ALLISON Transmission 6000 Series Full Service Repair Manual

Service Manual CL(B)T 5000, 6000 Series M 5600, 6600 Series S 5600, 6600 Series Transmissions SM1866EN

SM1866EN CLBT, CLT, CT VCLBT, VCLT 5861, 5961, 5962, 5963 6061, 6062, 6063 M 5600(A)(R), S 5600(H)(M)(R) M 6600(A)(R), S 6600(H)(M)(R) JANUARY 1997 Revision 1, 1999 April Printed in the U.S.A. Copyright © 1997 General Motors Corp. Service Manual Allison Transmission Division of General Motors Corporation P.O. Box 894 Indianapolis, Indiana 46206-0894

INTRODUCTION ii Copyright © 1997 General Motors Corp. NOTE: This publication is revised periodically to include improvements, new models, special tools, and procedures. A revision is indicated by letter suffix to the publication number. Check with your Alli- son Transmission service outlet for the currently applicable publication. Additional copies of this publication may be purchased from authorized Allison Transmission service outlets. Look in your telephone directory under the heading of Transmissions — Truck, Tractor, etc. TRADEMARK USAGE The following trademarks are the property of the companies indicated: • DEXRON ® is a registered trademarks of General Motors Corporation. • Biobor ® JF is the registered trademark for a biological inhibitor manufactured by U.S. Borax and Chemical Corporation. • Loctite ® is a registered trademark of the Loctite Corporation. • Teﬂon ® is a registered trademark of the DuPont Corporation. • Marfak ® No. 2 is a registered trademark of Texaco Inc. • Lubriplate ® is a registered trademark of the Fiske Brothers Reﬁning Co., Newark, New Jersey. • Oxweld ® is a registered trademark of the Oxweld Acetylene Company. • Amojell ® is a registered trademark of the Amoco Oil Corporation.

Copyright © 1997 General Motors Corp. iii WARNINGS, CAUTIONS, AND NOTES Three types of headings are used in this manual to attract your attention: NOTE: is used when an operating procedure, practice, etc., is essential to highlight. WARNING! is used when an operating procedure, practice, etc., which, if not correctly followed, could result in personal injury or loss of life. CAUTION: is used when an operating procedure, practice, etc., which, if not strictly observed, could result in damage to or destruction of equipment. IMPORTANT SAFETY NOTICE IT IS YOUR RESPONSIBILITY to be completely familiar with the Warnings and Cau- tions described in this Service Manual. These Warnings and Cautions advise against the use of specific service methods that can result in personal injury, damage to the equipment, or cause the equipment to become unsafe. It is, however, important to understand that these Warnings and Cautions are not exhaustive. Allison Transmission could not possibly know, evaluate, and advise the service trade of all conceivable ways in which service might be done or of the possible hazardous consequences of each way. Conse- quently, Allison Transmission has not undertaken any such broad evaluation. Accord- ingly, ANYONE WHO USES A SERVICE PROCEDURE OR TOOL WHICH IS NOT RECOMMENDED BY ALLISON TRANSMISSION MUST first be thoroughly satisfied that neither personal safety nor equipment safety will be jeopardized by the service methods selected. Proper service and repair are important to the safe, reliable operation of the equipment. The service procedures recommended by Allison Transmission and described in this Ser- vice Manual are effective methods for performing service operations. Some of these service operations require the use of tools specifically designed for the purpose. The special tools should be used when and as recommended.

