Allison 1000 & 2000 Transmission Service & Repair Manual

INDEX Copyright © ATSG 2000 May, 2000 ALLISON 1000/2000 SERIES 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. 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 AUTOMATIC TRANSMISSION SERVICE GROUP 18639 S.W. 107TH AVENUE MIAMI, FLORIDA 33157 (305) 670-4161 BACK BACK BACK GO TO PAGE

INTRODUCTION ALLISON 1000/2000 SERIES 1 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. 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. Updated October, 2003 DALE ENGLAND FIELD SERVICE CONSULTANT ED KRUSE TECHNICAL CONSULTANT WAYNE COLONNA TECHNICAL SUPERVISOR PETER LUBAN TECHNICAL CONSULTANT JIM DIAL TECHNICAL CONSULTANT GREGORY LIPNICK TECHNICAL CONSULTANT JERRY GOTT TECHNICAL CONSULTANT JON GLATSTEIN TECHNICAL CONSULTANT DAVID CHALKER TECHNICAL CONSULTANT MIKE SOUZA TECHNICAL CONSULTANT ROLAND ALVAREZ TECHNICAL CONSULTANT GERALD CAMPBELL TECHNICAL CONSULTANT "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. Copyright © ATSG 2000 AUTOMATIC TRANSMISSION SERVICE GROUP 18639 S.W. 107TH AVENUE MIAMI, FLORIDA 33157 (305) 670-4161

AUTOMATIC TRANSMISSION SERVICE GROUP Technical Service Information 3 Copyright © 2000 ATSG Allison Allison Allison Allison ALLISON 1000/2000 SERIES TWO WHEEL DRIVE FOUR WHEEL DRIVE Engine Speed Sensor Engine Speed Sensor Turbine Speed Sensor Turbine Speed Sensor Neutral Start Switch Neutral Start Switch Output Speed Sensor Figure 1

AUTOMATIC TRANSMISSION SERVICE GROUP Technical Service Information 4 Copyright © 2000 ATSG ** Range Ratios 1000 2000 C2 Clut C3 Clut C4 Clut C5 Clut Sol "A" Sol "B" Sol "C" Sol "D" Sol "E" Sol "F" C1 Clut Park Reverse X X X ON ON ON ON ON ON ON ON ON ON ON ON ON ON X 4.49 3.10 1.81 1.41 1.00 0.71 5.09 3.51 1.90 1.44 1.00 0.74 * * * * ** ** ** ** ** ** ** ** ** ** ** ** ** ** ** ** X X X X X X X X 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. * ALLISON 1000/2000 SERIES TRANSMISSION "C5" CLUTCH "C4" CLUTCH "C3" CLUTCH "C2" CLUTCH "C1" CLUTCH Figure 2

AUTOMATIC TRANSMISSION SERVICE GROUP Technical Service Information 5 Copyright © 2000 ATSG Allison Transmission Allison Transmission Transmission D I V I S I O N O F G E N E R A L M O T O R S C O R P . INDIANAPOLIS, INDIANA MODEL UAW 933 1000 SERIES DATE 99F21 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 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 X X X X X - X X X X TID SERIAL NO. EFCN ALLISON IDENTIFICATION TAG LOCATION TRANSMISSION IDENTIFICATION TAG Figure 3 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 Heavy-duty automatic transmission with parking pawl. Maximum GVW = 19850 lb. Heavy-duty automatic transmission with parking pawl. Maximum GVW = 26000 lb. Heavy-duty automatic transmission without parking pawl. Maximum GVW = 30000 lb. 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. 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 Technical Service Information 6 Copyright © 2000 ATSG Figure 4 GENERAL DESCRIPTION AND OPERATION TYPICAL MANUAL SHIFT TOWER 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 cut- away 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. P R N D 4 2 1 DO NOT SHIFT DO NOT SHIFT 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.

