1K 2K Technician's Guide

TECHNICIANS’ GUIDE
INSPECTION AND ANALYSIS OF THE

ALLISON 1000 & 2000
PRODUCT FAMILIES
GN4062EN
(5/05)
ALLISON 1000 & 2000 PRODUCT FAMILIES
Glossary Of Terms . . . . . . . . . . 2 P2 Planetary and

P3 Ring Gear . . . . . . . . . . . 31-32
Introduction . . . . . . . . . . . . . . . . 3
P3 Planetary Assembly . . . . . 33
General Inspection
Guidelines for Output Shaft . . . . . . . . . . . . . . 34
Q Cast Parts & Machined
Front Support and
Surfaces . . . . . . . . . . . . . . . . . . 4 Charging Oil Pump
Q Gears . . . . . . . . . . . . . . . . . . . . 5 Module . . . . . . . . . . . . . . . . 35-39
Q Splines . . . . . . . . . . . . . . . . . . . 6
Rotating Clutch Housing . . 40-41
Q Bearings . . . . . . . . . . . . . . . . 7-8
Turbine Shaft . . . . . . . . . . . 42-43
Q Bushings . . . . . . . . . . . . . . . . . 9
Q Retaining Rings
C1 Clutch Pack
. . . . . . . . . . 10
NOTICE: This guide is intended Components . . . . . . . . . . . . 44-45
Q Thrust Washers . . . . . . . . . . . 11
for use by technicians skilled in C2 Clutch Pack
diagnosis and repair of Q Clutch Plates . . . . . . . . . . 12-13
Components . . . . . . . . . . . . 46-47
automatic transmissions. Q Springs . . . . . . . . . . . . . . . . . 14
C3 and C4 Clutch Pack
Contact an authorized Allison Components . . . . . . . . . . . . 48-49
Transmission service outlet for Control Valve Body
further information or Main Housing . . . . . . . . . . . 50-51
Assembly . . . . . . . . . . . . . . 15-21
clarification if required. All C5 Clutch Pack
Torque Converter . . . . . . . . 22-23
specifications provided in this Components . . . . . . . . . . . . 52-53
manual are subject to change Torque Converter Park Pawl Components . . . 54-55
without notice. Housing . . . . . . . . . . . . . . . 24-25
Speed Sensors . . . . . . . . . . . . 56
Rear Cover Assembly . . . . 26-27
Neutral Start Backup
Main Shaft . . . . . . . . . . . . . . . . 28 (NSBU) Switch . . . . . . . . . . 57-58
P1 Planetary and Wear Limits and
P2 Ring Gear . . . . . . . . . . . 29-30 Spring Data . . . . . . . . . . . . . 59-63
ALLISON TRANSMISSION TECHNICIANS’ GUIDE i

 2005 General Motors Corporation.
GLOSSARY OF TERMS
Abrade - Scrape off Metal Transfer - Metal from one

component embedded in a mating
Battering - Wear or damage due to component
hard usage or repeated blows
Nick - Small notch
Brinelling - Permanent deformation
of a bearing surface where rollers or Pit - Local areas where material has
balls contact a race; Results from been removed
excessive load or impact;
Characterized by indentations Porosity - Porous area where air,
on a bearing surface fluid, or light may pass through
Burr - Sharp metal extending Score - Deep scratch

beyond normal surface Scuff - Wear due to two moving
Chipped - Having a small piece parts coming together with no
broken off lubricant
Cone - A shape whose base is a Spalled - Damage characterized by

circle and whose sides taper up metal flaking or breaking down on
to a point a wear surface; Similar to pitting
damage
Crimped - Pinched or pressed
together tightly Stripped - Threads broken or
damaged so part will not hold
Crocus cloth - Fine grit cloth torque
Discoloration - Change in color TAN - Total Acid Number;
Oil acidity should not change by
Distortion - Change from original more then 3 from the new fluid
shape TAN when oil sampling is used to
Erosion - Gradual uneven removal determine oil change intervals
of material Twisted - Bent from original shape
Fracture - A break or crack
Gall - Wear between

parts such that metal
transfer occurs
Grooves - Long narrow
depressions
Inadequate -
Not enough
Light Stoning - Using a
medium India oilstone to
remove material
2 ALLISON TRANSMISSION TECHNICIANS’ GUIDE

INTRODUCTION TO INSPECTION & ANALYSIS
The Technicians’ Guide is

intended to provide additional
guidance with the inspection and
analysis of transmission parts. This
guide should be used by technicians
who overhaul Allison 1000 and 2000
Product Family transmissions in
conjunction with the 1000 and
2000 Product Families Service
Manual (SM3191EN) when
inspecting parts to determine their
serviceability and reuse.
General Rework Guidelines

Replace parts that cannot be
re-worked as outlined in this
manual and Service Manual
SM 3191EN. A soft stone or crocus
cloth can be used to attempt
removal of “high spots” from
transmission parts. After the
attempted rework, the part must
meet specification if it is going to be
reused. Some seal surfaces (for
example the output yoke sealing surface
and the converter pump hub sealing
surface) cannot be reworked. Both of
these seal surfaces have a controlled
finish that can result in a fluid leak if
the part is altered by rework.
ALLISON TRANSMISSION TECHNICIANS’ GUIDE 3

GENERAL INSPECTION GUIDELINES FOR
CAST PARTS & MACHINED SURFACES
A. Housings
B. Machined
Surfaces
D. Splines
A. Replace housings or other cast C. Inspect all fluid passages for
parts that are cracked or broken. obstructions, porosity, broken
Inspect clutch housing sealing lands, cracks and land surface
surfaces for imperfections that imperfections.
could damage the piston seals or
interfere with mating parts. D. Replace housings that have
Inspect threaded holes for bad splines worn beyond wear limits.
threads. Clean damaged threads Refer to the Wear Limits in Service
with the correct size tap. Manual SM3191EN.
B. Inspect all machined surfaces NOTE: Do not use impact guns (air
for damage that could cause fluid wrenches, electric impact C. Fluid
leakage. Inspect mounting faces wrenches, etc.) when working with Passages
and bores for damage. aluminum threads or when torque
sequencing bolts.
NOTE: Use of caustic acid and hot
tanks can damage aluminum parts,
including sealring grooves and
machined surfaces.

GEARS
A. Gear
Teeth
Check gears for

damaged or
missing teeth. B. Thrust Face
Surface
A. Inspect gears for damaged or

broken teeth. Inspect gear teeth for
wear that has changed the original
tooth shape. If this condition is noted,
replace the gear. Inspect gears for load
pattern and signs of distress. Any
signs of distress indicate the gear may
fail during operation. Reusing
distressed gears is an individual
customer decision based on
experience. Backlash cannot be used
to establish critical gear wear. Pits,
scuffs, scores or galling are typically
evident long before backlash exceeds
specification.
B. Inspect the thrust face of gears
A. Gear for damage. If these defects cannot
Teeth be removed with a soft stone, replace
the gear.
SPLINES
A. Splines
Inspect splined parts

for burrs, damage
and excessive wear.
A. Inspect splined parts for 0.38 mm (0.015 inches) if not

damage. Remove burrs with a soft otherwise listed in Wear Limits in
stone. Spline wear is not considered Service Manual SM3191EN. Do not
harmful except where it affects the reuse a splined part that exceeds
fit of the splined parts. Spline wear the published maximum spline
is determined by comparing feeler wear. Backlash cannot be used to
gauge thickness with the thickness establish critical spline wear.
of the worn area on the spline. Accurate backlash measurement
Replace parts having excessive requires the mating parts to be
spline wear. The maximum concentrically located.
movement allowed at the splines is

BEARINGS
A. Ball Bearing
(Under B. Bearing
Retainer) Race
C. Retainer
A & B. Replace the bearing if any C. Replace the bearing if any

rollers/balls or races are rusted. retainer or retainer clip is
Replace the bearing if balls/rollers fractured, bent, dented or missing.
have a feeling of looseness in the Replace the bearing if any retainer
retainer or race compared to a new is rusted. Replace the bearing if
bearing. Replace the bearing if there is a feeling of looseness
balls/rollers or races are discolored between the retainer and ball/roller
from heat, lack of lubrication or compared to a new bearing. Replace
the bearing if it catches or feels
debris lapping. Replace the bearing
rough after being thoroughly
if the balls/rollers or races are worn,
cleaned.
galled or abraded. Replace the (continued)
bearing if it catches or feels rough
after being thoroughly cleaned.

