVICE GROUP

31

Technical Service Information

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

16

33

15

32

42

38

14

30 16

37

32

16

40 2

40

32

16

30

39

38

2

37

2

16

37

41

2

43

16

33

2

44

37

16

39

15

32

31

15

44

45

35

45

37

40

57

2

57

44

37

51

37

2

53

32

11

30

2

14

16

44

34

36

34

35

51

40

5454

47

36

56

37

53

16

2 9

9

31

56 36

51

15

34

40

56

55

47

15

37

11

9

5

11

13

2

10

30

6

9

15

37

30

15

9

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32

16

11

14

16

LEGEND FOUND ON PAGE 30.

Figure 39

AUTOMATIC TRANSMISSION SERVICE GROUP

14

10

9

13

15

14

Technical Service Information

MAIN VALVE BODY "BOTTOM VIEW" PASSAGE I.D.

16

30

39

16

31

30

DuPage

29536840

30

16

32

38

50

33

16

16. EXHAUST.

30. REVERSE PRESSURE SWITCH.

31. "D" SHIFT VALVE PRESSURE SWITCH.

32. "E" SHIFT VALVE PRESSURE SWITCH.

33. "C" SHIFT VALVE PRESSURE SWITCH.

38. "A" TRIM SOLENOID SIGNAL.

39. "B" TRIM SOLENOID SIGNAL.

50. FLUID TEMPERATURE SENSOR (THERMISTER).

AUTOMATIC TRANSMISSION SERVICE GROUP

Figure 40

33

Technical Service Information

TYPICAL VALVE BODY SPACER PLATE

56

36

16

3534

15

16

43

37

41

39

38

37 40

2

42

16

56

30

15

37

9 14

11

55

30

10

30

13

47

13

37

11

47

14

55

2

10

31

2

53

56 36 40 34

51

53

31

35

47

54

51

32

45

37

44

37

40

15

57

37

2

33

2

44

57

54

53

44 31

2

37

16

11

32

14

6837

34

LEGEND FOUND ON PAGE 30.

Figure 41

AUTOMATIC TRANSMISSION SERVICE GROUP

Technical Service Information

MAIN CASE "BOTTOM VIEW" PASSAGE I.D.

16

11

16

35

1

29536808

34 16

36

56

10

14

13

2

15

9

1. SUCTION.

2. MAIN LINE PRESSURE.

9. TCC APPLY.

10. C-1 CLUTCH.

11. C-2 CLUTCH.

13. CUT-BACK (OverDrive).

14. CONTROL MAIN TO FILTER.

15. CONTROL MAIN FROM FILTER.

16. EXHAUST TO SUMP .

34. C-3 CLUTCH.

35. C-4 CLUTCH.

36. C-5 CLUTCH.

56. C-5 CLUTCH (Power -Off State).

AUTOMATIC TRANSMISSION SERVICE GROUP

Figure 42

35

Technical Service Information

TRANSMISSION DISASSEMBLY

EXTERNAL COMPONENTS

1. Remove the six PTO cover retaining bolts or the Power Take Off whichever it is equipped with, on the right hand side of the transmission as shown in Figure 43.

2. Install holding fixture similar to the one shown in Figure 43, onto the PTO surface, to be used with the bench fixture base. Caution: Because of the mass and the weight

of this unit, we feel it necessary to use holding fixture shown in Figure 43, with the fixture base or in a suitable turn-over stand.

3. Using a suitable hoist, lift the transmission and install into bench fixture base, or the suitable turn-over stand.

4. With transmission assembly locked, in the pan facing down position, remove the converter by pulling it straight out (See Figure 44). Caution: This torque converter weighs about

60 pounds, so exercise extreme caution.

5. Remove the engine speed sensor, turbine speed sensor and output speed sensor, as shown in Figure 45. Note: The engine speed sensor, if equipped,

the turbine speed sensor, and the output speed sensor on 2WD models are all the same part number (See Figure 45).

6. Remove and discard the "O" rings from the 3 speed sensors (See Figure 45).

7. Remove the Neutral Start Back-Up switch from the side of case, as shown in Figure 45. Note: The NSBU Switch is exactly the same

as the 4L60-E switch (See Figure 45).

8. Rotate the transmission in the fixture so that the oil pan is facing up (See Figure 46).

Continued on Page 38

36

9 .8

9

.8

9 .8

9

.8

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9 . 8

9 .

8

9 . 8

9 .

8

9 . 8

BENCH FIXTURE BASE

HOLDING FIXTURE

Figure 43

AUTOMATIC TRANSMISSION SERVICE GROUP

Technical Service Information

1

3

0

1

3

5

9

2

n

onAlli

on

o

s

Alli

ENGINE SPEED SENSOR

(SOME MODELS)

TURBINE SPEED SENSOR

(ALL MODELS)

1

3

0

1

3

5

9

2

Figure 44

lli

llis

A

OUTPUT SPEED SENSOR

(2WD MODELS)

nA

n

o

so

NSBU SWITCH

29536408

Figure 45

AUTOMATIC TRANSMISSION SERVICE GROUP

12450016

37

Technical Service Information

CONTINUED FROM PAGE 36

9. Remove the twelve bottom pan retaining bolts, using a 13 mm socket (See Figure 46).

10. Remove the bottom oil pan (See Figure 46).

11. Remove and discard the bottom pan gasket, as shown in Figure 46.

12. Remove and discard the bottom pan filter and filter seal, as shown in Figure 47.

13. Remove the inside detent roller and spring assembly retaining bolts, using an 8mm socket, as shown in Figure 48.

14. Remove the inside detent roller and spring assembly, as shown in Figure 48.

15. Remove the pass through case connector from the case bore using the Teckpakä GM harness removal tool, as shown in Figure 49.

16. Remove the 15 valve body to case retaining bolts, using an 8mm socket (See Figure 50). Note: Remove "Only" the valve body to case

bolts that are shaded as shown in Figure 50.

Continued on Page 40

BOTTOM PAN

PAN BOLTS

12 REQUIRED

BOTTOM PAN

FILTER

PAN GASKET

FILTER SEAL

1

8

1

8

D

u

P

D

u

P

a

g

8

0

8

0

6

8

3

6

5

3

9

5

2

9

2

e

8

0

8

0

6

8

3

6

5

3

9

5

2

9

2

age

8

38

Figure 46 Figure 47

AUTOMATIC TRANSMISSION SERVICE GROUP

Technical Service Information

DETENT ROLLER AND

SPRING ASSEMBLY

DETENT ROLLER AND

SPRING ASSEMBLY

RETAINING BOLTS

1

8

Du

Pag

8

0

8

0

6

8

3

6

5

3

9

5

2

9

2

e

TECKPAKä

GM HARNESS

REMOVAL TOOL

9

.

8

9

.

8

9

.

8

9

.

8

9

.

8

X X

X

9

X

9

X

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S

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X

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X

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X

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AN

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X

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X

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X

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X

3

W

Figure 48 Figure 49

9

.

8

9.

8

9

.

8

9

.

9

.

8

SIX VALVE BODY

TO CASE BOLTS

FOUR VALVE BODY

TO CASE BOLTS

29536808

29536840

DuPage

FIVE VALVE BODY

TO CASE BOLTS

Figure 50

AUTOMATIC TRANSMISSION SERVICE GROUP

39

Technical Service Information

CONTINUED FROM PAGE 38

17. After the 15 valve body bolts are removed, you can remove the valve body, ensuring that you disengage the manual valve pin from the inside detent lever, as shown in Figure 51.

18. Set the complete valve body assembly aside for the component rebuild process.

19. Remove the external oil filter from the cooler manifold or the bell housing, depending on the design, as shown in Figure 52.

20. Remove the cooler manifold assembly retaining bolts, as shown in Figure 54.

21. Remove the cooler manifold assembly from the bell housing, as shown in Figure 54.

22. Remove and discard the 2 cooler manifold gaskets, as shown in Figure 54.

23. Rotate the transmission in the fixture so that the bell housing is facing up (See Figure 53).

Continued on Page 42

VALVE BODY

TO CASE BOLTS

15 REQUIRED

VALVE BODY

TO CASE BOLTS

15 REQUIRED

D

u

P

ag

e

1

8

0

8

0

6

8

3

6

5

3

9

5

2

9

2

40

Figure 51

AUTOMATIC TRANSMISSION SERVICE GROUP

EXTERNAL OIL FILTER

8

0

8

0

8

6

3

5

3

5

9

2

9

2

Technical Service Information

1

8

7

6

5

3

Figure 52

4

3

1

11

88

08

368

95

2

95

2

9

5

3

1

0

3

1

2

1. TRANSMISSION CASE.

2. TRANSMISSION BELL HOUSING.

3. COOLER MANIFOLD SPACER PLATE GASKET (2 REQUIRED).

4. COOLER MANIFOLD SPACER PLATE.

5. COOLER MANIFOLD ASSEMBLY .

6. COOLER MANIFOLD RETAINING BOLT, M8 x 1.25 x 30 (8 REQ).

7. COOLER MANIFOLD RETAINING BOLT, M8 x 1.25 x 40 (4 REQ).

Figure 53 Figure 54

AUTOMATIC TRANSMISSION SERVICE GROUP

41

Technical Service Information

1

2

1

24. Remove 2 bell housing bolts from each side of

CONTINUED FROM PAGE 40

the case that are not inside the bell housing, as shown in Figure 55.

25. Remove the bell housing to case bolts that are shaded, from inside the bell housing, as shown in Figure 56. Note: Remove the shaded bolts only, as shown

in Figure 56. There will be 11 bolts that are 50mm long and 5 bolts that are 70mm long. The remaining bolts retain pump to bell.