iv Copyright © 1997 General Motors Corp. LIST OF WARNINGS This manual contains the following Warnings — IT IS YOUR RESPONSIBILITY TO BE FAMILIAR WITH ALL OF THEM. • Arc welding equipment requires dangerously high currents and voltages which cannot be sufficiently reduced to permit its use for jump-starting. To help avoid injury or equipment damage, do not attempt to jump-start the equipment using an arc welder. • Welding on the equipment may induce currents and voltages in the transmission electronic controls. Sudden and unexpected movement may occur if the transmission controls are accidentally activated. To avoid injury or property damage, always disconnect the Shift Pattern Generator (SPG) before welding on the equipment. • To help avoid injury and property damage caused by sudden and unexpected vehicle movement, do not begin a stationary stall test until you: • Put the transmission in N (Neutral).... and • Set the parking brake and service brakes, and make sure they are properly engaged... and • Chock the wheels and take any other steps necessary to keep the vehicle from moving... and • Warn people to keep clear of the vehicle and its path. • Electricity must never , under any circumstances, be applied to any electric valve body component while the engine is running, while the mechanic is working under the vehicle, or while personnel are working in the vehicle path. Sudden and unexpected movement may occur if the control valve solenoids are activated by an external power supply. A runaway vehicle could only be stopped by applying the vehicle brakes or shutting down the engine: removal of the power supply would not stop the vehicle because of the fail-protection system. To help avoid injury or property damage, always shut off the engine, set the vehicle brakes, and lock the wheels before any troubleshooting of the solenoids. • Removing the wiring harnesses from the transmission while the equipment power supply is ON can cause unexpected shifts resulting in sudden, uncontrolled vehicle or equipment movement. To help avoid injury or property damage, power from the equipment electrical system must be switched OFF before disconnecting the transmission wiring. • Toxic gases are produced by burning Teflon ® . Exposure to these gases is extremely hazardous and can be fatal. DO NOT burn discarded Teflon ® seals. • Drying a ball or roller bearing by spinning it with compressed air can cause the bearing to disintegrate, allowing balls or rollers to become lethal flying projectiles. Spinning the bearing without lubrication can also damage the bearing. To avoid injury and component failure, never dry bearings by spinning them with compressed air. • To prevent any unexpected shift during removal of the wiring harnesses, be sure that the power supply from the equipment electrical system is switched off. • Lifting the torque converter drive housing or flywheel assembly from the transmission can dislodge lockup clutch parts from the housing or assembly. To avoid injury from falling parts, stay clear of the area beneath the raised components and do not attempt to hold the parts in the assembly using your hands. • The cadmium-plated material used in the brazed joints of the main-pressure hose fittings produces toxic yellow-brown gases when welded. Exposure to these gases is extremely hazardous and can be fatal. DO NOT attempt to repair hose fitting joints by welding. • Interference between the main-pressure transfer tube assembly hose and the equipment causes binding and abrasion of the hose. Failure of an abraded hose releases pressurized, heated fluid (pressures and temperatures in the assembly can exceed 350 psi (2413 kPa) and 275° F (135°C)). To help avoid injury due to hose failure, prevent physical contact between the hose and equipment when installing the transfer tube assembly.