GENERAL INSPECTION
GUIDELINES FOR
BEARINGS (continued)
General Bearing Handling When immersing in solvent, place

& Storage bearings in a wire basket so there is
plenty of space for cleaner to reach
Dirt is the greatest single enemy all parts. Tanks should have a
of any antifriction bearing. screened false bottom to prevent
Cleanliness - using clean tools in a settled debris from being stirred up Fractured races - a fractured race
clean environment - is at the top into the bearings. Agitate the can be caused by forcing a cocked
of the list of good service basket frequently until grease, oil or bearing on or off a shaft. An
techniques. Keep bearings sealed in sludge is thoroughly loosened and excessively tight press fit can also
original containers. Do not allow can be flushed out. Blow solvent cause a race to fracture.
anyone to open boxes and handle out of bearings using dry, filtered
bearings. A new bearing, if not Worn, galled or abraded
air. Be careful not to spin the surfaces - worn, galled or abraded
protected, can quickly pick up bearing using air pressure.
enough dust even in an apparently surfaces on a bearing may be the
Lubricate bearings immediately result of a loose fit on a shaft or in a
clean place to seriously affect its life after drying t avoid rust.
and operation. Minimize the housing. A locked bearing spinning
possibility of rusting or lubricant NOTE: Wear eye protection and on a shaft or in a housing can also
aging in storage by using the oldest follow the appropriate safety create this type of damage.
bearings in stock first. guidelines when using solvents to General feeling of roughness -
clean components. inspect for a general feeling of
If any part of a bearing assembly
has been compromised, replace all Badly discolored rollers and races roughness which remains
detail parts in the assembly are usually a sign of inadequate unchanged by thorough cleaning.
(example - races, retainers and the lubrication. Replace badly This condition generally indicates
bearing itself). Most bearings fail discolored bearings. Moderately damage to raceways or rollers
from preventable causes. Follow a discolored rollers, cages and races caused by dirt, pitting, brinelling or
regular system for inspection. Look do not necessarily mean that the corrosion.
for bearings with obvious damage bearing needs replacement. Catchy feeling - inspect for a
first. catchy feeling at one or more points
Technicians should always try to
determine the root cause of failure which repeated flushing will not
General Bearing Inspection when inspecting failed components. remove. This condition generally
It’s important the root cause be indicates a spalled or fatigued spot
Do not try to judge the condition of on the race. Thorough flushing is
identified and repaired to avoid the
a bearing until after cleaning. Do necessary to be sure the catchy or
same failure in the future. Bearings
not spin bearings while cleaning rough feeling is not caused by
should be replaced for the
them. Rotate them slowly while foreign debris in the bearing.
following reasons:
washing. Do not spin any bearings
with air pressure. Put bearings Rusted rollers, balls or Excessive looseness - inspect for
under axial pressure while rotating raceways - rusted rollers, balls or excessive looseness which indicates
to bring the balls and races firmly in raceways are usually caused by water lapping by dirt or an abrasive
contact with each other. For single passing worn or defective seals, or by contaminate in the lubricant. If in
row angular contact bearings, condensation inside the housing. doubt, compare the end play
pressure must always be applied on against the end play of an identical
thrust faces. new bearing. The races, balls and
rollers will appear dull gray when
lapped by dirt.

BUSHINGS
A. Bushing
Bushing wear is
strongly influenced
by the quantity and
condition of the
lubricant.
A. Inspect bushings for wear General Bushing Information Some bushings are susceptible to
beyond service limits. Replace any material leaching. This can be
Mechanically, bushings are the
bushing which is excessively worn. caused by oxidized oil that has
simplest type of journal bearing and
Inspect bushings for discoloration turned acidic combined with heat
are often referred to as “plain”
and surface damage due to lack of and mechanical loading. The TAN
bearings. A bushing is simply a
lubrication. Replace any bushing (Total Acid Number) of the
sleeve of bearing material, such as
which is damaged. transmission oil should not change
bronze or aluminum, in which a
by more than 3 from the baseline
component rides. Bushing wear is
(new fluid) TAN. Changing
strongly influenced by the quantity
transmission oil per recommended
and condition of the lubricant.
change intervals or based on a
Bushing bearing surfaces are
successful oil sampling program
sometimes grooved to better
will help prevent material leaching.
distribute lubrication across the
bearing surface.

RETAINING RINGS
A. Retaining
Rings
A. Inspect retaining rings for Examine retaining

damage, distortion and excessive rings for damage,
wear. Replace retaining rings if distortion or
excessive wear.
damage cannot be repaired using a
soft stone or crocus cloth.

THRUST WASHERS
A. Thrust
Washers
A. Replace thrust washers if they

are worn beyond service limits.
Replace thrust washers if they are
galled, abraded or distorted.
Replace thrust washers if they are
damaged due to a lack of
lubrication.

CLUTCH PLATES
Oil grooves Spline teeth battered D. Spline
appear shallow and worn - may be an Teeth
or worn away - indication of driveline A. Contact
measure plate issues. Replace Surface
thickness and clutch plates and
check driveline. C. Oil
groove depth. Groove
Depth
A. Inspect friction plate contact C. Measure friction plate oil clutch plate if spline teeth are
faces and splines for excessive groove depth. Replace any plates broken or missing.
wear, damage and coning. Inspect that are not within Service Manual
NOTE: Anti-freeze (glycol) and/or
the plates for burrs, pitted faces, SM3191EN minimum groove depth water will adversely affect the
cracks, distortion and damaged specification. bonding agent between the friction
spline teeth. material and steel core. Replace any
D. Inspect spline teeth for
excessive wear and battering. friction plates which have been
B. Measure friction plate exposed to water and/or
thickness and coning. Reference Replace the clutch plate if damage
cannot be repaired using a soft glycol.Reference SIL 18-TR-98,
the Service Manual SM3191EN for Rev. A, for details.
stone or crocus cloth. Replace the (continued)
minimum thickness and maximum
coning specifications. Do not reuse
friction plates that do not meet B. Clutch Plate
Thickness and
published specifications. If reused
Coning Coned Plate
plates are slightly coned (within
specification), make sure each plate Check Using
is stacked with the cone facing the Flat Plate
Feeler Gauge
same direction.
Thickness

(continued) CLUTCH PLATES
C. Tangs Acceptable
discoloration -
reuse plates.
Excessive scoring -
replace plates.
B. Thickness
& Coning
(see prior
page
graphic) Broken tangs -
replace plates.
B. Measure reaction plate

thickness and coning. Reference
the Service Manuals for minimum
thickness and maximum coning
specifications. Do not reuse plates
A. Contact that do not meet published
Surfaces
specifications. If reused plates are
slightly coned (within
specification), make sure each plate
is stacked with the cone facing the
same direction.
A. Inspect reaction plates for
excessive wear, warping, coning C. Inspect reaction plate tangs
and surface damage. Replace any for damage. Replace the plate if
plate with wear exceeding service damage cannot be repaired using a
limits or with damage which soft stone or crocus cloth.
cannot be repaired using a soft
stone or crocus cloth..