26. Remove bell housing and oil pump assembly from the transmission case, by lifting straight up, as shown in Figure 55.

2

9

5

3

1

0

3

1

27. Remove and discard the pump spacer plate to case gasket (See Figure 55).

1

28. Set the bell housing and pump assembly aside for the component rebuild process.

29. Remove the C1/C2 clutch housing from the

1

3

case by lifting straight up using the turbine, as shown in Figure 57. Note: Remove the sun gear/planetary carrier

thrust bearing if it is not stuck to sun gear as shown in Figure 57.

4

5

1. BELL HOUSING TO CASE BOLTS, M10 X 1.5 X 50, (11 INSIDE BELL, 2 EACH SIDE ON OUTSIDE, TOTAL 15 REQ.)

2. BELL HOUSING TO CASE BOLTS, M10 X 1.5 X 70, (5 REQUIRED)

3. BELL HOUSING AND PUMP ASSEMBLY

4. BELL HOUSING SPACER PLATE TO CASE GASKET

5. MAIN TRANSMISSION CASE ASSEMBLY

Figure 55 Figure 56

1

3

0

3

5

9

1

2

5 BOLTS 70mm IN LENGTH

OTHER 11 ARE 50mm IN LENGTH

42

AUTOMATIC TRANSMISSION SERVICE GROUP

Technical Service Information

30. Set C1/C2 clutch housing aside for component rebuild process that is covered later.

31. Rotate transmission case so that the extension housing is facing up as shown in Figure 58.

32. Remove the yoke from the transmission if it is equipped with one, as shown in Figure 58. Note: Some models are equipped with the

parking brake as shown in Figure 58. Four Wheel Drive models will have neither.

Continued on Page 45

C1/C2 CLUTCH

HOUSING ASSEMBLY

(SOME MODELS)

THRUST

BEARING

9.

8

9.

8

9.

8

9.

8

9.

8

X X

X

9

X

9

X

1

F2

SE

0

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E

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0

F

1

R

X

C

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S

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X

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A

X

3

W

9.

8

9 . 8

9

.

8

9.

8

9.

8

Figure 57 Figure 58

AUTOMATIC TRANSMISSION SERVICE GROUP

43

Technical Service Information

EXTENSION

HOUSING

EXTENSION HOUSING

BOLTS M10 X 1.5 X 40

(16 REQUIRED)

P3 PLANETARY

CARRIER ASSEMBLY

OUTPUT

SHAFT

THRUST

BEARING

EXTENSION

HOUSING

GASKET

P3 SUN GEAR

C

1000

310

1

00

8

00

1

0

/2

T

A

T

A

2

R

1

r

M8

a

0

1

nsmi

l

11

lis

s

o

ion

n

C

1000

310

1

00

8

00

1

0

/2

T

A

T

A

2

R

1

r

M8

a

0

1

nsmi

l

11

lis

s

o

ion

n

44

Figure 59

AUTOMATIC TRANSMISSION SERVICE GROUP

Figure 60

Technical Service Information

CONTINUED FROM PAGE 43

33. Remove the 16 extension housing bolts, using a 15mm socket (See Figure 59).

34. Remove the extension housing assembly and set aside for the component rebuild process,as shown in Figure 59.

35. Remove and discard the extension housing gasket, as shown in Figure 59.

36. Grasp the output shaft splines and lift straight up, removing the output shaft and P3 planetary carrier as an assembly (See Figure 60).

37. Remove the P3 sun gear and the thrust bearing as shown in Figure 60.

38. Grasp the main shaft splines and lift straight up removing the main shaft, P2 sun gear and the sun gear spacer, as shown in Figure 62.

39. Remove the parking pawl shaft by pulling up and twisting motion at the same time. This will help in the removal as it is air locked in the case bore (See Figure 62).

40. Remove the parking pawl by slight twisting motion to disconnect from the parking pawl return spring (See Figures 61 and 62).

SUN GEAR

SPACER

P2 SUN GEAR

MAIN SHAFT

PARKING PAWL

RETURN SPRING

Continued on Page 47

PARKING PAWL

SHAFT

PARKING

PAWL

C

10

310

1

00 1

00

8

001

0 2

/2

T

A

T

A

RM8

1

r

a

011

1

ns

l

lis

m

i

s

o

ion

n

Figure 61 Figure 62

AUTOMATIC TRANSMISSION SERVICE GROUP

45

Technical Service Information

C5 CLUTCH

RETURN SPRING

ASSEMBLY

C5 CLUTCH STEEL PLATE

1

2

(6 REQUIRED)

C

1

3

0

10

1

0

88/2

00

0 1

00 2

0101

T

All

T

All

RM8

1

r

a

1

n

s

1

m

is

iss

o

io

n

1. P2 PLANETARY CARRIER/P2 SUN GEAR THRUST BEARING

2. P2 PLANETARY CARRIER ASSEMBL Y

C5 CLUTCH

LINED PLATE

(6 REQUIRED)

C5 CLUTCH

BACKING PLATE

C

1

3

000 1

1

10001

0

8

0

8/2

0 2

T

Al

T

Al

R

1

r

M8

a

0

1

n

1

smis

l

1

i

s

o

i

o

n

46

Figure 63

AUTOMATIC TRANSMISSION SERVICE GROUP

Figure 64

Technical Service Information

CONTINUED FROM PAGE 45

41. Remove the P2 planetary carrier assembly by lifting up with a slight twisting motion. Refer to Figure 63. Note: The planetary carrier to P2 sun gear

thrust bearing will be removed with the planetary carrier (See Figure 63).

42. Remove the C5 clutch return spring assembly from case, as shown in Figure 64.

43. Remove the C5 clutches both lined and steel from case, as shown in Figure 64.

45. Remove the C5 clutch backing plate from the case, as shown in Figure 64.

46. Remove the P1 planetary carrier assembly by lifting up with a slight twisting motion. Refer to Figure 65. Note: The P1 planetary carrier/P2 planetary

carrier thrust bearing, and the P2 ring gear to P1 ring gear thrust washer will be removed with the carrier assembly (See Figure 65).

1

2

3

Continued on Page 49

C31000

10

1

00 1

0

8

00

8

/2

T

Al

T

2

1

Al

R

1

r

M

a

0

n

1

8

smi

li

1

s

o

i

o

n

1. P1 PLANET CARRIER/P2 PLANET CARRIER THRUST BEARING

2. P1 PLANETARY CARRIER ASSEMBL Y

3. P1 RING GEAR/P2 RING GEAR "PEEK" THRUST WASHER

Figure 65

AUTOMATIC TRANSMISSION SERVICE GROUP

47

Technical Service Information

C4 CLUTCH

BACKING PLATE

SNAP RING

C4 CLUTCH

BACKING PLATE

SNAP RING

SPIRAL

SNAP RING

SPIRAL

SNAP RING

C4 CLUTCH

BACKING PLATE

C4 CLUTCH LINED PLATE

(5 REQUIRED)

C4 CLUTCH STEEL PLATE

(4 REQUIRED)

PARKING

ACTUATOR

GUIDE

C31

10

1

00 1

0

8

000

00

8

/2

T

A

T

2

1

A

R

1

r

M

a

0

n

l

1

8

smi

li

1

s

o

io

n

C4 CLUTCH APPLY PLATE

RETURN SPRING

ASSEMBLIES

(3 REQUIRED)

C3

10

1

10

00

0

8

0

8

00

1R

0

/21

Tra

21

A

10

M

ll

1

n

8

sm

1

i

s

i

s

on

s

i

o

n

48

Figure 66

AUTOMATIC TRANSMISSION SERVICE GROUP

Figure 67

Technical Service Information

CONTINUED FROM PAGE 47

47. Remove the parking actuator guide from case as shown in Figure 66.

48. Remove the C4 clutch backing plate snap ring from the groove in case (See Figure 66).

49. From the same groove in the case, remove the spiral snap ring from case (See Figure 66). Note: Refer to the cut-away in Figure 66 to

see how these snap rings are in groove.

50. Remove the C4 clutch backing plate from the case as shown in Figure 67.

51. Remove the C4 clutches both lined and steel from the case, as shown in Figure 67.

52. Remove the C4 clutch apply plate with the 3 return spring assemblies on it from the case as shown in Figure 67. Note: These three return spring assemblies

just clip onto apply plate (See Figure 67).

53. Remove the C4 clutch apply piston from case by blowing compressed air into the C4 clutch passage as shown in Figure 68. Note:Figure 74 on Page 51 will identify the

C4 clutch passage for the compressed air.

54. Remove the P1 planetary ring gear from the C3 clutches in the case (See Figure 69).

Continued on Page 50

C4 CLUTCH

APPLY PISTON

P1 PLANETARY

RING GEAR

C3

10

1

10

00

0

8

00

8

00

1R

/21

A

Tra

21

10

M

l

n

1

8

l

sm

1

i

s

i

s

on

s

i

o

n

Figure 69Figure 68

AUTOMATIC TRANSMISSION SERVICE GROUP

C3

10

1

10

00

0

8

00

8

00

1R

/21

Al

Tra

21

10

M

n

1

8

l

sm

1

i

s

i

s

on

s

i

on

49

C3 CLUTCH

BACKING PLATE

SNAP RING

C3 CLUTCH

BACKING PLATE

C3 CLUTCH LINED PLATE

(4 REQUIRED)

Technical Service Information

CONTINUED FROM PAGE 49

55. Rotate the transmission in fixture so that the front of the transmission case is facing up, as shown in Figure 70.

56. Remove the C3 clutch backing plate snap ring from the case, as shown in Figure 70.

57. Remove the C3 clutch backing plate from the case, as shown in Figure 70. Note: Inspect the three thrust washer surfaces

that are pop riveted onto the backing plate as shown in Figure 71. These pieces are not serviced seperately.

58. Remove the C3 clutch plates both the lined and steel, as shown in Figure 70.

59. Remove the C3 clutch apply plate with the 3 return spring assemblies on it from the case, as shown in Figure 72. Note: These three return spring assemblies

just clip onto apply plate (See Figure 72).