Copyright © 1997 General Motors Corp. v TABLE OF CONTENTS Paragraph Page Paragraph Page Section 1. GENERAL INFORMATION 1–1. SCOPE a. Coverage . . . . . . . . . . . . . . . . . . . . . . . . . 1–1 b. Illustrations. . . . . . . . . . . . . . . . . . . . . . . . 1–1 c. Maintenance Information. . . . . . . . . . . . . 1–2 1–2. SUPPLEMENTARY INFORMATION 1–3. ORDERING PARTS a. Transmission Nameplate.. . . . . . . . . . . . . 1–3 b. Electronic-Control Models. . . . . . . . . . . . 1–3 c. Parts Catalog. . . . . . . . . . . . . . . . . . . . . . . 1–4 1–4. DESIGN FEATURES a. Transmission-to-Engine Coupling . . . . . . 1–5 b. Torque Converter. . . . . . . . . . . . . . . . . . . 1–5 c. Planetary Gearing. . . . . . . . . . . . . . . . . . . 1–5 d. Clutches.. . . . . . . . . . . . . . . . . . . . . . . . . . 1–5 e. Hydraulic System. . . . . . . . . . . . . . . . . . 1–5 f. Power Takeoff.. . . . . . . . . . . . . . . . . . . . . 1–5 g. Lockup Clutch.. . . . . . . . . . . . . . . . . . . . . 1–6 1–5. SHIFT CONTROL SYSTEMS a. Manual-Electric Shift. . . . . . . . . . . . . . . . 1–6 b. Automatic-Electric Shift . . . . . . . . . . . . . 1–6 c. Electronic-Control Shift . . . . . . . . . . . . . . 1–6 d. Manual-Hydraulic Shift. . . . . . . . . . . . . . 1–7 1–6. OPTIONS a. Hydraulic Retarder. . . . . . . . . . . . . . . . . . 1–7 b. Parking Brake. . . . . . . . . . . . . . . . . . . . . . 1–7 c. Transfer Gears (Dropbox) . . . . . . . . . . . . 1–7 d. Output Disconnects . . . . . . . . . . . . . . . . . 1–7 e. Flanges . . . . . . . . . . . . . . . . . . . . . . . . . . . 1–7 f. Speedometer Drive . . . . . . . . . . . . . . . . . 1–7 1–7. OPERATING INSTRUCTIONS a. Operator’s Manual. . . . . . . . . . . . . . . . . . 1–7 b. Manual Mode . . . . . . . . . . . . . . . . . . . . . . 1–8 c. Cold Weather Starts . . . . . . . . . . . . . . . . . 1–8 d. Towing . . . . . . . . . . . . . . . . . . . . . . . . . . . 1–8 1–8. SPECIFICATIONS AND DATA Section 2. DESCRIPTION AND OPERATION 2–1. SCOPE a. Two Configurations . . . . . . . . . . . . . . . . . 2–1 b. Control Systems . . . . . . . . . . . . . . . . . . . . 2–1 2–2. MOUNTING, INPUT DRIVES a. Remote Mounting . . . . . . . . . . . . . . . . . . 2–1 b. Direct Mounting . . . . . . . . . . . . . . . . . . . . 2–1 2–3. LOCKUP CLUTCH a. Description . . . . . . . . . . . . . . . . . . . . . . . 2–1 b. Operation . . . . . . . . . . . . . . . . . . . . . . . . . 2–2 2–4. TORQUE CONVERTER — FIXED CAPACITY a. Description . . . . . . . . . . . . . . . . . . . . . . . . 2–2 b. Operation . . . . . . . . . . . . . . . . . . . . . . . . . 2–2 2–5. TORQUE CONVERTER — VARIABLE CAPACITY a. Description . . . . . . . . . . . . . . . . . . . . . . . . 2–3 b. Operation . . . . . . . . . . . . . . . . . . . . . . . . . 2–4 2–6. HYDRAULIC RETARDER a. Description . . . . . . . . . . . . . . . . . . . . . . . . 2–5 b. Operation . . . . . . . . . . . . . . . . . . . . . . . . 2–5 2–7. POWER TAKEOFF (PTO) DRIVES a. Description . . . . . . . . . . . . . . . . . . . . . . . . 2–5 b. Operation . . . . . . . . . . . . . . . . . . . . . . . . . 2–5 2–8. SPLITTER CLUTCHES, GEARING a. Description . . . . . . . . . . . . . . . . . . . . . . . . 2–5 b. Operation . . . . . . . . . . . . . . . . . . . . . . . . . 2–6 2–9. HIGH-RANGE CLUTCH (FIFTH AND SIXTH RANGE) a. Description . . . . . . . . . . . . . . . . . . . . . . . . 2–6 b. Operation . . . . . . . . . . . . . . . . . . . . . . . . . 2–6 2–10. INTERMEDIATE-RANGE CLUTCH, PLANETARY (THIRD AND FOURTH RANGE) a. Description . . . . . . . . . . . . . . . . . . . . . . . . 2–6 b. Operation . . . . . . . . . . . . . . . . . . . . . . . . . 