PPE Stage 5, Stage 4 Installation Manual

Stage5 Installation Guide

Rev: 01-31/18 | v19

PPEdiesel.com

Technical Support [phone]

2006-2010 Allison LBZ/ LLM

STAGE 5 TRANSMISSION KIT

INSTALLATION GUIDE

Stage5 Installation Guide

2

DISCLAIMER OF LIABILITY

This is a performance product which can be used with increased horsepower above and

beyond factory specications. Additional horsepower creates more stress on the drivetrain
components, which could result in drivetrain failure. Legal in California only for racing
vehicles which may never be used on the highway.

This agreement sets forth the terms and conditions for the use of this product. The instal­lation of this product indicates that the Buyer has read and understands this agreement
and accepts the terms and conditions.
Pacic Performance Engineering Inc., its distributors, employees, and dealers (the
“Seller”) shall not be responsible for the product’s proper use and service. The buyer
hereby waives all liability claims.
The Buyer hereby acknowledges no reliance on the Sellers skill or judgment to select or
furnish goods suitable for any particular purpose and that there are no liabilities which

extend beyond the description on the face hereof, and the Buyer hereby waives all

remedies or liabilities expressed or implied, arising by law or otherwise (including without
any obligation of the Seller with respect to tness, merchantability and consequential
damages), or whether or not occasioned by the Seller’s negligence. The Seller disclaims
any warranty and expressly disclaims any liability for personal injury or damages. The
Buyer acknowledges and agrees that the disclaimer of any liability for personal injury is a
material term for this agreement and the Buyer agrees to indemnify the Seller and to hold
the Seller harmless from any claim related to the item of equipment purchased. Under no
circumstances will the Seller be liable for any damages or expenses by reason of use or
sale of any such equipment.The Seller assumes no liability regarding the improper instal­lation or misapplication of its products. It is the installer’s responsibility to check for proper
installation and if in doubt contact the manufacturer.
The Buyer is solely responsible for all warranty issues from the manufacturer.

LIMITATION OF WARRANTY

The Seller gives Limited Warranty as to description, quality, merchantability, and tness for
a particular purpose, productiveness, or any other matter of Seller’s product sold herewith.

The Seller shall not be responsible for the products proper use and service and the Buyer

hereby waives all rights other than those expressly written herein. This warranty shall not
be extended, altered or varied except by a written instrument signed by Seller and Buyer.
The Warranty is limited to two (2) years from the date of sale and limited solely to the parts
contained within the products kit. All products that are in question of Warranty must be

returned prepaid to the Seller and must be accompanied by a dated proof of purchase

receipt. All Warranty claims are subject to approval by Seller. Under no circumstances will
the Seller be liable for any labor charged or travel time incurred in diagnosis for defects,
removal, or reinstallation of this product or any other contingent expenses.
Under no circumstances will the Seller be liable for any damage or expenses incurred
by reason of the use or sale of any such equipment. In the event that the buyer does
not agree with this agreement: the buyer may promptly return this product, in a new and
unused condition in its original packaging, with a dated proof of purchase to the place
of purchase within ten (10) days from date of purchase for a full refund. The installation
of this product indicates that the buyer has read and understands this agreement and
accepts its terms and conditions.

Stage5 Installation Guide

3

Remove the C4 retaining rings while compressing the backing plate. Remove
the C4 clutch pack. Remove the C4 piston. Remove 3 spring sets from Apply
Plate. Discard OEM Apply Plate and Clutch Pack.

Remove plastic thrust washer from the front of the P1 carrier. Using assembly
gel install the washer onto steel shim provided, index tangs on washer to slots
in shim. Apply assembly gel to the rear side of the shim and install onto the P1
carrier (shim towards carrier) indexing into the slots on the carrier. Make sure
the shim and washer are all the way (down) evenly onto the carrier. Install thrust
bearing to the rear of the P1 carrier, retaining with assembly gel. Install P1 the
carrier into the P1 ring gear in case.

Lubricate and install C-4 piston furnished with the Air Bleed hole into line the with
top of case at the 12 o’clock position. Install return springs onto the new .250
Pressure Plate and install with groove side up. Install C-4 clutch pack (fur­nished). Starting with Friction against Apply Plate and alternating with Kolene®
Steel.

(Continue Step 2 next page)

Step 1

After the torque converter is removed place the transmission into a holder or stand
it up in a drain pan on oor. Place transmission with bell housing down. Remove
the rear extension housing as an assembly. Remove park pawl pin, park pawl, C5
return spring assembly. Remove P3 sun gear and thrust bearing.

NOTE: Pay attention to the directional install of Torrington bearing. Inverting
bearings will result in Extreme Damage.

Grasp the main shaft splines and lift straight up to remove the main shaft, P2
sun gear and spacer. Remove P2 planet carrier and thrust bearing. Remove C5
clutch pack and backing plate. Remove P1 planet carrier assembly and thrust
bearing. By lifting up with a slight twisting motion leaves the P1 ring gear in place.