60. Remove the C3 clutch apply piston from case by blowing compressed air into the C3 clutch passage, as shown in Figure 73. Note: Figure 74 on Page 51 will identify the

C3 clutch passage for the compressed air.

61. This ends transmission disassembly.

C3 CLUTCH

STEEL PLATE

(3 REQUIRED)

Figure 70

C3 CLUTCH

BACKING PLATE

WITH 3 THRUST

WASHER SURFACES

Figure 71

50

AUTOMATIC TRANSMISSION SERVICE GROUP

Technical Service Information

C3 CLUTCH APPLY PLATE

C3 CLUTCH

APPLY PISTON

RETURN SPRING

ASSEMBLIES

(3 REQUIRED)

C4 CLUTCH

PASSAGE

C3 CLUTCH

PASSAGE

Figure 73Figure 72

29536808

Figure 74

AUTOMATIC TRANSMISSION SERVICE GROUP

51

Technical Service Information

LINKAGE/PARK RELATED PARTS AND

EXTERNAL CASE PARTS EXPLODED VIEW

5

6

7

8

4

3

2

1

5

4

3

NN

10

12 13

9

11

14

15 16

17

1. TRANSMISSION CASE ASSEMBLY.

2. IDENTIFICATION TAG AND RIVET .

3. PTO COVER RETAINING BOLTS, M10 X 1.5 X 20 (12 REQUIRED).

4. PTO COVER ASSEMBLY (2 REQUIRED).

5. PTO COVER TO CASE GASKET (2 REQUIRED).

6. TURBINE SHAFT SPEED SENSOR.

7. TURBINE SHAFT SPEED SENSOR "O" RING.

8. SPEED SENSOR RETAINING BOLT, M6 X 1.0 X 13 (1 REQUIRED).

9. MANUAL SHAFT ASSEMBLY.

52

AUTOMATIC TRANSMISSION SERVICE GROUP

10. MANUAL SHAFT SEAL.

11. MANUAL DETENT LEVER.

12. MANUAL DETENT LEVER FLANGE NUT.

13. PARKING PAWL APPLY ROD ASSEMBL Y .

14. PARKING PAWL APPLY ROD GUIDE.

15. PARKING PAWL SUPPORT SHAFT .

16. PARKING PAWL ASSEMBLY.

17. PARKING PAWL RETURN SPRING.

Figure 75

Technical Service Information

COMPONENT REBUILD

TRANSMISSION CASE

1. Remove the parking linkage as necessary and install a new manual linkage seal into the case bore, as shown in Figure 75.

2. Inspect the C3 clutch molded apply piston and replace as necessary (See Figure 76).

3. Lubricate C3 clutch piston with a small amount of TransJelä, and install into the case bore, as shown in Figure 76.

4. Install the three return spring assemblies onto the wide tabs of C3 apply plate and install the apply plate assembly on top of the piston, as shown in Figure 78.

5. Inspect the three washer surfaces that are pop riveted onto the C3 clutch backing plate, as shown in Figure 77. Note: These 3 pieces and rivets are available

as service items. Replace as necessary.

C3 CLUTCH

BACKING PLATE

WITH 3 THRUST

WASHER SURFACES

C3 CLUTCH

APPLY PISTON

Continued on Page 54

Figure 77

C3 CLUTCH APPLY PLATE

RETURN SPRING

ASSEMBLIES

(3 REQUIRED)

Figure 76 Figure 78

AUTOMATIC TRANSMISSION SERVICE GROUP

53

C3 CLUTCH

BACKING PLATE

SNAP RING

C3 CLUTCH

BACKING PLATE

C3 CLUTCH

LINED PLATE

(4 REQUIRED)

Technical Service Information

CONTINUED FROM PAGE 53

6. Install C3 clutch pack beginning with a lined plate on top of the apply plate and alternating with a steel plate until you have installed four lined plates and three steel plates, as shown in Figure 79.

7. Install the pre-inspected C3 backing plate with the 3 washer surfaces facing down, as shown in Figure 79.

8. Install the C3 clutch backing plate snap ring in the case groove (See Figure 79).

9. Check the C3 clutch clearance using a feeler gage, through the front opening in transmission case, as shown in Figure 80.

10. Correct clearance should be .040"-.060" Note: There are no selectives. If clearance is

not correct, there is a mis-assembly.

11. Rotate the transmission in the fixture so that the rear of the transmission is facing up, as shown in Figure 80.

C3 CLUTCH

STEEL PLATE

(3 REQUIRED)

CHECKING C3 CLUTCH CLEARANCE

54

Figure 79

AUTOMATIC TRANSMISSION SERVICE GROUP

Figure 80

Technical Service Information

12. Install the P1 planetary ring gear into the case and engaging into the C3 lined plates until it is fully seated against the washer surfaces on the C3 backing plate (See Figure 81).

13. The transmission case is now ready for the final assembly process. Caution: Do not rotate the transmission from

this position as the ring gear may fall out and create damage or injury.

COMPONENT REBUILD (Cont'd)

OIL PUMP ASSEMBLY

1. Remove the bolts from inside the bell housing that are shaded, as shown in Figure 82, so that the oil pump assembly is seperated from the bell housing (See Figure 82).

Continued on Page 57

3/4 View

P1 PLANETARY

RING GEAR

Front View

1

3

0

3

5

9

1

2

9.8

Figure 81

AUTOMATIC TRANSMISSION SERVICE GROUP

C3

10

1

10

00

0

8

00

8

00

1R

/21

A

Tra

21

10

M

l

n

1

8

l

sm

1

i

s

i

s

on

s

i

on

Figure 82

55

Technical Service Information

OIL PUMP AND BELL HOUSING

EXPLODED VIEW

56

9.

8

Figure 83

AUTOMATIC TRANSMISSION SERVICE GROUP

Technical Service Information

CONTINUED FROM PAGE 55

2. Remove the five oil pump cover to oil pump retaining bolts to disassemble the oil pump, as shown in Figure 84.

3. Disassemble the oil pump and oil pump cover using Figures 85 and 86 as a guide.

4. Remove and discard the pump spacer plate to bell housing gasket and the pump spacer plate to case gasket (See Figure 83, 85 and 86).

5. Remove and discard the 3 sealing rings on the back side of pump cover (See Figure 85).

6. Remove and discard the 2 sealing rings on the stator shaft in front (See Figure 85).

7. Remove and discard the front pump converter metal clad seal from the pump body, as shown in Figure 85.

8. Inspect all oil pump parts thoroughly for any wear and/or damage.

9. Clean all oil pump and cover parts thoroughly and dry with compressed air.

Continued on Page 60

PUMP COVER

TO OIL PUMP

RETAINING BOLTS

29536810

29536681

2

26

20E9

Figure 84

AUTOMATIC TRANSMISSION SERVICE GROUP

PUMP COVER

TO OIL PUMP

RETAINING BOLTS

57

Technical Service Information

OIL PUMP ASSEMBLY EXPLODED VIEW

18

17

16

15

14

13

12

6

5

4

3

2

9.8

8

7

4

9.8

58

Figure 85

AUTOMATIC TRANSMISSION SERVICE GROUP

11

Technical Service Information

OIL PUMP ASSEMBLY EXPLODED VIEW

910

1

1. PUMP SPACER PLATE TO CASE GASKET.

2. C1/C2 SEALING RINGS (3 REQUIRED).

3. PUMP COVER TO C1/C2 CLUTCH HOUSING THRUST WASHER.

4. CAGED NEEDLE BEARING ASSEMBLY.

5. PUMP COVER/PUMP BODY BOLTS, M8 x 1.25 x 55 (5 REQUIRED).

6. PUMP COVER ASSEMBLY.

7. PUMP STATOR SHAFT SEAL RING (LARGE).

8. PUMP STATOR SHAFT SEAL RING (SMALL).

9. PUMP SPACER PLATE.

10. PUMP SPACER PLATE TO BELL HOUSING GASKET.

11. PUMP WEAR PLATE.

12. INNER OIL PUMP GEAR.

13. OUTER OIL PUMP GEAR.

14. PUMP BODY TO PUMP COVER DOWEL PINS (2 REQUIRED).

15. OIL PUMP BODY ASSEMBLY .

16. OIL PUMP BODY/CONVERTER HUB BUSHING.

17. OIL PUMP BODY METAL CLAD SEAL.

18. PUMP BODY TO BELL HOUSING SEAL RING.

Figure 86

AUTOMATIC TRANSMISSION SERVICE GROUP

59

Technical Service Information

CONTINUED FROM PAGE 57

10. Install new front pump body bushing into the pump body as necessary, using proper bushing driver (See Figure 88).

11. Install a new front pump body metal clad seal into pump body using the proper seal driver. Refer to Figure 88.

12. Install new pump body to bell housing "O" ring seal in pump body groove, and lubricate using a small amount of TransJelä. (See Figure 88).

13. Lubricate the inner and outer pump gears with transmission fluid and install in the pump body with marks facing up, as shown in Figure 87.

14. Install the two dowel pins into the pump body, if they were removed, as shown in Figure 88.

15. Assemble the valves, springs, bore plugs and retainers into the pump cover exactly as they are shown in Figure 89. Note: Lubricate all valves in the pump cover

with LubeGard® spray lubricant.