SPRINGS
Reference the Service

Manual Spring Data
Charts for spring
identification and
specifications.
A. Springs
A. Inspect springs for permanent

set and wear due to rubbing
adjacent parts. Replace the spring if
any of these defects are identified or
if the spring fails to meet published
service limits. Reference the Service
Manual SM3191EN Spring Data
Charts for spring identification and
service limit specifications.
Inspect springs for signs of

discoloration, permanent
set or wear due to rubbing
adjacent parts.

CONTROL VALVE BODY ASSEMBLY
Identification Detail: Control Valve Body Assembly
Reverse Modulated Main

Signal Separator Plate Valve Body
Tube
Shift Valve
Body
Main Valve
Body
Pressure
Switch
Manifold
General Valve Body

Component Inspection Reverse
Pressure
Signal Tube
Guidelines Switch
Manifold G Solenoid
Inspect valve bodies. Inspect valve
bores and oil passages for nicks,
bores, scoring and debris. Replace A Solenoid
the valve body if damage cannot be
repaired using a soft stone or
crocus cloth.
Valves must be free of nicks, burrs
and scoring. A soft stone or crocus
cloth can be used to attempt B Solenoid
removal of slight irregularities.
Valves must operate in their bores C Solenoid
D Solenoid Manual
smoothly without sticking or F Solenoid
E Solenoid (Lockup) Selector
hanging. Valve
(continued)

CONTROL VALVE BODY ASSEMBLY (continued)
Identification Detail: Exhaust

Main Valve Body Backfill
Assembly Valve
Control
Relief Valve
E Solenoid
D Solenoid
Identification Detail:
F Solenoid C Solenoid Shift Valve Body Assembly
Retainer Control
C Shift Main
Valve Valve
B Solenoid
Accumulators Plug
Trim
Valve
Gain E Shift
Valve Valve
A/B D Shift
Retaining A Solenoid Valve
Bracket
Manual Selector
Valve & Pin
NOTE: 1000/2000 Product Families Retaining clips and retention pins Inspect the separator plate for
valves are anodized aluminum. Do must be free of nicks, burrs, scoring, scoring, scratches, burrs and nicks.
not remove the gray coating from battering and other damage. Replace the plate if damage cannot
the valve surface. Replace retainers or pins which be repaired using a soft stone or
have damage that cannot be crocus cloth, or if the plate is
NOTE: Do not use impact guns (air
removed using a light stone or cracked or bent.
wrenches, impact wrenches, etc.) crocus cloth. (continued)
when working with aluminum
threads or when torque sequencing Replace solenoids if they are visibly
bolts. damaged or if they have been
exposed to anti-freeze and/or
Replace valve springs which are water. Check solenoid resistance
broken, cracked, permanently set or following Troubleshooting Manual
worn due to rubbing adjacent parts. TS3192 guidelines and
Reference the Spring Data Charts in specifications. Replace the solenoid
the Service Manual for spring if resistance is not within
specifications and identification. Troubleshooting Manual
specifications.

(continued) CONTROL VALVE BODY ASSEMBLY
Identification Detail: Identification Detail:

Main Valve Body (front) Main Valve Body (back)
Inspect the internal wiring Modulated Main Valve G Solenoid
Body Detail Valve Body
harness connectors and terminals
for visible damage. Inspect the
harness protective covering and Retaining
plastic retainer for cracks, chafing, Clip
rubbing and broken pieces. Replace
and repair components as
necessary. Replace the main
connector O-ring if it is cracked,
fretted or does not properly fit in its
groove or in the main housing.
NOTE: Reference the 1000/2000 Supply Port
Product Families Principles of G Solenoid
(Control
Operation Manual (PO3065) for Main)
complete valve body oil passage Pressure
detail. Output
(continued)

Valve bores
must be free
of nicks, burrs
and scoring.
B. Valve
Bores
A. Valves
Valves should
move freeely in
their bores, when
dry, under their
own weight.
A. Valves must be free of nicks, B. Valve bores must be free of

burrs and scoring and operate nicks, burrs and scoring. No honing
smoothly in their bores without of any kind is allowed. A soft stone
sticking. Dry valves must move or crocus cloth can be used in an
freely in their bores by their own attempt to repair slight
weight. Replace damaged valves. irregularities.
A soft stone or crocus cloth can be
NOTE: Use caution not to round
used in an attempt to repair slight
irregularities. land edges on valves or valve bores.
Excessive rounding can cause
unwanted leakage.

C, D, E and G Solenoids (on/off)
Solenoids
Supply Port
(Control Main) F Solenoid
Lockup
Pressure (PWM)
Output
Pressure Supply
Output Port
A Trim
Solenoid Exhaust
(PPC)
Trim B Trim Solenoid
Signal (PPC)
Identification Detail: Not Reference the

Pressure Switch Used Troubleshooting
Reverse
Manifold Manual for switch
D Pressure testing procedures.
Switch
Exhaust
Backfill &
Thermister
E Pressure
Switch
Reverse
C Pressure D Pressure
Switch Switch
E Pressure
Switch
Exhaust
Backfill & C Pressure
Thermister Switch
(continued)
Internal Wiring
Harness Assembly
B Solenoid F Solenoid
A Solenoid
D Solenoid
G Solenoid
E Solenoid
Supersession Information
TCM And Calibration Updates - Reference
C Solenoid SILs 2-1K2K-01, 4-1K2K-02, 3-1K2K-03,
7-1K2K-03, 26-1K2K-03
Pressure
Switch
Manifold Main
Connector
TCM And Calibrations Have Evolved

And Continue To Update
(continued)
The A/B
solenoid
bracket
should be
slightly
bent as
shown. Inspect the
reverse
signal tube
for cracks,
broken welds
and improper
bends.

TORQUE CONVERTER
B. Converter Stator
(Inside Converter)
A. Converter
Exterior
C. Converter
Hub
A. Visually inspect the converter NOTE: Erratic speed sensor signals B. Inspect the stator for proper
exterior for impact damage and can be caused by a dented torque locking and freewheeling action.
signs of discoloration. The ribs on converter or deformed torque The stator inner race should lock
the back of the pump housing are converter ribs. Inspect the when rotated counterclockwise and
used by the engine speed sensor to converter carefully. Dents and rotate freely when rotated
detect converter rotation. Replace deformities are sometimes hard clockwise. Check the stator with
the converter if any ribs are to identify. the converter on its edge, and with
damaged or deformed. the converter placed at a 45 degree
The converter must not show signs
angle, hub down. Replace the
of leakage when pressurized to 517
converter if the stator fails this
kPa (75 psi) and submerged in
inspection.
water. If bubbles appear during this
test, the converter is leaking and Check converter endplay
must be replaced. following Service Manual
NOTE: After pressure testing the SM3191EN guidelines. Replace the
torque converter, all air pressure converter if endplay exceeds 1.015
must be exhausted from the mm (0.040 inch).
Dented converter near rib (continued)
creates erratic speed
converter before loosening the test
sensor signal. fixture nut.