2–7 2–11. LOW-RANGE CLUTCH, PLANETARY (FIRST AND SECOND RANGE) a. Description . . . . . . . . . . . . . . . . . . . . . . . . 2–7 b. Operation . . . . . . . . . . . . . . . . . . . . . . . . . 2–7 2–12. REVERSE CLUTCH, PLANETARY a. Description . . . . . . . . . . . . . . . . . . . . . . . . 2–8 b. Operation . . . . . . . . . . . . . . . . . . . . . . . . . 2–8 2–13. SPEEDOMETER DRIVE a. Description . . . . . . . . . . . . . . . . . . . . . . . . 2–8 b. Operation . . . . . . . . . . . . . . . . . . . . . . . . . 2–8 2–14. PARKING BRAKE a. Description . . . . . . . . . . . . . . . . . . . . . . . . 2–8 b. Operation . . . . . . . . . . . . . . . . . . . . . . . . . 2–9 2–15. PAN, STRAINER a. Description . . . . . . . . . . . . . . . . . . . . . . . . 2–9 b. Operation . . . . . . . . . . . . . . . . . . . . . . . . . 2–9 2–16. INPUT PRESSURE AND SCAVENGE PUMP a. Description . . . . . . . . . . . . . . . . . . . . . . . . 2–9 b. Operation . . . . . . . . . . . . . . . . . . . . . . . . . 2–9

vi Copyright © 1997 General Motors Corp. TABLE OF CONTENTS Paragraph Page Paragraph Page 2–17. HOUSING, COVERS a. Front Cover (Remote Mount Models) . . 2–9 b. Torque Converter Housing . . . . . . . . . . . 2–9 c. Main Housing . . . . . . . . . . . . . . . . . . . . . 2–9 2–18. HYDRAULIC SYSTEM a. System Functions . . . . . . . . . . . . . . . . . 2–10 b. System Schematics . . . . . . . . . . . . . . . . 2–10 c. Filter, Main-Pressure Regulator Valve. . . . . . . . . . . . . . . . . . . 2–10 d. Lockup Clutch Shift Valve . . . . . . . . . . 2–10 e. Flow (Lockup Cutoff) Valve (Models With Non-Electric Lockup) . . 2–11 f. Check Valve (Models With Non-Electric Lockup) . . . . . . . . . . . . . . 2–11 g. Hydraulic Retarder Valve (Models With Retarder) . . . . . . . . . . . . . . . . . . . . . . . . 2–11 h. Converter Pressure Relief Valve (All Models) . . . . . . . . . . . . . . . . . . . . . . . . . 2–11 i. Converter Pressure Regulator Valve (Models With Retarder) . . . . . . . . . . . . 2–11 j. Lubrication Pressure Regulator Valve (Models Without Retarder). . . . . 2–11 k. Converter-In Check Valve (Models With Retarder) . . . . . . . . . . . . 2–11 2–19. MANUAL-HYDRAULIC CONTROL SYSTEM a. Manual Selector Valve . . . . . . . . . . . . . 2–12 b. Neutral Trimmer Valve . . . . . . . . . . . . . 2–12 c. Intermediate-Range Trimmer Valve . . . 2–12 2–20. MANUAL-HYDRAULIC CONTROL SYSTEM CIRCUITS a. Neutral . . . . . . . . . . . . . . . . . . . . . . . . . . 2–12 b. First Range . . . . . . . . . . . . . . . . . . . . . . 2–14 c. Second Range . . . . . . . . . . . . . . . . . . . . 2–14 d. Third Range . . . . . . . . . . . . . . . . . . . . . . 2–14 e. Fourth Range . . . . . . . . . . . . . . . . . . . . . 2–14 f. Fifth Range . . . . . . . . . . . . . . . . . . . . . . 2–14 g. Sixth Range . . . . . . . . . . . . . . . . . . . . . . 2–15 h. Reverse . . . . . . . . . . . . . . . . . . . . . . . . . 2–15 2–21. MANUAL-ELECTRIC CONTROL HYDRAULIC SYSTEM a. Reverse Shift Valve. . . . . . . . . . . . . . . . 2–15 b. Low-Range Shift Valve. . . . . . . . . . . . . 2–15 c. Intermediate-Range Shift Valve . . . . . . 2–15 d. High-Range Shift Valve . . . . . . . . . . . . 2–16 e. Solenoid Pressure Regulator Valve. . . . 2–16 f. Priority Valve . . . . . . . . . . . . . . . . . . . . 2–16 g. Splitter Shift Valve . . . . . . . . . . . . . . . . 2–16 h. Protection in the Event of Electrical Interruption . . . . . . . . . . . . . . 2–16 i. Trimmer System . . . . . . . . . . . . . . . . . . 2–17 j. Reverse Trimmer . . . . . . . . . . . . . . . . . . 2–17 k. Low-Range Trimmer . . . . . . . . . . . . . . . 2–17 l. Intermediate-Range Trimmer . . . . . . . . 2–18 m. Splitter-Low Trimmer . . . . . . . . . . . . . . 