Figure 87

18

17

OIL PUMP ASSEMBLY

16

Continued on Page 62

15

14

13

12

12. INNER OIL PUMP GEAR.

13. OUTER OIL PUMP GEAR.

14. PUMP BODY TO PUMP COVER DOWEL PINS (2 REQUIRED).

15. OIL PUMP BODY ASSEMBLY .

16. OIL PUMP BODY/CONVERTER HUB BUSHING.

17. OIL PUMP BODY METAL CLAD SEAL.

18. PUMP BODY TO BELL HOUSING SEAL RING.

60

AUTOMATIC TRANSMISSION SERVICE GROUP

14

Figure 88

Technical Service Information

OIL PUMP COVER ASSEMBLY

VALVE AND SPRING IDENTIFICATION

Spring Diameter = .635"

5

Free Length = 1.068"

Number Coils = 8

Spring Diameter = .380"

Wire Diameter = .025"

1

Free Length = 1.388"

Number Coils = 7

Wire Diameter = .055"

2

Free Length = 2.825"

Spring Diameter = .890"

Wire Diameter = .108"

3

Number Coils = 11

6

4

7

8

Spring Diameter = .535"

12 13

1. CONVERTER FLOW VALVE.

2. CONVERTER FLOW VALVE SPRING.

3. CONVERTER FLOW VALVE STOP.

4. CONVERTER FLOW VALVE STOP RETAINING PIN.

5. MAIN PRESSURE REGULATOR VAL VE.

6. MAIN PRESSURE REGULATOR VAL VE SPRING.

7. PRESSURE REGULATOR VAL VE STOP.

8. PRESSURE REGULATOR VAL VE STOP RETAINING PIN.

9. CLUTCH BACKFILL VALVE.

10. CLUTCH BACKFILL VALVE SPRING.

Free Length = 1.980"

Number Coils = 12

Wire Diameter = .055"

10

9

14

11. CLUTCH BACKFILL VALVE RETAINER .

12. CONVERTER RELIEF VALVE.

13. CONVERTER RELIEF VALVE SPRING.

14. CONVERTER RELIEF VALVE SPRING RETAINER.

15. LUBE REGULATOR VALVE.

16. LUBE REGULATOR VALVE SPRING.

17. LUBE REGULATOR VALVE SPRING STOP.

18. LUBE REGULATOR VALVE STOP "O" RING.

19. LUBE REGULATOR VALVE STOP RETAINING PIN.

11

Free Length = 1.400"

Number Coils = 7

Spring Diameter = .635"

Wire Diameter = .055"

15

16

17 18

19

Figure 89

AUTOMATIC TRANSMISSION SERVICE GROUP

61

Technical Service Information

CONTINUED FROM PAGE 60

16. Install the C1/C2 clutch drum thrust washer on the pump cover and retain with a small amount of TransJelä (See Figure 90).

17. Install three new C1/C2 clutch drum sealing rings as shown in Figure 90. Note: Ensure that the sealing rings will rotate

freely in the ring grooves (See Figure 90).

18. Install two new sealing rings onto the stator shaft in their proper grooves (See Figure 90). Note: Ensure that the sealing rings will rotate

freely in their ring grooves (See Figure 90

19. Inspect the caged needle bearing and replace as necessary (See Figure 90).

20. Place the completed oil pump cover assembly on a flat work surface with the stator shaft facing up, as shown in Figure 91.

21. Install the bell housing to pump cover spacer plate onto the pump cover (See Figure 91).

22. Install the spacer plate to bell housing gasket on top of the spacer plate (See Figure 91).

23. Install the oil pump wear plate on top of spacer plate, as shown in Figure 91.

24. Install the pre-assembled oil pump assembly on top of the wear plate as shown in Figure 92.

Continued on Page 64

8

1. PUMP SPACER PLATE TO CASE GASKET.

2. C1/C2 SEALING RINGS (3 REQUIRED).

3. PUMP COVER TO C1/C2 CLUTCH HOUSING THRUST WASHER.

4. CAGED NEEDLE BEARING ASSEMBLY.

5. PUMP COVER/PUMP BODY BOLTS, M8 x 1.25 x 55 (5 REQUIRED).

6. PUMP COVER ASSEMBLY.

7. PUMP STATOR SHAFT SEAL RING (LARGE).

7

6

5

9.8

4

9.8

4

9.8

3

2

62

Figure 90

AUTOMATIC TRANSMISSION SERVICE GROUP

OIL PUMP

WEAR PLATE

Technical Service Information

SPACER PLATE TO

BELL GASKET

OIL PUMP

ASSEMBLY

BELL HOUSING

SPACER PLATE

2

9

5

3

1

0

3

1

OIL PUMP COVER

ASSEMBLY

Figure 91 Figure 92

AUTOMATIC TRANSMISSION SERVICE GROUP

63

Technical Service Information

29536810

PUMP COVER TO

OIL PUMP

RETAINING BOLTS

29536681

2

26

20E9

CONTINUED FROM PAGE 62

25. Install the 5 required pump cover to oil pump bolts, size identified in Figure 95 and location is identified in Figure 93, and torque the bolts to 27 Nm (20 ft.lb.).

26. Assemble the completed oil pump and cover assembly to the bell housing (See Figure 94). Note: There are currently four different bell

housings available. Refer to Figures 98 & 99 for the various models.

27. Install the 10 required bell housing to pump cover bolts, size identified in Figure 95 and location is identified in Figure 96, and torque the bolts to 43 Nm (32 ft.lb.). Note: Notice in Figure 95 that these 10 bolts

have a required seal on the bolt. Ensure that new seals are installed.

28. Set completed bell housing and pump assembly aside for the final assembly process, as shown in Figure 97.

PUMP COVER TO

OIL PUMP

RETAINING BOLTS

Figure 93

OIL PUMP AND BELL HOUSING ASSEMBLY

9.8

BELL HOUSING ASSEMBLY

(4 DIFFERENT VERSIONS)

64

BELL HOUSING TO

SPACER PLATE GASKET

OIL PUMP AND PUMP

COVER ASSEMBLY

Figure 94

AUTOMATIC TRANSMISSION SERVICE GROUP

Technical Service Information

13mm Head

Pump Cover To

Oil Pump (5 Req)

M8 X 1.25 X 55

Bolts Drawn Actual Size

15 mm Head

SEAL

Bell Housing To

Pump Cover (10 Req)