(continued) TORQUE CONVERTER
D. Converter
Pilot
C. Inspect the converter pump engine/transmission installation E. Inspect for missing or damaged
hub for deep scratches, scoring, when this type of damage exists. converter lugs. Inspect welds for
nicks, burrs and signs of cracks. Replace the converter if
D. Inspect the converter cover
overheating. DO NOT ATTEMPT damage cannot be repaired using a
to clean up hub damage using pilot for impact damage, nicks,
burrs, cracks and signs of soft stone or crocus cloth. Replace
crocus cloth or a soft stone. the converter if any lugs are
Polishing the hub will cause fluid discoloration. Replace the converter
if damage or discoloration is missing. Replace the converter if
leakage at seal areas. Minimum lug threads are damaged and cannot
allowable pump diameter is excessive. Minimum allowable
pilot diameter is 43.080mm be repaired.
58.25mm (2.2933 inches). Minimum
allowable distance between (1.696 inches).
converter hub flats (the charging
pump drive surface) is 51.816mm
(2.040 inches).
NOTE: Damage to the torque E. Converter
converter hub and/or the torque Lugs
converter pilot may indicate an
engine/transmission adaptation
issue. Carefully inspect the

TORQUE CONVERTER HOUSING
B. Machined
Mounting
A. Housing B. Machined Surface
Sealing
Surface
C. Cooler Ports
D. Filter and Pressure
Attachment Tap Threads
Tube
A. Inspect the housing for impact damage cannot be repaired. Some pressure tap threads for stripping
damage, chips and cracks. Inspect models use a cooler manifold which and damage. Inspect the manifold
bolt holes for damaged threads. bolts to the torque converter channel plate for scratches, burrs
Replace the housing if damage housing. When used, inspect the and damage. Replace the manifold if
cannot be repaired. cooler manifold cooler port and damage cannot be repaired.
(continued)
B. Inspect machined surfaces for
damage which might prevent A magnet sits on top of
proper sealing and/or seating. the control main filter
Inspect for deep scratches, scoring, and fits over the filter
grooves, nicks, burrs, chips and attachment tube.
cracks. Replace the housing if
C. Inspect cooler port and
pressure tap threads for stripping
and damage. Replace the housing if

(continued) TORQUE CONVERTER HOUSING
Main Oil Passage Detail

Knockdown Exhaust
Pressure
(Overdrive)
Overage
N/A
Exhaust or Drain Back
Exhaust Suction
Lube
or Drain Pressure From
Back
Cooler
From
Control
Main
Filter
N/A
To Control
Main Filter To
Main Pressure Cooler To Control
Main Filter
C1 Pressure C2
From Control Main To From
Pressure
Main Filter Pressure Cooler Cooler
D. Inspect the filter attachment F. Inspect the input speed sensor

F. Input tube threads for stripping and for obvious external damage.
Speed damage. Replace the fitting if damage Inspect the seal ring for wear,
Sensor cannot be repaired. Replace the damage and proper fit on the sensor
housing if the threaded bore is and in the speed sensor bore. Speed
damaged and cannot be repaired. sensor resistance can be checked
using an ohmmeter. Reference
E. Inspect the input speed sensor Troubleshooting Manual TS3192 for
bore for scoring, nicks, burrs, chips procedures and specifications.
or cracks. Replace the housing if
the damage cannot be repaired
E. Input using a soft stone or crocus cloth.
Speed
Sensor
Bore

REAR COVER ASSEMBLY
B. Machined Standard Park Brake B. Machined Sealing,

Sealing, Rear Cover Mounting, Bearing
Mounting, Surfaces
Bearing
Surfaces
A. Housing
C. Output
Speed
Sensor
D. Output
Tone
Wheel
A. Inspect the housing for impact damage cannot be repaired using a D. Replace the output speed
damage, chips and cracks. Inspect soft stone or crocus cloth. sensor tone wheel if any teeth are
bolt holes for damaged threads. chipped, missing, damaged or worn
Replace the housing if damage C. Inspect the output speed in a way that changes a tooth’s
cannot be repaired. sensor for obvious external damage. original shape. Inspect the internal
Replace the sensor if it has body, splines for burrs, twisting or signs
NOTE: If cracks are detected on the terminal or connector damage. of battering. Replace the tone wheel
four-wheel drive adapter housing, Inspect the seal ring for wear, if spline damage cannot be repaired
perform thorough driveline analysis damage and proper fit on the sensor using a soft stone or crocus cloth.
checks to ensure driveline and in its bore. Speed sensor Inspect the tone wheel’s contact
components are within resistance can be checked using an surface faces for scoring, grooves,
specifications. ohmmeter. Reference nicks and other damage which
Troubleshooting Manual TS3192 for might prevent proper component
B. Inspect machined surfaces for procedures and specifications.
damage which might prevent seating. Replace the tone wheel if
Inspect the output speed sensor face damage cannot be repaired
proper sealing and/or seating. bore for scoring, nicks, burrs, chips
Inspect for deep scratches, scoring, using a soft stone or crocus cloth.
or cracks. Replace the housing if
grooves, nicks, burrs, chips and (continued)
the damage cannot be repaired
cracks. Replace the housing if using a soft stone or crocus cloth.

(continued) REAR COVER ASSEMBLY
B. Machined Sealing,
Mounting, Bearing
Surfaces
A. Housing F. Spacer
(4WD)
E. Selective
Four-Wheel Drive Shim
C5 Feed
Adapter Housing Park Pawl
Retaining
Pin Bore
E. Inspect the selective shim for

Tone wheel tooth
chips, bends, cracks, wear or signs
imperfections - replace
tone wheel. of deformity. Replace the shim if
F. Inspect the output spacer on
four-wheel drive models for cracks,
burrs, chips and thrust surface face
wear. Replace the spacer if damage
cannot be repaired using a soft
stone or crocus cloth.
NOTE: If cracks are detected on the
four-wheel drive adapter housing,
perform thorough driveline analysis
checks to ensure driveline
components are within
specifications.

MAIN SHAFT ASSEMBLY
E. P3 Sun
Gear
F. Spacer
D. P2 Sun
Gear
Main
Shaft
B. Splines
A. Journal
and Pilot
Surfaces
C. Oil
Passages
B. Splines
A. Inspect the main shaft pilot C. Oil passages must be clean and and signs of battering. Replace the
and journal areas for scoring, burrs, unobstructed. Inspect the edges of gear if damage cannot be repaired
nicks and signs of overheating. each orifice for cracks, chips, burrs using a soft stone or crocus cloth.
Replace the shaft if damage cannot and metal fatigue. Replace the shaft
be repaired using a soft stone or if damage cannot be repaired using F. Inspect the spacer for cracks.
crocus cloth. Minimum allowable a soft stone or crocus cloth. Inspect internal splines for step
pilot outside diameter is 19.987mm wear, twisting, chips, burrs and
(0.7869 inch). Minimum allowable D. Inspect the P2 sun gear for signs of battering. Inspect the
diameter for the P2 bushing journal chipped, broken, pitted and missing thrust surfaces for nicks, burrs,
surface is 35.405mm (1.4333 teeth. Inspect the internal splines scoring and excessive wear. Replace
inches). for step wear, twisting, chips, burrs the spacer if damage cannot be
and signs of battering. Replace the repaired using a soft stone or crocus
B. Inspect the splines for step gear if damage cannot be repaired cloth.
wear, twisting, chips, burrs and using a soft stone or crocus cloth.
signs of battering. Replace the shaft
if damage cannot be repaired using E. Inspect the P3 sun gear for
a soft stone or crocus cloth. chipped, broken, pitted and missing
teeth. Inspect the internal splines
for step wear, twisting, chips, burrs