2–18 n. Exhaust Regulator Valve. . . . . . . . . . . . 2–18 o. Solenoids . . . . . . . . . . . . . . . . . . . . . . . . 2–18 p. Shift Selector Assembly . . . . . . . . . . . . 2–19 q. Wiring Harness . . . . . . . . . . . . . . . . . . . 2–19 2–22. MANUAL-ELECTRIC CONTROL HYDRAULIC SYSTEM CIRCUITS a. Neutral . . . . . . . . . . . . . . . . . . . . . . . . . . 2–19 b. Protection in the Event of Electrical Interruption While Operating in Neutral . . . . . . . . . . . . . . . . . . . . . . . . 2–20 c. Protection in the Event of Electrical Interruption While Operating in Forward Ranges. . . . . . . . . . . . . . . . . . . 2–21 d. First-Range Operation . . . . . . . . . . . . . . 2–21 e. Second-Range Operation . . . . . . . . . . . 2–21 f. Third-Range Operation . . . . . . . . . . . . . 2–22 g. Fourth-Range Operation . . . . . . . . . . . . 2–22 h. Fifth-Range Operation. . . . . . . . . . . . . . 2–22 i. Sixth-Range Operation . . . . . . . . . . . . . 2–23 j. Reverse Operation . . . . . . . . . . . . . . . . . 2–23 k. Protection in the Event of Electrical Interruption While Operating in Reverse . . . . . . . . . . . . . . . . . . . . . . . 2–23 l. Protection in the Event of Electrical Interruption While Operating Dual-Electric Equipment . . . . . . . . . . . . 2–23 2–23. SPG-CONTROL AUTOMATIC-ELECTRIC HYDRAULIC SYSTEM AND CIRCUITS a. Description . . . . . . . . . . . . . . . . . . . . . . 2–24 b. Operation . . . . . . . . . . . . . . . . . . . . . . . . 2–24 c. Lock-In-Range Downshift Protection . . 2–26 d. Lock-In-Range Reset Procedure . . . . . . 2–26 e. Operation After Lock-In-Range Reset . . . . . . . . . . . . . . . . . . . . . . . . . . . 2–26 f. Electrical Connections. . . . . . . . . . . . . . 2–26 g. Negative-Ground System . . . . . . . . . . . 2–26 h. Positive-Ground System . . . . . . . . . . . . 2–28 i. Fusing and Overload Protection . . . . . . 2–28

Copyright © 1997 General Motors Corp. vii TABLE OF CONTENTS Paragraph Page Paragraph Page 2–24. ELECTRONIC CONTROL HYDRAULIC SYSTEM AND CIRCUITS (Models Without Trim Boost) a. Electronic Control Unit (ECU) . . . . . . . 2–28 b. Shift Selector . . . . . . . . . . . . . . . . . . . . . 2–28 c. CHECK TRANS Light . . . . . . . . . . . . . 2–30 d. Throttle Sensor . . . . . . . . . . . . . . . . . . . . 2–30 e. Output Speed Sensor . . . . . . . . . . . . . . . 2–30 f. Wiring Harnesses . . . . . . . . . . . . . . . . . . 2–32 g. Lockup (Models With Electric Lockup) . . . . . . . . . . . . . . . . . . . . . . . . . 2–32 h. Operation of the Electronic Control System. . . . . . . . . . . . . . . . . . . . 2–32 2–25. ELECTRONIC CONTROL HYDRAULIC SYSTEM AND CIRCUITS (Models With Trim Boost) a. Trimmer System . . . . . . . . . . . . . . . . . . 2–33 b. Reverse Trimmer . . . . . . . . . . . . . . . . . . 2–33 c. Low-Range Trimmer . . . . . . . . . . . . . . . 2–34 d. Intermediate-Range Trimmer . . . . . . . . 2–34 e. Splitter-High Trimmer . . . . . . . . . . . . . . 2–34 f. Splitter-Low Trimmer . . . . . . . . . . . . . . 2–34 g. Trim Boost Valve. . . . . . . . . . . . . . . . . . 2–35 2–26. TORQUE PATHS THROUGH THE TRANSMISSION a. Torque Converter Operation . . . . . . . . . 2–35 b. Lockup Operation . . . . . . . . . . . . . . . . . 2–35 c. Neutral Torque Path . . . . . . . . . . . . . . . . 2–36 d. First-Range Torque Path . . . . . . . . . . . . 2–37 e. Second-Range Torque Path . . . . . . . . . . 2–38 f. Third-Range Torque Path . . . . . . . . . . . 2–39 g. Fourth-Range Torque Path . . . . . . . . . . 2–40 h. Fifth-Range Torque Path . . . . . . . . . . . . 2–41 i. Sixth-Range Torque Path . . . . . . . . . . . . 2–42 j. Reverse or Reverse-1 Torque Path . . . . 2–43 k. Reverse-2 Torque Path. . . . . . . . . . . . . . 