M10 X 1.5 X 50

1

3

0

3

5

9

1

2

Figure 96Figure 95

COMPLETED BELL HOUSING AND PUMP ASSEMBLY

CAUTION: THERE ARE FOUR DIFFERENT

BELL HOUSING CONFIGURATIONS

REFER TO FIGURES 98 AND 99

2

9

5

3

1

0

3

1

Figure 97

AUTOMATIC TRANSMISSION SERVICE GROUP

65

Technical Service Information

SAE NUMBER 3 BELL HOUSING

WITH INTEGRAL FILTER AND

COOLER PORTS

SAE NUMBER 3 BELL HOUSING

WITH MANIFOLD FOR FILTER

AND COOLER PORTS

9

7 6

3

2

1

1. MAIN CONTROL FILTER ASSEMBLY .

2. MAIN CONTROL FILTER MAGNET.

3. MAIN CONTROL FILTER ADAPTER TUBE.

4. MAIN LINE PRESSURE TAP PLUG.

5. MAIN LINE PRESSURE PLUG "O" RING.

6. TO COOLER SHIPPING PLUG.

7. TO COOLER SHIPPING PLUG "O" RING.

8. FROM COOLER SHIPPING PLUG.

9. FROM COOLER SHIPPING PLUG "O" RING.

10. COOLER MANIFOLD RETAINING BOLT, M8 x 1.25 x 30 (8 REQ).

11. COOLER MANIFOLD RETAINING BOLT, M8 x 1.25 x 40 (4 REQ).

5 4

8

11

10

9

7 6

3 2

1

5 4

8

66

Figure 98

AUTOMATIC TRANSMISSION SERVICE GROUP

Technical Service Information

SAE NUMBER 2 BELL HOUSING

WITH MANIFOLD FOR FILTER

AND COOLER PORTS

SAE NUMBER 8 BELL HOUSING

WITH INTEGRAL FILTER AND

COOLER PORTS

11

13

3

2

1

10

1. MAIN CONTROL FILTER ASSEMBLY .

9

7 6

3 2

1

5 4

8

2. MAIN CONTROL FILTER MAGNET.

3. MAIN CONTROL FILTER ADAPTER TUBE.

4. MAIN LINE PRESSURE TAP PLUG.

5. MAIN LINE PRESSURE PLUG "O" RING.

6. TO COOLER SHIPPING PLUG.

7. TO COOLER SHIPPING PLUG "O" RING.

8. FROM COOLER SHIPPING PLUG.

9. FROM COOLER SHIPPING PLUG "O" RING.

10. COOLER MANIFOLD RETAINING BOLT, M8 x 1.25 x 30 (8 REQ).

11. COOLER MANIFOLD RETAINING BOLT, M8 x 1.25 x 40 (4 REQ).

12. TO COOLER CONNECTOR FITTING ASSEMBLY.

13. FROM COOLER CONNECTOR FITTING ASSEMBLY.

12

5 4

Figure 99

AUTOMATIC TRANSMISSION SERVICE GROUP

67

Technical Service Information

C1/C2 CLUTCH HOUSING EXPLODED VIEW

12

1

13 14

2

15 16

3

17

18

4

19

68

28

27

29

LEGEND FOR FIGURES 100 AND 101 FOUND ON PAGE 70

Figure 100

AUTOMATIC TRANSMISSION SERVICE GROUP

31

30

Technical Service Information

20

5

6

21

7

8

22

9

10

24

11

25

26

C1/C2 CLUTCH HOUSING EXPLODED VIEW

32

34

33

LEGEND FOR FIGURES 100 AND 101 FOUND ON PAGE 70

Figure 101

AUTOMATIC TRANSMISSION SERVICE GROUP

23

35

37

36

69

Technical Service Information

LEGEND FOR FIGURES 100 AND 101

1. TURBINE SHAFT SEAL RINGS (2 REQUIRED).

2. TURBINE SHAFT ASSEMBLY.

3. C1/C2 CLUTCH HOUSING ASSEMBLY .

4. TURBINE SHAFT RETAINING SNAP RING.

5. C2 CLUTCH PISTON BALANCE "D" RING SEAL.

6. C2 CLUTCH PISTON OUTER "D" RING SEAL.

7. C2 CLUTCH PISTON.

8. C2 CLUTCH PISTON INNER LIP SEAL.

9. C2 CLUTCH PISTON RETURN SPRING ASSEMBLY .

10. C1 CLUTCH HOUSING "O" RING SEAL.

11. C1 CLUTCH HOUSING ASSEMBLY .

12. C1 CLUTCH HOUSING RETAINING SNAP RING.

13. C2 CLUTCH BALANCE PISTON ASSEMBLY (MOULDED).

14. C2 CLUTCH BALANCE PISTON RETAINING SNAP RING.

15. C1 CLUTCH PISTON OUTER "D" RING SEAL.

16. C1 CLUTCH PISTON ASSEMBLY .

17. C1 CLUTCH PISTON INNER TEFLON LIP SEAL (iNNER LIP).

18. C1 CLUTCH PISTON RETURN SPRING ASSEMBLY .

19. C1 CLUTCH PISTON RETURN SPRING SNAP RING.

C2 CLUTCH PISTON

INNER LIP SEAL

C2 CLUTCH

PISTON

C2 PISTON BALANCE

"D" RING SEAL

C2 PISTON OUTER

"D" RING SEAL

20. C1 CLUTCH BALANCE PISTON ASSEMBLY (MOULDED).

21. C1 CLUTCH BALANCE PISTON RETAINING SNAP RING.

22. C1 CLUTCH STEEL PLATES, INTERNAL SPLINE (6 REQUIRED).

23. C1 CLUTCH LINED PLATES, EXTERNAL SPLINE (6 REQUIRED).

24. C1 CLUTCH BACKING PLATE (SELECTIVE).

25. C1 CLUTCH BACKING PLATE SNAP RING (EXTERNAL).

26. C1 CLUTCH BACKING PLATE SPIRAL SNAP RING (INTERNAL).

27. TURBINE SHAFT/C1 CLUTCH HUB THRUST BEARING.

28. C1 CLUTCH HUB ASSEMBLY .

29. C1 CLUTCH HUB/C2 CLUTCH HUB THRUST BEARING.

30. C2 CLUTCH STEEL PLATES (7 REQUIRED).

31. C2 CLUTCH LINED PLATES (6 REQUIRED).

32. C2 CLUTCH HUB ASSEMBLY .

33. C2 CLUTCH HUB/INPUT SUN GEAR THRUST WASHER.

34. INPUT SUN GEAR ASSEMBLY.

35. INPUT SUN GEAR/P1 PLANETARY CARRIER THRUST BEARING.

36. P1 PLANETARY DRIVE FLANGE.

37. P1 PLANETARY DRIVE FLANGE RETAINING SNAP RING.

Figure 102

COMPONENT REBUILD (Cont'd)

C1/C2 CLUTCH HOUSING

1. Disassemble the C1/C2 clutch housing using Figures 100 and 101 as a guide.

2. Remove and discard all "O" rings, "D" rings and lip seals (See Figures 100 and 101).

3. Inspect all C1/C2 clutch housing parts for any wear and/or damage.

4. Clean all C1/C2 housing parts thoroughly, and dry with compressed air.

5. If turbine shaft was not removed, it should be removed at this time, as it makes the assembly of the C1/C2 clutch housing much easier.

6. Install the C2 clutch piston inner lip seal with the lip facing direction shown in Figure 103.

7. Install the C2 clutch piston balance "D" ring seal into the piston groove (See Figure 103).

8. Install the C2 clutch piston outer "D" ring seal into the lower piston groove (See Figure 103).

9. Lubricate all three C2 clutch piston seals with a small amount of TransJelä.

10. Install the C2 clutch piston and seals into the C1/C2 clutch housing as shown in Figure 105. Note: Care should be used during assembly

so as not to damage piston seals.

11. Install the C2 piston return spring assembly on top of the C2 piston in the housing, as shown in Figure 105.

70

Figure 103

AUTOMATIC TRANSMISSION SERVICE GROUP

Technical Service Information

C1 CLUTCH HOUSING

SNAP RING

C1 CLUTCH HOUSING

SNAP RING

C1 CLUTCH

HOUSING

C1 CLUTCH HOUSING

"O" RING SEAL

C1 CLUTCH HOUSING

"O" RING SEAL

C2 CLUTCH RETURN

SRING ASSEMBLY

Figure 104

12. Install the C1 clutch housing "O" ring seal into the lower groove in the C1/C2 clutch housing, as shown in the cut-away in Figure 104.

13. Lubricate the installed "O" ring seal and inside diameter of the C1 clutch housing with a small of TransJelä, and install the C1 clutch housing as shown in Figure 105.

14. Compress the C1 clutch housing against the return spring assembly and install the C1 clutch housing snap ring into the upper groove in the C1/C2 clutch housing, as shown in cut-away in Figure 104. Note: Refer to Figure 106 for snap ring I.D.

for all snap rings in the C1/C2 housing.

C2 CLUTCH

PISTON AND SEALS

C1/C2 CLUTCH

HOUSING

Continued on Page 73

AUTOMATIC TRANSMISSION SERVICE GROUP

Figure 105

71

Technical Service Information

SNAP RING IDENTIFICATION CHART FOR C1/C2 CLUTCH HOUSING

Snap Ring Number 1 = .090" Thick, Largest Diameter "Eyelet" Snap Ring. (C1 Clutch Housing Retaining Snap Ring) Snap Ring Number 2 = .079" Thick, Approximate 3-3/16" Diameter. (C1 Clutch Piston Return Spring Retaining Snap Ring) Snap Ring Number 3 = .079" Thick, Approximate 6-1/2" Diameter. (C1 Clutch Balance Piston Retaining Snap Ring) Snap Ring Number 4 = .092" Thick, Approximate 8-3/8" Diameter, Same as Snap Ring Number 8. (C2 Clutch Balance Piston Retaining Snap Ring) Snap Ring Number 5 = .090" Thick, Smallest Diameter "Eyelet" Snap Ring. (Turbine Shaft Retaining Snap Ring) Snap Ring Number 6 = .078" Thick, Approximate 2-7/8" Diameter. (C1 Clutch Backing Plate Retaining Snap Ring) Snap Ring Number 7 = "Spiral" Snap Ring, Approximate 3-1/4" Diameter. (C1 Clutch Backing Plate Snap Ring, "Spiral" Retaining Snap Ring) Snap Ring Number 8 = .092" Thick, Approximate 8-3/8" Diameter, Same as Snap Ring Number 4. (C2 Clutch Backing Plate Retaining Snap Ring)

Snap Ring

No. 8

Snap Ring

No. 7

Snap Ring

No. 6

Snap Ring

No. 5

Snap Ring

No. 4

Snap Ring

No. 3

72

Snap Ring

No. 2

Snap Ring

No. 1

Figure 106

AUTOMATIC TRANSMISSION SERVICE GROUP

Technical Service Information

CONTINUED FROM PAGE 71

15. Install new C1 clutch piston inner lip seal, as shown in Figure 107. Note: This seal is hard plastic and difficult to

remove. If the inner lip seal is good, leave it alone and re-use it, or replace as necessary.

16. Install new C1 clutch piston outer "D" ring seal in piston groove, as shown in Figure 107.

17. Lubricate both the seals with a small amount of TransJel®, and install piston into the C1 clutch housing, as shown in Figure 108.

18. Install C1 clutch piston return spring assembly onto the C1 clutch piston (See Figure 108).

19. Compress the return spring and install the snap ring into the groove ensuring that it is properly seated (See Figure 108). Note: This snap ring is also difficult to install.

Use the proper tools and refer to Figure 106 for snap ring identification.

C1 CLUTCH HOUSING

SNAP RING

C1 CLUTCH HOUSING

RETURN SPRING ASM.

C1 CLUTCH PISTON

INNER SEAL

C1 CLUTCH

PISTON

C1 CLUTCH PISTON

OUTER "D" RING

Continued on Page 74

C1 CLUTCH

PISTON AND SEALS

C1/C2 CLUTCH

HOUSING

Figure 108Figure 107

AUTOMATIC TRANSMISSION SERVICE GROUP

73

Technical Service Information

CONTINUED FROM PAGE 73

20. Lubricate the molded C1 clutch balance piston with small amount of TransJel®, and install in C1/C2 clutch housing (See Figure 109). Note: Replace balance piston as necessary.

21. Install the C1 clutch balance piston snap ring as shown in Figure 109, and ensure that it is fully seated (See Figure 109).

22. Lubricate the molded C2 clutch balance piston with small amount of TransJel®, and install in C1/C2 clutch housing (See Figure 109). Note: Replace balance piston as necessary.

23. Install the C2 clutch balance piston snap ring as shown in Figure 109, and ensure that it is fully seated (See Figure 109).

C2 CLUTCH

BALANCE PISTON

SNAP RING

C1 CLUTCH

BALANCE PISTON

SNAP RING

TURBINE SHAFT

SNAP RING

C1/C2 CLUTCH HOUSING ASM.

C2 CLUTCH

BALANCE PISTON

TURBINE SHAFT

ASSEMBLY

74

C1 CLUTCH

BALANCE PISTON

TURBINE SHAFT

SEALING RINGS

Figure 109 Figure 110

AUTOMATIC TRANSMISSION SERVICE GROUP

Technical Service Information

24. Install two new sealing rings onto turbine shaft as shown in Figure 110.

25. Now install the turbine shaft into the splines of the C1/C2 clutch housing and install the eyelet snap ring in bottom groove (See Figure 110). Note: This is the smaller of the 2 eyelet snap

rings in this housing. Refer to Figure 106 for positive snap ring identification.

26. Install C1 clutch pack beginning with a steel plate, and alternating with a lined plate until you have installed 6 required steel plates and 6 required lined plates (See Figure 111). Note: Notice that the steel plates have internal

teeth and the lined plates have external teeth.

27. Install the C1 clutch backing plate in housing in the direction shown in Figure 111, and make sure that it is fully seated.

28. Install the external C1 clutch backing plate snap ring as shown in Figure 111. Note: The Spiral snap ring must be removed

from the backing plate to install the external snap ring. Refer to Figure 106 for positive snap ring identification.