P1 PLANETARY AND P2 RING GEAR
E. Pinion Needle
Bearings G. Thrust Bearing
(Internal) Surface
C. Pinion
Gears A. Splines
D. Pinion
Thrust
Washers
B. Carrier
Housing
F. Bushing
P1
Planetary
A. Inspect the splines where the B. Inspect the carrier housing for D. Inspect the pinion thrust
P2 ring gear indexes to the carrier cracks, chips, impact damage and washers for damage, distortion and
housing. Inspect the splines on the signs of discoloration. Replace the signs of overheating. Replac the
front hub. Inspect for step wear, assembly if damage cannot be carrier assembly if any damage is
twisting, chips, burrs and signs of repaired using a soft stone or crocus identified. Replace the carrier
battering. Replace the carrier if cloth. assembly if any pinion gear endplay
damage cannot be repaired using a readings exceed 1.010 mm (0.040
soft stone or crocus cloth. With the C. Inspect pinion gears for inch).
P2 ring gear installed, maximum chipped, broken, pitted or missing
allowable carrier/ring gear spline teeth. Replace the carrier assembly E. With the planetary clean and
movement is 0.38mm (0.015 inch). if damage cannot be repaired using oiled, check the pinion needle
Replace the ring gear and/or carrier a soft stone or crocus cloth. bearings by slowly spinning each
as needed to bring spline movement pinion gear and feeling for rough
within specification. spots. Replace the carrier assembly
if any pinion gear wobbles, has
rough spots or makes noise during
the spin test.
(continued)

P1 PLANETARY AND P2 RING GEAR (continued)
H. Splines
P1 Ring Assembled P1 Planetary

Gear J. Tangs and P2 Ring Gear.
I. Thrust
Washer
F. Inspect the carrier bushing for G. Thrust bearings are located NOTE: Inspect the P1 ring gear
nicks, burrs, scoring, signs of inside and on the front of the following these same guidelines and
discoloration and signs that the carrier. Inspect thrust bearing procedures.
bushing has spun in its bore. surfaces for grooves, scoring, pitting
Replace the bushing if damage and signs of overheating. Replace I. Inspect the thrust washer for
cannot be repaired using a soft the carrier assembly if damage cracks, bends, chips and deformity.
stone or crocus cloth. Maximum cannot be repaired using a soft Replace the washer if any damage is
allowable bushing inside diameter stone or crocus cloth. identified.
is 50.690mm (1.9957 inches). J. Inspect the thrust washer
During bushing replacement, H. Inspect the ring gear internal
and external splines for step wear, tangs for chips, cracks, breaks,
inspect the bushing bore in the bends, impact damage and signs of
carrier for scoring, burrs and nicks. twisting, chips, burrs and signs of
battering. Replace the ring gear if battering. Replace the washer if any
Replace the carrier assembly if damage is identified.
damage cannot be repaired using a damage cannot be repaired using a
soft stone or crocus cloth. soft stone or crocus cloth.
Reference "A" in this section for
installed spline wear check
procedures.

P2 PLANETARY AND P3 RING GEAR
B. Carrier
A. Splines
Housing
H. Splines
C. Pinion P3 Ring
Gears Gear
D. Thrust
Washers
E. Pinion Inspect hub Inspect
P2 Planetary Needle splines ring gear
Assembly Bearings splines
(Internal)
A. Inspect the splines where the assembly if damage cannot be

P3 ring gear indexes to the carrier repaired using a soft stone or
housing. Inspect the splines on the crocus cloth.
front hub. Inspect for step wear,
twisting, chips, burrs and signs of C. Inspect pinion gears for
battering. Replace the carrier if chipped, broken, pitted or missing
damage cannot be repaired using a teeth. Replace the carrier assembly
soft stone or crocus cloth. With the if damage cannot be repaired using
P3 ring gear installed, maximum a soft stone or crocus cloth. Assembled P2 Planetary
and P3 Ring Gear
allowable carrier/ring gear spline D. Inspect the pinion thrust
movement is 0.38mm (0.015 inch). washers for damage, distortion and E. With the planetary clean and
Replace the ring gear and/or carrier signs of discoloration. Replace the oiled, check the pinion needle
as needed to bring spline movement carrier assembly if any damage is bearings by slowly spinning each
within specification. identified. Replace the carrier pinion gear and feeling for rough
B. Inspect the carrier housing for assembly if any pinion gear endplay spots. Replace the carrier assembly
cracks, chips, impact damage and readings exceed 1.010mm (0.040 if any pinion gear wobbles, has
signs of discoloration. Replace the inch). rough spots or makes noise during
the spin test.
(continued)

P2 PLANETARY AND P3 RING GEAR (continued)
G. Thrust
Bearing
Surface P3 Ring Gear Retaining Ring
Groove Inspection Procedures -
Reference SIL 8-1K2K-03
INSPECT
FOR
CHAMBER
F. Bushing
Retaining Groove Should Not
Have A Chamfered Edge.
F. Inspect the carrier bushing for G. Thrust bearings are located

nicks, burrs, scoring, signs of inside and on the front of the Supersession Information
overheating and signs that the carrier. Inspect thrust bearing P3 Ring Gear Update -
bushing has spun in its bore. surfaces for grooves, scoring, pitting Reference SIL 31-1K2K-01
Replace the bushing if damage and signs of distress. Replace the
cannot be repaired using a soft carrier assembly if damage cannot
stone or crocus cloth. Maximum be repaired using a soft stone or
allowable bushing inside diameter crocus cloth.
is 35.575mm (1.440 inches). During
bushing replacement, inspect the H. Inspect the ring gear internal
bushing bore in the carrier for and external splines for step wear,
scoring, burrs and nicks. Replace twisting, chips, burrs and signs of
the carrier assembly if damage battering. Replace the ring gear if
cannot be repaired using a soft damage cannot be repaired using a
stone or crocus cloth. soft stone or crocus cloth.
Reference “A” in this section for
installed spline wear check Current Ring Gear Has
procedures. Fewer Spline Teeth.

Park pawl equipped (left) and non-park
pawl carriers with P3 Sun Gears installed.
P3 PLANETARY ASSEMBLY
A. Housing
C. Pinion E. Splines
Thrust
Washers
P3 Sun Pinion
Gear Pin
A. Housing
Pinion
Pin
E. Splines
B. Pinion
Gears
B. Pinion Supersession Information

Gears
P3 Sun Gear And T6 Bearing Updates -
D. Pinion
Needle
F. Park Pawl Bearings
Engagement Cogs (Internal)
A. Inspect the carrier housing for D. With the planetary clean

cracks, chips, impact damage and and oiled, check the pinion
signs of discoloration. Replace the needle bearings by slowly
assembly if damage cannot be spinning each pinion gear and
repaired using a soft stone or crocus feeling for rough spots.
cloth. Replace the carrier assembly
B. Inspect pinion gears for if any pinion gear has rough
chipped, broken, pitted or missing spots or makes noise during
teeth. Replace the assembly if the spin test.
E. Inspect the splines where
the output shaft indexes for
C. Inspect the pinion thrust Sun Gear and Bearing Updates
step wear, twisting, chips, Enable Increased Capacity.
washers for damage, distortion and burrs and signs of battering.
signs of discoloration. Replace the Replace the assembly if
carrier assembly if any damage is F. Inspect the park pawl cogs for
identified. Replace the carrier bending, distortion, step wear,
assembly if any pinion gear endplay scoring, chips, and rounded edges.
readings exceed 1.010mm Replace the assembly if any damage
(0.040 inch). is detected.