We recommend performing all C4 clutch modications rst.

Step 2

Stage5 Installation Guide

4

We recommend soaking Frictions in ATF for a 30 minutes prior to installation.
When installing Frictions and Steels, align the slots in each plate with holes in
Apply Plate at the 12 o’clock position. Install 6 Frictions and 5 Steels. Install and
compress the C-4 backing plate, install Spiral Ring and then the Snap Ring. Po­sition gap in Snap Ring should be at the 1:30 position, aligning with a wide gap in
the case. Clearance should be from .060” to .075”.

Reassemble the rear section, be sure to align the slot in Sun Gear Spacer with
lube hole in Shaft Shoulder, when installing extension housing. The housing
will be spring loaded for the last ½” above case. GENTLY pull down evenly with
speed handle until ush. Torque to 45 ft.lbs.

Step 2 (Continued)

After a few years of service, wiring gets brittle. CAREFULLY disconnect all
electrical connections from the VB. Remove bolts. After bolts are out, wiggle VB
to lift it o󰀨 the dowels. Careful not to lose Manual Valve Link when removing VB.

Step 4

A

Gold bolts

Black bolts

A. Long bolt goes here.

Remove oil pan (12 x 13mm bolts)

Step 3

Stage5 Installation Guide

5

Remove tube.

Step 5

Remove Pressure Switch.

Step 6

Separator Plate

Step 8

Enlarge two holes on separator plate with the smaller drill furnished (.125).

Step 7

Separate the VB to access the Separa-

tor Plate.

Stage5 Installation Guide

6

Discard original trim valves and the springs from the small end of the valves.
Place new ball bearings the small spring into the hollow end of the new trim
valves. Use transmission gel (or petrolium jelly) to hold ball bearing in place. In­sert new outer springs over the small end of the trim valves. Install the assembly
into the Valve Body. Don’t force them, a little wiggle and they will drop in. Install
outer spring, solenoid valves and solenoids as shown. Outer spring must be
installed in the “A” Line up.

Step 9

Valve

A line up

B line up

Bell housing - Front View

Stator

With the bell housing o󰀨 the trans, remove 10 bolts in the bell housing, these
bolts have O-Rings under bolt heads.

Step 10

Remove 5 bolts from rear. Lift o󰀨
stator and ip it over.

Step 11

Replace Trim Valves

Valve A

has rib

Stage5 Installation Guide

7

Step 12 - C1 Disassembly

Stator - BST Assembly

A1-Lockup-BST

Hot Rod Allison Lockup

Boost Valve

Step 13

Remove and discard the original Converter Flow Valve, Spring and End Plug.
Install the New Valve, 3/8” Check Ball, Spring and new End Plug. Reuse pin.

Narrow

Wide

3/8”

White

End Plug

Pin

Stage5 Installation Guide

8

Remove the Converter housing and Stator support assembly. If your Stator has
the early style Babbitt bushing, replace it with a new stator support bushing (not
furnished). It is not necessary to remove pump from Converter housing. Using
PTO cover bolt, install as illustrated. Depress main regulator valve stop and
remove retaining pin. Remove valve stop, no need to remove spring or valve.
Install steel shim on spring side of Plug, Reinstall Plug and Retaining Pin.

Stator

Step 14

Make sure all valves are free. Remove the rotating clutch module from trans­mission by lifting and wiggle as you lift to avoid disturbing the main shaft lube to
the spacer position. Do not lift up on the main shaft. Disassemble the rotating
module and modify as per Valve Body Kit instructions. Converter housing on
bench provides a nice stand for working on and testing the module.

Stage5 Installation Guide

9

Step 15

Re-assemble the Stator support to housing with a new gaskets and install into
transmission. There have been a few of these leaking from the bell housing bolts
due to roughness in the casting. A little silicone under the bolt heads is highly
recommended.

Step 16

Assemble Stator, C1/C2 using the diagram below. Replace C1 clutches and
Bottom Apply Plate. (Clearance .095”-.110”)

Stage5 Installation Guide

10

Step 17

Install the stepped Apply Plate at side up. Make sure the bearing is on top of
the C-1 hub. Install the C-2 hub and start the clutch ordering with a Friction
against Apply Plate. Alternate Kolene® Steel and Frictions (8 Frictions and 8
Steels), ending with a Steel Plate on top. Install a bronze washer on the C2 hub.
Install the P1 Plate, Sun Gear and Snap Ring. Clearance should be from .070” to
.085”.
With rotating module in Converter housing you may air check the C-1 and the
C-2 with a rubber tipped blow gun. 3/8” hole should be at the 7 o’clock position
for the C1, C2 needs to be at the 5 o’clock position.