29. After the external backing plate snap ring has been installed, now install the "Spiral" snap ring on the inside groove of backing plate, as shown in Figure 111. Note: The Spiral snap ring must be installed

in backing plate to retain the external snap from possibly coming off from centrifugal force. Refer to Figure 106 for positive I.D. of snap rings in C1/C2 housing.

C1 CLUTCH

"SPIRAL"

SNAP RING

C1 CLUTCH

BACKING PLATE

SNAP RING

C1 CLUTCH

BACKING PLATE

C1 STEEL

PLATES

(6 REQ.)

C1 LINED

PLATES

(6 REQ.)

Continued on Page 76

AUTOMATIC TRANSMISSION SERVICE GROUP

C1/C2 CLUTCH

HOUSING ASSEMBLY

Figure 111

75

C1 CLUTCH HUB TO

C2 CLUTCH HUB

THRUST BEARING

C1 CLUTCH HUB

TURBINE SHAFT TO

C1 CLUTCH HUB

THRUST BEARING

Technical Service Information

CONTINUED FROM PAGE 75

30. Install dial indicator onto C1/C2 clutch housing as shown in Figure 112, with indicator indexed against the C1 selective backing plate, and set the dial to zero.

31. Lift up on both sides of C1 clutch pack until the selective backing plate is against the snap ring, and record dial indicator reading. Note: C1 clutch clearance is .105" - .125".

32. Change the C1 backing plate as necessary to obtain correct clutch clearance.

33. Install the turbine shaft/C1 clutch hub thrust bearing assembly onto the turbine shaft in the direction shown in Figure 112.

34. Install the C1 clutch hub over the external teeth of the lined plates, in a twisting back and forth motion until fully seated (See Figure 112).

35. Install the C1 clutch hub/C2 clutch hub thrust bearing assembly onto the C1 clutch hub in the direction shown in Figure 112.

36. Install the C2 clutch hub over C1 clutch hub, as shown in Figure 113.

37. Install C2 clutch hub to input sun gear thrust washer, ensuring that tabs are engaged into the slots on C2 clutch hub, as shown in Figure 113

CHECKING C1 CLUTCH CLEARANCE

Clearance Should Be .105" - .125"

0

1010

2020

3030

4040

5050

0

INDICATOR

DIAL

76

Figure 112

AUTOMATIC TRANSMISSION SERVICE GROUP

Technical Service Information

38. Install the C2 clutch pack into the housing, as shown in Figure 114, beginning with a steel plate and alternating with lined plates until you have installed 7 steel plates and 6 lined plates. Note: In the C2 clutch pack you begin with a

steel plate and end with a steel plate as shown in Figure 114.

Continued on Page 78

C2 CLUTCH HUB TO

INPUT SUN GEAR

THRUST WASHER

C2 CLUTCH

HUB

C2

STEEL

PLATES

C2

LINED

PLATES

Figure 113

AUTOMATIC TRANSMISSION SERVICE GROUP

Figure 114

77

P1 PLANETARY

DRIVE FLANGE

P1 PLANETARY

(INPUT) SUN GEAR

Technical Service Information

CONTINUED FROM PAGE 76

36. Install the P1 planetary drive flange snap ring into the lower groove in the clutch housing, as shown in Figure 117.

37. Check the C2 clutch clearance using a feeler gage, as shown in Figure 117. Note: Correct C2 clutch clearance should be

.060" - .085" (See Figure 117). There are no selectives for C2 clutch. If the clearance is

P1 PLANETARY

DRIVE FLANGE

SNAP RING

WIDE

TOOTH

not correct, there is a mis-assembly.

38. Remove the P1 planetary drive flange snap ring from the lower groove in the clutch housing.

39. Install P1 planetary (Input) sun gear through the P1 planetary drive flange from the bottom as shown in Figures 115 and 116.

40. Holding the assembly by the sun gear, install the sun gear and drive flange assembly into the C1/C2 housing engaging the drive flange teeth into the splines of housing (See Figure 115). Note: Notice that drive flange has three wide

teeth that must be indexed to 3 wide grooves in the housing (See Figure 115).

41. Install the P1 planetary drive flange snap ring into top groove in housing (See Figure 115). Note: Refer to Figure 106 for C1/C2 clutch

housing snap ring identification as necessary.

78

P1 SUN GEAR AND DRIVE FLANGE ASSEMBLED

P1 PLANETARY

(INPUT) SUN GEAR

P1 PLANETARY

DRIVE FLANGE

Figure 115 Figure 116

AUTOMATIC TRANSMISSION SERVICE GROUP

Technical Service Information

42. Install the P1 sun gear to P1 planetary carrier thrust bearing onto the sun gear in the direction shown in Figure 118, and retain with a small amount of TransJel®.

43. Set completed C1/C2 Clutch Housing assembly aside for the final assembly process. Refer to Figure 118.

"COMPONENT REBUILD"

Continued on Page 82

CHECKING C2 CLUTCH CLEARANCE

Clearance should be .060" - .085"

P1 SUN GEAR TO

P1 PLANETARY CARRIER

THRUST BEARING

COMPLETED

C1/C2 CLUTCH

HOUSING

Figure 117

AUTOMATIC TRANSMISSION SERVICE GROUP

Figure 118

79

Technical Service Information

ALLISON SERIES 1000/2000 COMPLETE VALVE BODY

Accumulator

Valve Springs

Accumulator

Valves

Retainer Assembly

80

PRESSURE SWITCH

ASSEMBLY

Shift Solenoid "E"

(Normally Closed)

Trim Solenoid "B"

(Normally Open)

Trim Solenoid "A"

(Normally Closed)

Shift Solenoid "C"

(Normally Closed)

Figure 119

AUTOMATIC TRANSMISSION SERVICE GROUP

TCC Solenoid "F"

(N/C PWM)

Shift Solenoid "D"

(Normally Closed)

"Shift" Valve body

(See Figure 124)

Spacer Plate

"Main" Valve body

(See Figure 123)

Technical Service Information

Internal Wire

Harness Asm.

5

4

1. PRESSURE SWITCH ASSEMBLY .

2. REVERSE SIGNAL PIPE ASSEMBLY.

3. VALVE BODY TO VALVE BOD Y BOLT , M6 X 1.0 X 65 (1 REQUIRED).

4. VALVE BODY TO VALVE BOD Y BOLT , M6 X 1.0 X 50 (23 REQUIRED).

5. VALVE BODY TO CASE BOLTS, M6 X 1.0 X 50 (15 REQUIRED).

Figure 120

1

2

3

AUTOMATIC TRANSMISSION SERVICE GROUP

81

Technical Service Information

COMPONENT REBUILD (Cont'd)

VALVE BODY ASSEMBLY

1. Disassemble the valve body assembly, using Figures 119 and 120 as a guide.

2. Remove the two bolts retaining the reverse pipe, and remove the reverse pipe from valve body assembly (See Figure 121). Note: Notice the manual valve pin, as shown

in Figure 121. This pin can fall out and not be noticed. Remove it now and place in safe place until reassembly.

3. Remove the wire connector from the pressure switch assembly and all six solenoids as shown in Figure 119.

4. Remove the two solenoid retaining clips from valve body, shown in Figure 121 and remove the internal wire harness assembly.

5. Remove the three bolts from the trim solenoid retaining bracket and remove the bracket, as shown in Figure 119.

6. Remove the two trim solenoids using caution so that valve trains behind them do not come out at this time. Note: Notice that Trim Solenoid "A" has a

green "O" ring, and Trim Solenoid "B" has a black "O" ring. The snout diameters are also different, .645" for "A" and .665" for "B". Refer to Figure 122.

7. Air checks and resistance readings for all of the solenoids are provided in Figure 122, that can be performed now to determine if replacement is necessary. Note: Air checks should be made on fixture

with 40 PSI regulated air pressure.

Continued on Page 86

VALVE BODY ASSEMBLY

Internal Wiring Harness retained with

these two solenoid retaining clips.

Remove Reverse Pipe.

D

u

Pa

g

e

82

CAUTION: This manual valve pin is easily lost, as it may fall out un-noticed.

Figure 121

AUTOMATIC TRANSMISSION SERVICE GROUP

Technical Service Information

SOLENOID AIR CHECKS

TRIM SOLENOID "A"

(Normally Closed)

Snout

Diameter

= .645"

Blow Air

In Here

De-energized = No Air Here Energized = Air Here

Blow Air

In Here

Green

"O" Ring

5.5 - 8.0 W

@ 72°F

Snout

Diameter

= .665"

Blow Air

In Here

SHIFT SOLENOIDS "C", "D" AND "E"

20 - 30 W

@ 72°F

Blow Air

In Here

TRIM SOLENOID "B"

(Normally Open)

Black

"O" Ring

De-energized = Air Here

Energized = No Air Here

5.5 - 8.0 W

@ 72°F

De-energized = Air Exits Here

Blow Air

In Here

Energized = Air Exits Here

LOCK-UP SOLENOID "F"

8 - 15 W

@ 72°F

De-energized = Air Exits Here

Figure 122

AUTOMATIC TRANSMISSION SERVICE GROUP

83

Technical Service Information

"MAIN" VALVE BODY EXPLODED VIEW

1. MAIN VALVE BODY CASTING.

2. ALIGNMENT DOWELS (5 REQUIRED).

3. MAIN CONTROL RELIEF VALVE.

4. MAIN CONTROL RELIEF VALVE SPRING.

5. MAIN CONTROL RELIEF VALVE SPRING RETAINER.

6. EXHAUST BACKFILL VALVE SPRING RETAINER.

7. EXHAUST BACKFILL VALVE SPRING.

8. EXHAUST BACKFILL VALVE.

9. BOLT, M6 X 1.0 X 50 (23 REQUIRED)

10. SOLENOID "F" TRIM VALVE SPRING.

11. SOLENOID "F" TRIM VALVE.

12. SOLENOID "F" TRIM VALVE SLEEVE.

13. SOLENOID "F" SMALL "O" RING.

5

4

6

8

7

Free Length = .875"