ALLISON 1000 & 2000
PRODUCT FAMILIES
OUTPUT SHAFT
Shaft has normal journal Shaft has excessive galling

surface wear and can be and wear on the journal
reused if within service limits. surface - replace the shaft.
Two-Wheel Drive
Output Shaft D. Oil Passages
B. Journal
Surfaces
A. Splines
E. Yoke
Retaining
Bolt C. Output
Threads Nut
Threads
Four-Wheel Drive
Output Shaft
A. Inspect the splines for step C. On four-wheel drive models, F. Inspect the bushing where the
wear, twisting, chips, burrs and inspect for damaged locknut main shaft pilots for nicks, burrs,
signs of battering. Replace the threads. Replace the shaft assembly scoring, signs of overheating and
assembly if damage cannot be if damage cannot be repaired. signs that the bushing has spun in
repaired using a soft stone or crocus D. Oil passages must be clean and its bore. Replace the bushing if
cloth. unobstructed. Inspect the edges of damage cannot be repaired using a
B. Inspect journal surfaces for each orifice for cracks, chips, burrs soft stone or crocus cloth. Maximum
scoring, burrs, nicks and signs of and metal fatigue. Replace the shaft allowable bushing inside diameter is
overheating. Replace the shaft assembly if damage cannot be 20.070 mm (0.7940 inch). Replace
assembly if damage cannot be repaired using a soft stone or crocus the shaft assembly if the bushing
repaired using a soft stone or crocus cloth. bore is damaged.
cloth. Minimum allowable diameter E. On two-wheel drive models,
of the output roller bearing journal inspect for damaged yoke retaining F. Bushing
44.978mm (1.7708 inches). bolt threads. Replace the shaft
assembly if damage cannot be
NOTE: Damage to the output bearing
repaired.
journal surface may indicate
driveline issues. Perform thorough NOTE: The output shaft threads use
driveline analysis checks to ensure a Spiralok® design. Replace the
driveline components are within output shaft assembly if the
specifications. Sprialok® threads are damaged.
FRONT SUPPORT AND CHARGING
OIL PUMP MODULE
F. Separator
Plate
E. Charging
Pump
Wearplate
B. Ground
C. Charging
Sleeve
Pump
Body
G. Converter
Flow Valve
A. Front Support
D. Charging Housing
Pump
Gearset I. Clutch L. Thrust
Backfill Washer
Valve
K. Converter
Relief Valve
Inspect the seal bore on
the front of the charging
A. Inspect the front pump housing.
J. Lube
support housing. Inspect Regulator Seal
machined mating and Valve Bore
sealing surfaces and oil H. Main
passages for cracks, nicks, Regulator
Valve
grooves, scoring and
damage which might
prevent proper sealing or
seating. Inspect valve Inspect the three sealring grooves
bores for nicks, scoring, debris and on the back of the support for
any damage which might prevent burrs, chips, cracks and impact
proper valve operation. Replace the damage. Sealrings should fit
housing if damage cannot be snuggly, but move freely in the cloth. Inspect the ground sleeve
repaired using a soft stone or crocus groove. Inspect the thrust washer needle bearing for rough rotation
cloth. Replace both the ground surface at the base of the backside after cleaning and lubrication.
sleeve and the housing if the sleeve hub for grooves, nicks, scoring, Inspect the bearing for scored,
has rotated in the housing. burrs and scratches. Replace the pitted, cracked and chipped races.
housing if damage cannot be Replace the bearing if any defects
repaired using a soft stone or crocus are identified. (continued)

OIL PUMP MODULE (continued)
Turbine Shaft
Sealring Surface
Area Sealring
Grooves
Ground Sleeve Stator
Bushing Splines Thrust
Washer
Surface
Needle
Bearing
Ground
Sleeve
Key ground sleeve Key inspection items on the

inspection items. front support backside.
B. Inspect the ground sleeve using a soft stone or Gear Cavity

splines for step wear, twisting, crocus cloth. Maximum Depth and Bushing
chips, burrs and signs of battering. allowable ground sleeve Diameter
Replace the ground sleeve if any diameter in this area is
visible damage is detected. Inspect 45.450mm (1.7894
the ground sleeve bushing for nicks, inches).
burrs, scoring and signs that the
bushing has spun in its bore. When replacing the
Replace the bushing if damage ground sleeve, total
cannot be repaired using a soft runout cannot exceed
stone or crocus cloth. Maximum 0.20mm (0.008 inch)
allowable bushing inside diameter once the sleeve is
is 33.820mm (1.3315 inches). pressed into the front
support.
Inspect the turbine shaft sealring
surface inside the rear of the NOTE: If the ground Dowel
ground sleeve for grooves, scoring sleeve has rotated in the Pins Sealring
and damage which might prevent front support housing, Groove
proper sealing. Replace the ground replace the front
support assembly. Key inspection items on the charging
sleeve if damage cannot be repaired pump body backside.
(continued)

(continued) OIL PUMP MODULE
Identification Detail: Converter In

Overage
Oil Passage Detail Lockup Apply
Exhaust
Exhaust
To Cooler
Converter Out Lockup Signal
Exhaust
Main
Overage
Overage
N/A
Exhaust
Lube Knockdown
(Overdrive)
Exhaust
Main
Exhaust
Exhaust
From Cooler
To Cooler
C2 Suction C1
Exhaust
C. Inspect the charging pump bushing if this burnt orange color is abnormal wear patterns. Replace
body housing. Inspect the sealring not visible on the entire bushing the gearset if either gear has damage
groove for burrs, chips, cracks and contact area. Maximum allowable which cannot be repaired using a
impact damage. Inspect the housing bushing inside diameter is soft stone or crocus cloth. Inspect
sealing surfaces and gear contact 58.458mm (2.3015 inches). the flats on the drive gear for signs
areas for scoring, burrs, nicks, chips, of battering. Replace the gearset if
pitting and impact damage. Replace On the front side of the housing,
inspect the bore where the seal fits the flats are battered or damaged in
the housing if damage cannot be any way. Maximum allowable
repaired using a soft stone or crocus for burrs, nicks, scratches, scoring
and any damage which might distance between flats if 52.165mm
cloth. Inspect dowel pins and only
prevent proper seal installation or (2.0537 inches). Minimum
replace them if damaged. Maximum
allowable gear cavity inside diameter sealing. Replace the housing if allowable driven gear outside
is 109.191mm (4.2989 inches). damage cannot be repaired using a diameter is 108.987mm (4.2908
soft stone or crocus cloth. inches).
Inspect the housing bushing.
Replace the bushing if it has any D. Inspect the charging pump Install the gearset in the housing.
damage which cannot be repaired gearset for scored, chipped, broken, Use a straightedge and feeler gauge
using a soft stone or crocus cloth. missing or abnormally worn teeth. to measure side clearance.
The bushing uses a burnt orange Inspect the sides of the gears for Maximum allowable side clearance
Teflon® coating. Replace the scoring, nicks, grooves and for each gear is 0.066mm (0.0026
(continued)