2–44 Section 3. PREVENTIVE MAINTENANCE 3–1. SCOPE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3–1 3–2. GENERAL INSPECTION AND CARE . . . 3–1 3–3. IMPORTANCE OF PROPER TRANSMISSION FLUID LEVEL a. Effects of Improper Fluid Level . . . . . . . 3–1 b. Foaming and Aeration . . . . . . . . . . . . . . . 3–1 3–4. TRANSMISSION FLUID LEVEL CHECK PROCEDURE a. Cold Check. . . . . . . . . . . . . . . . . . . . . . . . 3–2 b. Hot Check . . . . . . . . . . . . . . . . . . . . . . . . 3–2 3–5. KEEPING TRANSMISSION FLUID CLEAN . . . . . . . . . . . . . . . . . . . . . . . 3–3 3–6. TRANSMISSION FLUID RECOMMENDATIONS a. Recommended Automatic Transmission Fluid. . . . . . . . . . . . . . . . . . 3–4 b. Recommended Viscosity Grade . . . . . . . 3–4 3–7. TRANSMISSION FLUID AND FILTER CHANGE INTERVALS . . . . . . . . . . . . . . . . 3–4 3–8. FLUID CONTAMINATION a. Examination at Fluid Change . . . . . . . . . 3–5 b. Metal Particles . . . . . . . . . . . . . . . . . . . . . 3–5 c. Coolant Leakage . . . . . . . . . . . . . . . . . . . 3–5 3–9. TRANSMISSION FLUID AND FILTER CHANGE PROCEDURES . . . . . . . . . . . . . . 3–5 3–10. BREATHER . . . . . . . . . . . . . . . . . . . . . . . . . 3–6 3–11. CHECKING FLUID TEMPERATURE, PRESSURES a. Fluid Temperature Gauge . . . . . . . . . . . . 3–6 b. Checking, Adjusting Main Pressure . . . . 3–6 c. Checking Lubrication Pressure . . . . . . . 3–7 d. Adjusting Lubrication Pressure (Models Without Retarder) . . . . . . . . . . . 3–7 e. Checking Converter-out Pressure . . . . . . 3–8 f. Checking Fluid Velocity Governor (Pitot) Pressure (Models With Non- Electric Lockup). . . . . . . . . . . . . . . . . . . . 3–9 g. Checking Stator Control Pressure (Models With Variable-Capacity Torque Converter) . . . . . . . . . . . . . . . . . . 3–9 h. Checking Range and Splitter Clutch Pressures. . . . . . . . . . . . . . . . . . . . . . . . . . 3–9 3–12. LINKAGE a. Manual Selector Valve Linkage (Manual-Hydraulic Models) . . . . . . . . . . 3–9 b. Retarder Valve Linkage . . . . . . . . . . . . . 3–10 c. Output Disconnect Linkage . . . . . . . . . . 3–10 3–13. EXTERNAL HYDRAULIC LINES AND COOLER a. External Lines . . . . . . . . . . . . . . . . . . . . 3–10 b. Cooler . . . . . . . . . . . . . . . . . . . . . . . . . . . 3–10 3–14. ADJUSTING LOCKUP SPEED (Models With Non-Electric Lockup) a. Lockup Speed (in the Equipment) . . . . . 3–10 b. Lockup Speed and Shift Points (Using a Test Stand). . . . . . . . . . . . . . . . 3–10 c. Lockup Speed Adjustment . . . . . . . . . . . 3–11

viii Copyright © 1997 General Motors Corp. TABLE OF CONTENTS Paragraph Page Paragraph Page 3–15. ADJUSTING PARKING BRAKE a. Description . . . . . . . . . . . . . . . . . . . . . . 3–11 b. Procedures . . . . . . . . . . . . . . . . . . . . . . . 3–11 c. Burnishing New Brakes . . . . . . . . . . . . 3–11 3–16. TRANSMISSION STALL TEST AND NEUTRAL COOL-DOWN CHECK a. Purpose . . . . . . . . . . . . . . . . . . . . . . . . . 3–11 b. Stall Test Preparation . . . . . . . . . . . . . . 3–12 c. Stall Test Procedures — Equipment Without Smoke-Controlled Engines . . . 3–12 d. Stall Test Procedures — Equipment With Smoke-Controlled Engines . . . . . 3–12 e. Neutral Cool-Down Check Procedure . . . . . . . . . . . . . . . . . . . . . . . 3–13 f. Results . . . . . . . . . . . . . . . . . . . . . . . . . . 3–13 3–17. PRESERVATION AND STORAGE a. Storage, New Transmissions (Prior to Installation) . . . . . . . . . . . . . . . 3–13 b. Preservation Methods . . . . . . . . . . . . . . 3–13 c. Storage, One Year — Without Transmission Fluid . . . . . . . . . . . . . . . . 3–13 d. Storage, One Year — With Transmission Fluid (Normally Installed in the Equipment) . . . . . . . . . . . . . . . . . . . . . . 