AUTOMATIC TRANSMISSION SERVICE GROUP Technical Service Information 7 Copyright © 2000 ATSG ALL 1000 AND 2400 SERIES ALL 2000 SERIES "WITH" AUTO-APPLY PARKING BRAKE ALL 2000 SERIES "WITHOUT" AUTO-APPLY PARKING BRAKE Figure 5 Shift Selector Position Shift Selector Position Shift Selector Position Shift Selector Position Shift Selector Position Shift Selector Position Shift Selector Position Shift Selector Position Shift Selector Position Gears Available Gears Available Gears Available Gears Available Gears Available Gears Available Gears Available Gears Available Gears Available P (Park) PB = (Park) P (Park) PB = (Park) P (Park) PB = (Park) R (Reverse) R (Reverse) R (Reverse) R (Reverse) R (Reverse) R (Reverse) R (Reverse) R (Reverse) R (Reverse) N (Neutral) N (Neutral) N (Neutral) N (Neutral) N (Neutral) N (Neutral) N (Neutral) N (Neutral) N (Neutral) D (Drive) D (Drive) D (Drive) D (Drive) D (Drive) D (Drive) D (Drive) D (Drive) D (Drive) 4 (Fourth) 4 (Fourth) 4 (Fourth) 4 (Fourth) 4 (Fourth) 4 (Fourth) 3 (Third) 3 (Third) 3 (Third) 2 (Second) 2 (Second) 2 (Second) 2 (Second) 2 (Second) 2 (Second) 3 (Third) 3 (Third) 3 (Third) 1 (First) 1 (First) 1 (First) 1 (First) 1 (First) 1 (First) 1 (First) 1 (First) 1 (First) Neutral* Neutral* Reverse Reverse Reverse Neutral Neutral Neutral 1-5 1-5 1-5 1-5 1-5 1-5 1-5 (1-4)** 1-5 (1-4)** 1-5 (1-4)** 1-4 1-4 1-4 1-4 1-4 1-4 1-3 1-3 1-3 1-3 1-3 1-3 1-2 1-2 1-2 1-2 1-2 1-2 1st 1st 1st 1st 1st 1st 1st 1st 1st Neutral Neutral Neutral Neutral Neutral Neutral Reverse Reverse Reverse Reverse Reverse Reverse Neutral* Neutral* Neutral* Neutral* * With Park Pawl Engaged * With Auto-Apply Parking Brake Engaged ** 4 Speed Calibration or Trailering Mode ** 4 Speed Calibration or Trailering Mode PB = Auto-Apply Parking Brake ** 4 Speed Calibration or Trailering Mode

AUTOMATIC TRANSMISSION SERVICE GROUP Technical Service Information 8 Copyright © 2000 ATSG Figure 6 TYPICAL TRANSMISSION CONTROL MODULE AND VEHICLE HARNESS TRANSMISSION CONTROL MODULE (TCM) TRANSMISSION (J2) HARNESS VEHICLE (J1) HARNESS "J1" CONNECTOR (GRAY) J 1939 CONNECTOR (OPTIONAL) VIW "X" CONNECTOR VIW "Y" CONNECTOR GP 19 CONNECTOR NSBU SWITCH CONNECTORS OUTPUT SPEED SENSOR CONNECTOR ENGINE SPEED SENSOR CONNECTOR TURBINE SPEED SENSOR CONNECTOR TPS CONNECTOR THROTTLE POSITION SENSOR (TPS) 7 PIN 4 PIN "J2" CONNECTOR (RED) Actual harness configuration may differ from this illustration.

AUTOMATIC TRANSMISSION SERVICE GROUP Technical Service Information 9 Copyright © 2000 ATSG ELECTRICAL OPERATION EXTERNAL COMPONENTS SPEED SENSORS TYPICAL SPEED SENSOR ENGINE SPEED SENSOR TURBINE SPEED SENSOR OUTPUT SPEED SENSOR Figure 7 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. 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. 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. 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. 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.

AUTOMATIC TRANSMISSION SERVICE GROUP Technical Service Information 10 Figure 8 Figure 10 Figure 9 THROTTLE POSITION SENSOR THROTTLE POSITION SENSOR Copyright © 2000 ATSG mm/inch (TPS) Distance of Travel Versus Volts 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 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. A B C Transmission Control Module (TCM) Throttle Position Sensor (TPS) 20 9 19 A B C TCM "J2" (RED) Connector Pink, 5V Supply Green, Ground Blue, Signal Ret. TPS Connector

Allison 1000 & 2000 Transmission Service & Repair Manual

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