OIL PUMP MODULE (continued)
Supersession Information Supersession Information

Main Regulator Valve Update - Charging Pump Bushing Update -
Reference SIL 3-1K2K-04 Reference SIL 6-1K2K-02
Current
Former
Former
Main / Used with

Main Pressure Group Serial Number Overage Separator
Valve Number Number Implemented Identification Clearance Plate
Prior to
29536693 10-628 6310037977 No ID grooves --- 29537327
29531323 10-642, Beginning w/ One ID groove at the .003 29531330

644, 648 6310037977 large valve end
29540486 10-643 Beginning w/ Two gooves under .004 29531330

6310200277 the third land and no
Commercial Truck
grooves on large end
29542361
♣
10-643, *6310307722 Three grooves
Service at the large .004 29541148
10-649 Replacement
For Truck Applications valve end
between 6310001000- Current Bushing
6310004116
Is Serviceable.
29541138 10-651 6310374684 No ID grooves .003 29541148
Current Production
Service .005 29531330

29542193♦ 10-650 Replacement Two grooves F. Inspect the separator plate for
For Bus Applications at the large
between 6310001000
valve end scoring and flatness. Replace the
6310004116 and
6310037978-6310203135 plate if damage cannot be repaired
* Also used in pre-production units: 6310292155-6310292563, 6310296468-6310296471, 6310301450-6310301451, 6310303122-6310303124 using a soft stone or crocus cloth.
♣ Modulated Main Implemented.
♦ Part was never production released-service only.
G, H, I, J, K. Inspect the front
inches). Measure the clearance E. Inspect the charging pump support valves, springs, stops and
between the outer (driven) gear and wear plate for nicks, burrs, scores, retainers for damage. Replace
the housing. Maximum allowable scratches, cracks, flatness and any components if damage is detected.
clearance is 0.204mm (0.008 damage which might prevent
L. Inspect the front support
inches). Measure the clearance proper seating and gear operation.
thrust washer for scoring, grooves,
between the inside (drive) gear and Do not attempt to repair damage
bends, impact damage and signs of
the crescent. Maximum allowable using a soft stone or crocus cloth -
overheating. Replace the washer if
clearance is 0.455mm (0.0179 inch). replace the wear plate if damage is
Replace worn parts as necessary. detected. Minimum allowable wear
soft stone or crocus cloth, or if any
plate thickness is 2.950mm (0.1161
of the thrust washer tangs are
inch).
deformed or missing.
(continued)

(continued) OIL PUMP MODULE
Supersession Information Supersession Information Supersession Information

Lube Regulator and Converter Double Lap Joint Sealrings - Front Support, Charging Pump,
Relief Valve Springs Update - Reference SIL 24-1K2K-02 Valves and Springs Update -
Reference SIL 29-1K2K-02 Reference SIL 3-1K2K-04
Current Sealring Design Is

Double Lap Joint - Must Be
Spring Updates Work Used On All Models And All
Together To Improve Pickup Truck Models Starting Model Year 04i Updates Are
Charging Pump Prime. With Model Year 03. Detailed In SIL 3-1K2K-04.
Identification Detail: Exhaust

to Sump
Oil Passage Detail
Overage
Overage
Main
Lube Exhaust to Sump
Torque Converter
Exhaust Clutch Apply
to Sump
Main
From
Cooler
Exhaust
To Cooler to Sump
C2 Suction C1

ROTATING CLUTCH HOUSING
E. Turbine
Shaft
Inspect the
internal splines C. Bushing
where the C2 B. PTO
reaction plates Drive
index. Gear
A. Rotating
Clutch
Housing
F. P1 Sun
Gear
Splines D. Speed
Sensor
Tone
Wheel
A. Inspect the rotating clutch pitting, grooves and scoring. B. Inspect the PTO drive gear
housing. Replace the housing if it Replace the housing if damage teeth for chips, cracks and
is cracked, dented or has damage cannot be repaired using a soft abnormal wear. Replace the
which cannot be repaired using a stone or crocus cloth. rotating clutch housing assembly if
soft stone or crocus cloth. damage cannot be repaired using a
Inspect the C1/C2 piston housing soft stone or crocus cloth, or if the
Inspect the internal splines where snap ring and sealring grooves for gear is missing teeth or loose on the
the C2 reaction plates index for burrs, chips and cracks. Replace the housing.
step wear, twisting, chips, burrs housing if damage cannot be
and signs of battering. Replace the repaired using a soft stone or crocus C. Inspect the rotating clutch
housing if damage cannot be cloth. housing bushing. Replace the
repaired using a soft stone or crocus bushing if it has any damage which
NOTE: Use the appropriate special cannot be repaired using a soft
cloth.
tools during C2 clutch piston snap stone or crocus cloth. Maximum
Inspect the surface just below the ring removal and installation to allowable bushing inside diameter
bushing where the three front avoid damaging the C1 clutch is 78.170mm (3.0776 inches).
support sealrings ride for cracks, sealring area. Reference Service
Manual SM3191 for procedures. (continued)

(continued) ROTATING CLUTCH HOUSING
C1/C2 piston housing

snap ring and sealring
grooves.
C1
C2 Clutch Clutch
Feed Feed
Front Support
Sealring Area
C1
C1 Return
Return Spring
Spring
Retaining
Retaining Ring
Ring
Groove
Groove
C1 Balance
Piston Feed
C2 Snap
Ring Groove
(Top Groove)
C1 Sealring Groove
(Bottom Groove)
D. Replace the speed sensor tone E. Reference the "Inspection and F. Inspect the P1 sun gear for
wheel if it is deeply scratched, Analysis of the Turbine Shaft" chipped, broken, pitted and missing
scored, dented, out-of-round or section of this manual for details. teeth. Replace the gear if damage
shows signs of impact damage. Any cannot be repaired using a soft
of these conditions can cause an stone or crocus cloth.
erratic turbine speed sensor signal.
The PTO gear

must be securely
attached to the
rotating clutch
housing.

TURBINE SHAFT
B. Bearing Journal
Turbine E. Splines
Shaft D. Oil Passage
(Lube)
D. Oil Passage
A. Bushing (Converter In)
Journal
E. Splines
C. Sealring
Grooves F. Snap Ring
Grooves
G. Bushing
A. Inspect the bushing journal C. Inspect the sealring grooves for

surface for nicks, burrs, grooves, burrs, chips and cracks. Replace the
scoring, pitting and signs of turbine shaft if damage cannot be
discoloration. Replace the shaft if repaired using a soft stone or crocus
damage cannot be repaired using a cloth.
soft stone or crocus cloth. D. Oil passages must be clean and
B. Inspect the bearing journal unobstructed. Inspect the edges of
surface for nicks, burrs, grooves, each orifice for cracks, chips, burrs
scoring, pitting and signs of and metal fatigue. Replace the shaft
discoloration. Replace the shaft if if damage cannot be repaired using
damage cannot be repaired using a a soft stone or crocus cloth.
soft stone or crocus cloth. (continued)

(continued) TURBINE SHAFT
Turbine Shaft Updates -
E. Inspect the splines for step G. Inspect the bushing. Replace

wear, twisting, chips, burrs and the bushing if it has any damage
signs of battering. Replace the which cannot be repaired using a
turbine shaft if damage cannot be soft stone or crocus cloth.
repaired using a soft stone or crocus Maximum allowable bushing inside
cloth. diameter is 20.117mm
F. Inspect the snap ring grooves (0.7920 inch).
for burrs, chips and cracks. Replace
the turbine shaft if damage cannot
be repaired using a soft stone or
crocus cloth.