Number Coils = 11

Spring Diameter = .490"

Wire Diameter = .034"

Free Length = 1.690"

Number Coils = 13

Spring Diameter = .550"

Wire Diameter = .058"

3

14. SOLENOID "F" LARGE "O" RING.

15. SOLENOID "F" (LOCK-UP PWM).

16. SOLENOID "F" RETAINING CLIP .

17. SHIFT SOLENOID "D" SMALL "O" RING.

18. SHIFT SOLENOID "D" LARGE "O" RING.

19. SHIFT SOLENOID "D".

20. SHIFT SOLENOID "D" RETAINING CLIP .

21. SHIFT SOLENOID "E" SMALL "O" RING.

22. SHIFT SOLENOID "E" LARGE "O" RING.

23. SHIFT SOLENOID "E".

24. TRIM PRESSURE ACCUMULATORS.

25. TRIM PRESSURE ACCUMULATOR SPRINGS.

26. TRIM SOLENOID "A" AND "B" RETAINING BRACKET.

27. TRIM "B" VALVE SPRING.

28. TRIM "B" VALVE.

29. TRIM GAIN VALVE.

30. TRIM SOLENOID "B" "O" RING (BLACK).

31. TRIM SOLENOID "B" (N/O PWM) (Snout Diameter = .665").

2

1

32. TRIM SOLENOID "A" (N/C PWM) (Snout Diameter = .645").

33. TRIM SOLENOID "A" "O" RING (GREEN).

34. TRIM GAIN VALVE.

35. TRIM "A" VALVE (Note I.D. Ring Between Lands).

36. TRIM "A" VALVE SPRING.

Free Length = .845"

Number Coils = 7

Spring Diameter = .384"

Wire Diameter = .028"

36

35

34

27

28

33

32

84

9

Free Length = .838"

Number Coils = 7

Spring Diameter = .382"

Wire Diameter = .028"

10

21

22

23

17

18

11

12

13

19

20

14

15

16

25

26

9

Figure 123

AUTOMATIC TRANSMISSION SERVICE GROUP

24

29

30

31

2

Free Length = 1.275"

Number Coils = 16

Spring Diameter = .306"

Wire Diameter = .043"

Technical Service Information

"SHIFT" VALVE BODY EXPLODED VIEW

1. SHIFT VALVE BODY CASTING.

2. SOLENOID SCREEN.

3. SHIFT SOLENOID "C".

4. SHIFT SOLENOID "C" RETAINING CLIP .

5. MANUAL SELECTOR VALVE.

6. MANUAL SELECTOR VALVE PIN.

7. SOLENOID "D" SHIFT VALVE.

8. SOLENOID "D" SHIFT VALVE SPRING.

9. SOLENOID "D" SHIFT VALVE BORE PLUG.

10. SOLENOID "D" SHIFT VALVE LINE-UP RETAINER.

11. SOLENOID "E" SHIFT VALVE.

12. SOLENOID "E" SHIFT VALVE SPRING.

13. SOLENOID "E" SHIFT VALVE BORE PLUG.

14. SOLENOID "E" SHIFT VALVE LINE-UP RETAINER.

15. SOLENOID "C" SHIFT VALVE.

16. SOLENOID "C" SHIFT VALVE SPRING.

17. SOLENOID "C" SHIFT VALVE LINE-UP RETAINER.

18. MAIN CONTROL VALVE.

19. MAIN CONTROL VALVE SPRING.

20. MAIN CONTROL VALVE LINE-UP RETAINER.

Free Length = 1.155"

Number Coils = 11

Spring Diameter = .435"

Wire Diameter = .037"

8

9

10

14

19

3

18

4

2

1

5

6

7

12

13

17

11

15

16

20

Free Length = 1.155"

Number Coils = 11

Spring Diameter = .435"

Wire Diameter = .037"

AUTOMATIC TRANSMISSION SERVICE GROUP

Free Length = 1.170"

Number Coils = 11

Spring Diameter = .435"

Wire Diameter = .037"

Figure 124

Free Length = 1.705"

Number Coils = 13

Spring Diameter = .550"

Wire Diameter = .057"

85

Technical Service Information

CONTINUED FROM PAGE 82

8. Place main valve body on a flat work surface, remove the valve trains one at a time and lay them out in order, as shown in Figure 123.

9. Clean and inspect all main valve body parts thoroughly and dry with compressed air.

10. Assemble the main valve body valve trains exactly as they are shown in Figure 123. Note: Notice that the various spring specs

are included in Figure 123, to ensure that they are installed in their proper locations. Lubricate all valves in the main valve body with LubeGard® spray lubricant.

11. Place shift valve body on a flat work surface, remove the valve trains one at a time and lay them out in order, as shown in Figure 124.

12. Clean and inspect all shift valve body parts thoroughly and dry with compressed air.

13. Assemble the shift valve body valve trains exactly as they are shown in Figure 124.

Note: Notice that the various spring specs are included in Figure 124, to ensure that they are installed in their proper locations. Lubricate all valves in the shift valve body with LubeGard® spray lubricant.

14. Lay the main valve body on flat work surface as shown in Figure 126, and install the spacer plate over the dowel pins.

15. Install the shift valve body on top of the spacer plate and over dowels, as shown in Figure 126.

16. Turn the entire assembly over on the flat work surface, as shown in Figure 125.

17. Install only 14, M6 x 1.0 x 50mm, main valve body to shift valve body bolts in the locations shown in Figure 125, and snug them down. Note: Do not tighten at this time.

18. Install both Trim Solenoids "A" and "B" in the exact locations shown in Figure 127. Note: The trim solenoids have different snout

dimensions and "O" ring colors, as shown in Figure 127. Ensure that they are installed in their proper locations.

19. Install the trim solenoid retaining bracket and three M6 x 1.0 x 50mm bolts, as shown in Figure 127, and snug them down. Note: Do not tighten.

Continued on Page 89

DuPage

29536840

ASSEMBLE SHIFT VALVE BODY TO MAIN VALVE BODY

Install 14 Only, M6 X 1.0 X 50, Main Valve Body to Shift Valve Body Bolts,

In The Locations Shown Here, and

Snug Them Down. Do Not tighten.

8 mm Head

Actual Size

86

Figure 125

AUTOMATIC TRANSMISSION SERVICE GROUP

"Shift" Valve body

Spacer Plate

"Main" Valve body

Technical Service Information

DuPage

29536840

Figure 126

ASSEMBLE TRIM SOLENOIDS

Install both Trim Solenoids "A" and "B" in the exact locations shown below, as they are different. Install the retaining bracket and 3 M6 x 1.0 x 50 bolts to retain bracket, and snug down. Do Not tighten.

Trim Solenoids

Retaining Bracket

Trim Solenoid "B", (N/O),

Snout Diameter = .665",

Requires Black "O" Ring.

8 mm Head

Actual Size

Figure 127

AUTOMATIC TRANSMISSION SERVICE GROUP

Trim Solenoid "A", (N/C),

Snout Diameter = .645",

Requires Green "O" Ring.

87

Technical Service Information

Install the Pressure Switch Assembly

and 5 M6 x 1.0 x 50 retaining Bolts

DuPage

in the locations shown here, and

Snug Them Down. Do Not tighten.

29536840

Pressure Switch Assembly

Figure 128

8 mm Head

Actual Size

8 mm Head 8 mm Head

DuPage

29536840

One M6 x 1.0 x 50mm

Reverse Pipe Retaining Bolt.

Reverse Feed Pipe

One M6 x 1.0 x 65mm

Reverse Pipe Retaining Bolt.

Figure 129

Actual Size

88

AUTOMATIC TRANSMISSION SERVICE GROUP

Technical Service Information

CONTINUED FROM PAGE 86

20. Inspect the pressure switch assembly to verify the condition and location of the "O" rings on the back side (See Figure 130).

21. One of the six switches in the pressure switch assembly is Normally Closed (N/C) and the other five are Normally Open (N/O), as shown in Figure 130. Note: Notice that two of the N.O. switches

are not used in this unit (See Figure 130).

22. Check the operation of all switches with your DVOM with the leads placed on the pins on each side of each switch (See Figure 130).

23. To check the resistance values for the TFT sensor, place the leads of the ohmmeter across pins "E" and "F" of pressure switch connector. Note: 3088-3942 Ohms @ 20°C (68°F).

159-198 Ohms @ 100°C (212°F).

24. Install the pressure switch assembly onto the valve body using five M6 x 1.0 x 50mm bolts, and installed only in the locations that are shown in Figure 128, and snug them down. Note: Do not tighten at this time.

25. Install the reverse pipe onto the valve body, as shown in Figure 129, using one 50mm long bolt and one 65mm long bolt in the locations shown in Figure 129 and snug them down. Note: Do not tighten at this time.

26. Now torque all valve body bolts to 12 N.m, (9 ft.lb), beginning in the center and working outward in a circle (See Figure 129). Note: Do not over-torque.

Continued on Page 90

"E" SHIFT (N/O)

NOT USED (N/O)

BENCH TESTING PRESSURE SWITCH ASSEMBLY

REVERSE (N/C)

(THERMISTER)

A B C D E F

Pressure Switch Assembly

Receptacle (Face View)

NOT USED (N/O)

TEMP SENSOR

"D" SHIFT (N/O)

"C" SHIFT (N/O)

Pressure Switch

Connector

C

A

NOT USED

D

B

E

C

NOT USED

R

D

E F

PRESSURE SWITCH

ASSEMBLY

TEMP

SENSOR

Figure 130

AUTOMATIC TRANSMISSION SERVICE GROUP

89

Technical Service Information

CONTINUED FROM PAGE 89

27. Orient both trim solenoids, TCC solenoid and shift solenoids with connectors pointed in the direction shown in Figure 131.