3–14 e. Restoring Transmission to Service . . . . 3–14 3–18. LUBRICATION OF SHIFT SELECTOR — SPG-CONTROL AUTOMATIC-ELECTRIC MODELS a. Lubrication Intervals . . . . . . . . . . . . . . . 3–14 b. Clean Before Lubricating . . . . . . . . . . . 3–15 c. Lubrication Points . . . . . . . . . . . . . . . . . 3–15 3–19. TROUBLESHOOTING THE CONTROL SYSTEM 3–20. CHECKING, ADJUSTING MANUAL- ELECTRIC CONTROL SYSTEM a. Field Test Kit . . . . . . . . . . . . . . . . . . . . . 3–15 b. Checking Wiring Harness . . . . . . . . . . . 3–15 c. Checking Main Control Valve Body . . 3–17 d. Checking Hydraulic Circuits . . . . . . . . . 3–17 3–21. CHECKING, ADJUSTING SPG-CONTROL AUTOMATIC-ELECTRIC SYSTEM a. Field Test Kit . . . . . . . . . . . . . . . . . . . . . 3–18 b. Checking Wiring Harnesses . . . . . . . . . 3–18 c. Checking Throttle Potentiometer . . . . . 3–20 d. Checking Magnetic Pickup (Speed Sensor). . . . . . . . . . . . . . . . . . . . 3–20 e. Checking Shift Pattern Generator (SPG) . . . . . . . . . . . . . . . . . . 3–20 f. Checking 24V Overload Protector . . . . 3–20 g. Checking 12V-to-24V Converter . . . . . 3–21 h. Checking Control Valve Assembly. . . . 3–21 i. Checking Hydraulic Circuit . . . . . . . . . 3–21 3–22. TESTING SHIFT SELECTOR ASSEMBLY a. Manual-Electric Test Equipment . . . . . 3–21 b. Shop-Constructed Test Lamp Bank . . . 3–21 c. Testing Manual-Electric Shift Selector . . . . . . . . . . . . . . . . . . . . . 3–22 d. Testing SPG-Control Automatic- Electric Shift Selector . . . . . . . . . . . . . . 3–23 3–23. TROUBLESHOOTING THE TRANSMISSION a. Before Removal or Operation . . . . . . . . 3–25 b. During Operation. . . . . . . . . . . . . . . . . . 3–25 c. After Removal From Equipment. . . . . . 3–25 d. Troubleshooting Table . . . . . . . . . . . . . 3–25 Section 4. GENERAL OVERHAUL INFORMATION 4–1. SCOPE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4–1 4–2. PROCEDURES SUBJECT TO CHANGE . . . . . . . . . . . . . . . . . . . . . . . . 4–1 4–3. WELDING PROCEDURES FOR ELECTRONIC CONTROL EQUIPMENT . . . . . . . . . . . . . . . . . . . . . . . . 4–1 4–4. REMOVAL, INSTALLATION OF TRANSMISSION . . . . . . . . . . . . . . . . . . . . . 4–1 4–5. REMOVAL OF WIRING HARNESSES (Manual-Electric and SPG-Control Models) a. Manual-Electric Shift Model. . . . . . . . . . 4–1 b. SPG-Control Automatic-Electric Shift Model . . . . . . . . . . . . . . . . . . . . . . . 4–2 4–6. REMOVAL OF REMOTE COMPONENTS (Manual-Electric and SPG-Control Models) a. Shift Selector Assembly . . . . . . . . . . . . . 4–5 b. Shift Pattern Generator (SPG), 12V-to-24V Converter, 24V Overload Protector, Throttle Potentiometer . . . . . . 4–5 4–7. INSTALLATION OF EXTERIOR COMPONENTS (Manual-Electric and SPG-Control Models) . . . . . . . . . . . . . . . . . . 4–5

Copyright © 1997 General Motors Corp. ix TABLE OF CONTENTS Paragraph Page Paragraph Page 4–8. TOOLS, EQUIPMENT a. Special Tools . . . . . . . . . . . . . . . . . . . . . . 4–5 b. Improvised Tools and Equipment . . . . . . 4–6 c. Mechanic’s Tools, Shop Equipment . . . 4–6 4–9. REPLACEMENT PARTS a. Ordering Information . . . . . . . . . . . . . . . . 4–7 b. Parts Normally Replaced . . . . . . . . . . . . . 4–7 c. Parts Replacement . . . . . . . . . . . . . . . . . . 4–7 4–10. CAREFUL HANDLING. . . . . . . . . . . . . . . . 4–8 4–11. CLEANING, INSPECTION a. Dirt-Free Assembly . . . . . . . . . . . . . . . . . 4–8 b. Cleaning Parts . . . . . . . . . . . . . . . . . . . . . 4–9 c. Cleaning Bearings . . . . . . . . . . . . . . . . . 4–10 d. Inspecting Bearings . . . . . . . . . . . . . . . . 4–10 e. Keeping Bearings Clean . . . . . . . . . . . . 4–10 f. Inspecting Cast Parts, Machined Surfaces . . . . . . . . . . . . . . . . . . . . . . . . . 