Step 18

Depress the C3 Top Plate and remove the Snap Ring, Top Plate, Clutch Pack,
Apply Plate, Springs and the C3 piston. Install the C3 piston (furnished), (bleed
hole nees to be at the 12 o’clock position) install return springs onto new .125”
Apply Plate (furnished). Install Apply Plate groove side up. Install the Fric­tions and Steels in same manner as the C4; 6 Frictions and 5 Kolene® Steels.
Aligning the slots with a 12 o’clock hole position. Install the C3 Pressure Plate
(furnished). Depress the plate and install the Snap Ring with the gap at the 1:30
position. Clearance should be from .065” to .075”.
Retain the bearing with assembly gel. Install the rotating module, making sure
module is fully seated. Install Converter housing with new gasket and torque to
45 ft.lbs. Check end play @ turbine shaft (.011” - .060”) Perform Valve Boy Modi­cations per Valve Body Kit instructions.

NOTE: Retain the C1, C3 Pressure Plates and C3, C4 Apply Pistons

for core deposit refund.

Step 19

IMPORTANT: Do not start the engine unless the transmission has been lled with trans­mission oil, minimum 16 quartz with Shallow Pan. 18 quartz with Heavy Duty DEEP pans.
Such as PPE aluminum pans.

Step 20

Complete the assembly and return the modied transmission to its original position on your
vehicle. Installation complete once the oil is lled to the correct level.

5 Frictions 4 Steels - Stock
6 Frictions 5 Steels - Preceding Kit
7 Frictions 6 Steels - Current Kit

Stage5 Installation Guide

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NOTE: To read and clear codes use the PPE’s Xcelerator tuner. Transmission
relearn procedure will take up to 2 hours, the PPE’s Xcelerator tuner can speed
up the process by using the re-set transmission procedure.

PPE Recommended Upgrades

PPE DEEP TRANSMISSION PAN

Includes Allison DEEP Pan Filter and
Installation Hardware. (Part #1280510)

Features:

• Increased uid capacity, runs up to 20 degrees cooler

• Easy to service

• High temperature drain plug magnet attracts metallic particles

• 1” ID port is large enough to use for lling

• Anodized nish for corrosion protection and added heat rejection

• Uses high quality re-usable OEM gasket

• Plugs, cap screws, and washers are stainless steel

• 2001-2011 Allison™1000 Transmission

Transmission Pan (Allison™)

The new Heavy Duty PPE Transmission pan is cast from A356-T6 aluminum
alloy. Fluid capacity is increased by 4 quarts. The robust side ribs provide added
strength to transmission. 1 1/4” high-internal heatsink ba󰀪es absorb heat and
channel oil ow to lter oil pick-up port. 3/4” deep-bottom heatsink, with ow
through channels, dissipates heat into passing air ow. Bare aluminum n­ish signicantly reduces transmission oil temperatures. 1/4”NPT and 1/8”NPT
threaded ports for gauge sensors. Retains use of high quality original Allison pan
gasket.

Stage5 Installation Guide

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**NOTE: RETAIN C1/C3 TOP PRESSURE PLATES

AND C3/C4 APPLY PISTONS FOR CORE DEPOSIT REFUND!**

****NOTE- Use the torque converter bolts that are supplied.****

Stage5 Installation Guide

13

Stage5 Installation Guide

14

PPE Recommended Upgrades

GM Performance Transmission Cooler

Keep your transmission cool with PPE’s performance transmission cooler. Lower
your transmission operating temperature with this bolt on replacement. 60%
increase in heat rejection surface lowers temperatures by 20-30 degrees. This
easy installation only takes about 30 minutes.
Available for 2001-2009 Duramax diesel engines.

Top View

06-10 Transmission Cooler

Billet Input Shaft (TGBIS)

The Billet Input shaft is for high performance transmissions, helping to withstand
higher horsepower and torque levels for towing or racing. This shaft is highly
recommended when installing Stage4 or Stage5 transmission kits.

Available for 2001-2009 Allison 1000 5 and 6 speed transmissions.

PPE

Stage5 Installation Guide

15

Notes:

PPEdiesel.com

[e-mail]

Phone: [phone]

Fax: [phone]

Allison TCM Fast Learn (with GM Tech 2 scan tool)

Note: Required after installing VBR upgrade kit, transmission upgrade kit

or complete transmission .

Note: Engine and transmission need to be at operating temperature
(105 – 210 F) or (40 - 120 C)

1) Plug Tech 2 into OBD2 port

2) Power on Tech 2

3) Select F0: Diagnostics

4) Select Vehicle Identication for Vehicle Year – for example “2007”

5) Select Vehicle Identication for Vehicle Type – for example “Light Duty Truck”

6) Select Vehicle Identication for Product Make – for example “GMC Truck”

7) Select Vehicle Identication for Product Line – for example “K” for 4WD

8) Select Vehicle Identication for Product Series – for example “Sierra Classic”

9) Select F0: Powertrain

10) Select Vehicle Identication for Engine Type – for example “(D) 6.6L V8 LBZ Diesel”

11) Select Vehicle Identication for Automatic Transfer Case – for example “YES”

12) Select F0: Transmission Control Module

13) Select F4: Module Setup

14) Select F0: Fast Learn Adapt. Process

15) Follow screen prompts as directed.