28. Install the internal wiring harness assembly, as shown in Figure 131, ensuring that connectors are fully seated and locked. Note: The wire harness assembly is retained

to the valve body with the two solenoid clips as shown in Figure 131.

29. Install the manual valve into the valve body and the manual valve pin, ensuring that the pin enters the slot in the valve body casting. Refer to Figure 131.

30. Set the completed valve body assembly aside for the final assembly process.

Internal Wiring Harness retained with

these two solenoid retaining clips.

MANUAL

VALVE PIN

MANUAL VALVE

D

uP

ag

e

90

Figure 131

AUTOMATIC TRANSMISSION SERVICE GROUP

Technical Service Information

EXTENSION HOUSING FOR TWO WHEEL DRIVE

ALL MODELS 2WD AND PARKING

BRAKE MODELS

EXTENSION HOUSING FOR MODELS WITH PARKING BRAKE

EXTENSION HOUSING FOR FOUR WHEEL DRIVE

Figure 132

AUTOMATIC TRANSMISSION SERVICE GROUP

91

Technical Service Information

EXTENSION HOUSING PARTS EXPLODED VIEW

1

2 3 4 5

12

9 10 11

11

13

92

14

Figure 133

AUTOMATIC TRANSMISSION SERVICE GROUP

Technical Service Information

EXTENSION HOUSING PARTS EXPLODED VIEW

6 7 8

15 16 17 18 19 20 21

1. P-3 PLANETARY CARRIER. (REFERENCE ONLY)

2. CAGED NEEDLE BEARING RETAINING SNAP RING.

3. CAGED NEEDLE BEARING ASSEMBLY.

4. OUTPUT SPEED SENSOR TONE WHEEL (MODEL SENSITIVE).

5. "SELECTIVE" SPACER.

6. C-5 CLUTCH PISTON ASSEMBL Y .

7. C-5 CLUTCH PISTON OUTER "D" RING SEAL.

8. C-5 CLUTCH PISTON INNER LIP SEAL.

9. EXTENSION HOUSING TO CASE GASKET.

10. EXTENSION HOUSING (MODEL SENSITIVE).

11. EXTENSION HOUSING BOLTS, M10 x 1.5 x 40 (16 REQUIRED).

12. OUTPUT SHAFT SPEED SENSOR (MODEL SENSITIVE).

13. OUTPUT SHAFT SPEED SENSOR "O" RING.

14. SPEED SENSOR RETAINING BOLT, M6 x 1.0 x 13.

15. FRETTING RING.

16. BALL BEARING ASSEMBLY.

17. BALL BEARING RETAINING SNAP RING.

18. EXTENSION HOUSING METAL CLAD SEAL (MODEL SENSIITIVE).

19. TRANSMISSIONYOKE ASSEMBLY (MODEL SENSITIVE).

20. YOKE WASHER (MODEL SENSITIVE).

21. YOKE RETAINING BOLT , 1/2"-20 (MODEL SENSITIVE).

Figure 134

AUTOMATIC TRANSMISSION SERVICE GROUP

93

Technical Service Information

COMPONENT REBUILD (Cont'd)

EXTENSION HOUSING ASSEMBLY

1. Disassemble the extension housing assembly using Figures 133 and 134 as a guide.

2. Remove and discard the C5 clutch piston seals from the C5 clutch piston.

3. Inspect all extension housing parts for any wear and/or damage.

4. Clean all extension housing parts thoroughly and dry with compressed air.

5. Position the extension housing on a flat work surface with the rear facing up, as shown in Figure 135.

6. Install the ball bearing fretting ring into the extension housing bore (See Figure 135).

7. Install the ball bearing and the retaining snap ring, as shown in Figure 135. Note: Ensure the snap ring is fully seated.

8. Install the rear metal clad seal (if used) into the extension housing, using the proper seal driver as shown in Figure 135.

9. Turn the extension housing over so the front side is facing up, as shown in Figure 136.

10. Install the selective spacer against ball bearing in extension housing (See Figure 136).

11. Install output speed sensor tone wheel (if used) in the direction shown in Figure 136.

Continued on Page 95

REAR SEAL

ASSEMBLY

BALL BEARING

SNAP RING

BALL BEARING

ASSEMBLY

FRETTING RING

(SPACER)

EXTENSION HOUSING

(MODEL SENSITIVE)

CAGED NEEDLE

BEARING

SNAP RING

CAGED NEEDLE

BEARING

SPEED SENSOR

TONE WHEEL

(MODEL SENSITIVE)

"SELECTIVE"

SPACER

EXTENSION HOUSING

(MODEL SENSITIVE)

94

Figure 135 Figure 136

AUTOMATIC TRANSMISSION SERVICE GROUP

C5 CLUTCH PISTON

INNER LIP SEAL

Technical Service Information

CONTINUED FROM PAGE 94

12. Install caged needle bearing in the extension housing bore, as shown in Figure 136.

13. Install the caged needle bearing retaining snap ring, as shown in Figure 136. Note: Ensure the snap ring is fully seated.

14. Install the C5 clutch piston inner lip seal into the piston with the lip facing direction shown in Figure 137.

15. Install the C5 clutch piston outer "D" ring seal into the groove in piston (See Figure 137).

16. Lubricate both piston seals, and seal surfaces in the extension housing with a small amount of TransJel® (See Figure 137).

17. Install the C5 clutch piston assembly into the extension housing, using care so as not to cut or damage the seals (See Figure 137).

18. Set the completed extension housing assembly aside for the final assembly process.

C5 CLUTCH PISTON

OUTER "D" RING

SEAL

COMPLETED EXTENSION HOUSING ASSEMBLY

EXTENSION HOUSING

(MODEL SENSITIVE)

Figure 137 Figure 138

AUTOMATIC TRANSMISSION SERVICE GROUP

95

Technical Service Information

GEAR TRAIN PARTS EXPLODED VIEW

3

1

2

9 10 11

4

96

17

18

2WD Version

4WD Version

Figure 139

AUTOMATIC TRANSMISSION SERVICE GROUP

19

Technical Service Information

GEAR TRAIN PARTS EXPLODED VIEW

5 6 7

8

12 13 14 15 16

1. INPUT SUN GEAR, P1SUN GEAR (INSTALLED IN C1/C2 HOUSING).

2. INPUT SUN GEAR/P1 PLANETARY CARRIER THRUST BEARING.

3. P1 PLANETARY INTERNAL RING GEAR.

4. P1 RING GEAR/P2 RING GEAR "PEEK" THRUST WASHER.

5. P1 PLANETARY SNAP RING, RET AINS P2 INTERNAL RING GEAR.

6. P1 PLANETARY CARRIER ASSEMBL Y .

7. P2 PLANETARY INTERNAL RING GEAR.

8. P1 PLANETARY CARRIER/P2 PLANETAR Y CARRIER THRUST BEARING.

9. P2 PLANETARY SNAP RING, RET AINS P3 INTERNAL RING GEAR.

10. P2 PLANETARY CARRIER ASSEMBL Y .

11. P3 PLANETARY INTERNAL RING GEAR.

12. TRANSMISSION MAIN SHAFT.

13. P2 PLANETARY CARRIER/P2 SUN GEAR THRUST BEARING.

14. P2 SUN GEAR.

15. SUN GEAR SPACER.

16. P3 SUN GEAR.

17. P3 SUN GEAR/OUTPUT SHAFT THRUST BEARING.

18. OUTPUT SHAFT (MODEL SENSITIVE)..

19. P3 PLANETARY CARRIER ASSEMBL Y .

Figure 140

AUTOMATIC TRANSMISSION SERVICE GROUP

97

Technical Service Information

COMPONENT REBUILD (Cont'd)

GEAR TRAIN ASSEMBLY

1. Inspect all gear train parts thoroughly, that are shown in Figures 139 and 140, for any wear and/or damage.

2. Check all 3 planetary carriers for proper pinion end play with a feeler gage (See Figure 143). Note: End play should be .020"-.030".

3. Lay the P2 ring gear (with notches) on a flat work surface in direction shown in Figure 141.

4. Install the P1 planetary carrier into the splines of the P2 ring gear, and install the P1 planetary snap ring, as shown in Figure 141.

P1 PLANETARY

SNAP RING

5. Install the P1/P2 ring gear thrust washer onto the assembly as shown in Figure 142. Note: This thrust washer will "Snap" in place

when it is fully seated.

6. Set the completed P1 planetary assembly aside for final assembly (See Figure 145).

7. Lay the P3 ring gear (no notches) on the flat work surface in direction shown in Figure 144.

8. Install the P2 planetary carrier into the splines of the P3 ring gear, and install the P2 planetary snap ring, as shown in Figure 144.

9. Set the completed P2 planetary assembly aside for final assembly (See Figure 145).

10. After P3 planetary carrier has been inspected and correct pinion end play has been verified, set it aside for final assembly (See Figure 145).

P1 PLANETARY

CARRIER

P2 PLANETARY

RING GEAR

P1/P2 RING GEAR

THRUST WASHER

P1 PLANETARY

CARRIER

ASSEMBLY

98

Figure 141 Figure 142

AUTOMATIC TRANSMISSION SERVICE GROUP

P2 PLANETARY

SNAP RING

Technical Service Information

COMPLETED

P1 PLANETARY

AND P2 RING GEAR

Figure 143

COMPLETED

P2 PLANETARY

AND P3 RING GEAR

P2 PLANETARY

CARRIER

P3 PLANETARY

RING GEAR

COMPLETED

P3 PLANETARY

Figure 144

AUTOMATIC TRANSMISSION SERVICE GROUP

Figure 145

99

Technical Service Information

1

8 9

2

CASE CLUTCH PARTS EXPLODED VIEW

3

4

5

10

100

11

16

17

18

Figure 146

AUTOMATIC TRANSMISSION SERVICE GROUP

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

Specifications and Main Features

Frequently Asked Questions

User Manual