4–10 g. Inspecting Bushings, Thrust Washers . . 4–11 h. Inspecting Seals, Gaskets . . . . . . . . . . . . 4–11 i. Inspecting Seal Contact Surfaces. . . . . . 4–11 j. Inspecting Gears. . . . . . . . . . . . . . . . . . . 4–11 k. Inspecting Splined Parts. . . . . . . . . . . . . 4–11 l. Inspecting Threaded Parts . . . . . . . . . . . 4–11 m. Inspecting Snaprings . . . . . . . . . . . . . . . 4–11 n. Inspecting Springs . . . . . . . . . . . . . . . . . 4–11 o. Inspecting Clutch Plates. . . . . . . . . . . . . 4–11 p. Inspecting Swaged, Interference- Fit Parts . . . . . . . . . . . . . . . . . . . . . . . . . 4–12 q. Inspecting Balls in Clutch Pistons . . . . . 4–12 r. Inspecting Pump Gears . . . . . . . . . . . . . 4–12 4–12. ASSEMBLY PROCEDURES a. Clutches, Pistons . . . . . . . . . . . . . . . . . . 4–12 b. Parts Lubrication . . . . . . . . . . . . . . . . . . 4–12 c. External Plugs, Hydraulic Fittings . . . . . 4–13 d. Oil-Soluble Grease . . . . . . . . . . . . . . . . . 4–14 e. Sealing Compounds . . . . . . . . . . . . . . . . 4–14 f. Lip-Type Seals (Metal-Encased) . . . . . . 4–14 g. Interference-Fit Parts . . . . . . . . . . . . . . . 4–15 h. Sleeve-Type Bearings . . . . . . . . . . . . . . 4–15 i. Bearings (Ball or Roller) . . . . . . . . . . . . 4–15 4–13. REMOVING (OR INSTALLING) TRANSMISSION a. Drain Transmission Fluid . . . . . . . . . . . 4–15 b. Check Linkages and Lines . . . . . . . . . . . 4–15 c. Remove, Clean Transmission . . . . . . . . 4–15 d. Install Transmission . . . . . . . . . . . . . . . . 4–15 4–14. WEAR LIMITS . . . . . . . . . . . . . . . . . . . . . . 4–16 4–15. SPRING SPECIFICATIONS . . . . . . . . . . . 4–16 4–16. TIGHT-FIT FLANGES a. Removal of Flanges . . . . . . . . . . . . . . . . 4–16 b. Installation of Flanges . . . . . . . . . . . . . . 4–17 4–17. TEFLON ® LIP-TYPE SEALRINGS a. Removal . . . . . . . . . . . . . . . . . . . . . . . . . 4–17 b. Installation . . . . . . . . . . . . . . . . . . . . . . . 4–17 4–18. DETERMINING PTO BACKLASH LIMITS a. Determining Backlash Between Drive and Driven Gear (Quantity A) . . . 4–18 b. Determining Backlash Between Drive and Driven Gear (Quantity B) . . . 4–18 c. Determining the Total Backlash in the Gear Train (Quantity C) . . . . . . . . 4–18 4–19. TORQUE SPECIFICATIONS . . . . . . . . . . 4–19 Section 5. DISASSEMBLY OF TRANSMISSION 5–1. SCOPE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5–1 5–2. GENERAL INFORMATION FOR DISASSEMBLY OF TRANSMISSION a. Preparation for Disassembly . . . . . . . . . . 5–1 b. Removal of Control Components . . . . . . 5–1 c. Disassembly Information . . . . . . . . . . . . . 5–1 d. Lifting, Handling . . . . . . . . . . . . . . . . . . . 5–1 5–3. TRANSMISSION DISASSEMBLY a. Removal of Exterior Components . . . . . . 5–1 b. Removal of Torque Converter and Related Components . . . . . . . . . . . . . . . . 5–8 c. Removing Torque Converter Elements . . . . . . . . . . . . . . . . . . . . . . . . . 5–10 d. Removal of Torque Converter Housing, Retarder Housing, and Related Components . . . . . . . . . . . . . . . 5–12 e. Removal of Pump, PTO, and Idler Gears . . . . . . . . . . . . . . . . . . . . . . . 5–12 f. Separating Converter Housing and Retarder Housing, and Removing Related Parts . . . . . . . . . . . . . . . . . . . . . 5–13 g. Disassembly of Retarder Housing, Turbine Shaft, and Related Parts (Models With Retarder) . . . . . . . . . . . . . 5–15 h. Disassembly of Converter Housing, Turbine Shaft, and Related Parts (Models Without Retarder) . . . . . . . . . . 5–16

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ALLISON Transmission 6000 Series Full Service Repair Manual

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