C1 CLUTCH PACK COMPONENTS
B. C1 Clutch
Backplate
A. C1 Clutch
Pack
E. C1
Drive
F. C1 Piston Hub
Housing
G. Thrust
Bearing
D. C1 Return
ID Minimum Thickness
Spring
Assembly 2420 11.400 mm (0.4488 inch)
6221/8521 11.840 mm (0.4661 inch)
H. C1 Clutch
Balance 6222/8522 12.280 mm (0.4835 inch)
C. C1 Clutch
Piston Piston 6223/8523 12.730 mm (0.5012 inch)
6224/8524 13.180 mm (0.5189 inch)
6225/8525 13.630 mm (0.5366 inch)
A. Inspect friction plate contact friction plates which have been crocus cloth. Replace the plate if
faces for excessive wear, embedded exposed to water and/or glycol. any tangs are broken, bent or
metal particles, cracking and Friction material which is loose or otherwise distorted. Minimum
distortion. Inspect the plate splines flaking indicates that the plates allowable plate thickness is
for burrs, cracks and damaged have been exposed to glycol and/or 2.135mm (0.0841 inch). Maximum
spline teeth. Replace the plate if water. Reference SIL 18-TR-98, allowable coning is 0.20mm
spline damage cannot be repaired Rev. A for details. (0.0079 inch).
using a soft stone or crocus cloth.
Minimum allowable friction plate NOTE: Battered and worn spline B. Inspect the C1 clutch
thickness is 2.375mm (0.0935 inch). teeth may be an indicator of backplate. Replace the backplate if
Minimum allowable oil groove driveline issues. Replace the clutch has burrs, scoring or other damage
depth is 0.20mm (0.008 inch). plates and check the driveline. which cannot be repaired using a
Maximum allowable coning is soft stone or crocus cloth. Replace
Inspect reaction plate contact the backplate if it is cracked or
0.225mm (0.009 inch). surfaces for chips, cracks, grooves, broken. Check the backplate for
NOTE: Anti-freeze (glycol) and/or scoring and signs of discoloration. coning. Replace the backplate if any
water will adversely affect the Inspect reaction plate tangs for coning is detected. Minimum
bonding agent between the friction chips, cracks and signs of battering. allowable plate thickness is
material and steel core. Replace any Replace the plate if damage cannot indicated in the chart above.
be repaired using a soft stone or
(continued)

(continued) C1 CLUTCH PACK COMPONENTS
Inspect drive hub Supersession Information

splines for wear
and battering. C1 Drive Hub And T1 Thrust
Bearing Updates - Reference
SIL 23-1K2K-04
Inspect
the C1
clutch
piston
internal Piston
and housing
external check ball
sealring must have
Drive Hub And Bearing
grooves. at least
Updates Necessitate New
1.00 mm
Clutch Pack Clearance Check
free travel.
Procedures And Tooling.
C. Inspect the C1 clutch piston for spring specifications and F. Inspect the C1 clutch piston
for burrs, chips and cracks. Inspect identification. housing for burrs, chips and cracks.
the internal and external sealring Inspect the area where sealrings
grooves for burrs, chips and cracks. E. Inspect the C1 drive hub. ride for grooves and scoring.
Replace the piston if damage Inspect the rear of the hub for Replace the piston if damage
cannot be repaired using a soft damage caused by contact with the cannot be repaired using a soft
stone or crocus cloth. main shaft. Replace the hub if stone or crocus cloth. The check
damage cannot be repaired using a ball must move freely and have a
D. Inspect the C1 clutch return soft stone or crocus cloth. minimum of 1.00mm (0.040 inch)
spring plate for cracks, chips, travel parallel to the housing’s
burrs, bends and distortion. Inspect the internal and external
housing splines and the hub centerline.
Replace the plate if damage cannot
be repaired using a soft stone or splines for step wear, twisting, G. Inspect the thrust bearings on
crocus cloth. Replace the assembly chips, burrs and signs of battering. both sides of the C1 hub. Replace
if springs are broken, cracked, Replace the assembly if damage the bearing if it fails any of these
permanently set, showing signs of cannot be repaired using a soft inspection procedures.
wear due to rubbing or showing stone or crocus cloth. Maximum
signs of discoloration. Reference the allowable spline wear is 0.38mm H. The C1 balance piston includes
Service Manual Spring Data Charts (0.015 inch). a bonded seal. Replace the piston
during overhaul.
Inspect C2
ALLISON 1000 & 2000 PRODUCT FAMILIES drive hub
interal,
C2 CLUTCH PACK COMPONENTS external
and hub
splines.
B. C2 Clutch
Piston
C. C2 Return H. C2 Clutch Inspect P1 sun gear

Spring Balance teeth and splines.
Assembly Piston
E. P1 Sun
Gear
G. C2 Drive
Hub
F. Thrust
Washer
A. C2 Clutch Pack
D. P1 Drive
Flange
A. Inspect friction plate contact exposed to water and/or glycol. any tangs are broken, bent or
faces for excessive wear, embedded Friction material which is loose or otherwise distorted. Minimum
metal particles, cracking and flaking indicates that the plates allowable plate thickness is 2.135
distortion. Inspect the plate splines have been exposed to glycol and/or mm (0.0841 inch). Maximum
for burrs, cracks and damaged water. Reference SIL 18-TR-98, allowable coning is 0.240 mm
spline teeth. Replace the plate if Rev. A for details. (0.0094 inch).
spline damage cannot be repaired B. Inspect the C2 clutch piston
using a soft stone or crocus cloth. NOTE: Battered and worn spline
teeth may be an indicator of for burrs, chips and cracks. Inspect
Minimum allowable friction plate the internal and external sealring
thickness is 2.375 mm (0.0935 driveline issues. Replace the clutch
plates and check the driveline. grooves for burrs, chips and cracks.
inch). Minimum allowable oil Replace the piston if damage
groove depth is 0.20 mm (0.008 Inspect reaction plate contact cannot be repaired using a soft
inch). Maximum allowable coning surfaces for chips, cracks, grooves, stone or crocus cloth.
is 0.225 mm (0.009 inch). scoring and signs of discoloration. C. Inspect the C2 clutch return
NOTE: Anti-freeze (glycol) and/or Inspect reaction plate tangs for spring plate for cracks, chips, burrs,
water will adversely affect the chips, cracks and signs of battering. bends and distortion. Replace the
bonding agent between the friction Replace the plate if damage cannot plate if damage cannot be repaired
material and steel core. Replace any be repaired using a soft stone or using a soft stone or crocus cloth.
friction plates which have been crocus cloth. Replace the plate if (continued)

Supersession Information Inspect the

P1 drive
C2 Clutch Piston Update - flange
Reference SIL 24-1K2K-02 internal
and
external
splines.
Spline surface roughness is

caused by stamping process
and is acceptable - reuse
drive flange.
Inspect the three
sealring grooves
on the C2 piston
for damage.
Rework Is Required If The Current

Piston Is Used In GM MY01 and
MY02 Pickup Trucks.
Replace the assembly if springs are E. Inspect the P1 sun gear teeth its tangs are broken, distorted or
broken, cracked, permanently set, for chips, burrs, scoring and pitting. missing. Minimum allowable thrust
showing signs of wear due to Replace the gear if it has missing or washer thickness is 2.59 mm (0.102
rubbing or showing signs of cracked teeth. Replace the gear if inch).
discoloration. Reference the Service damage cannot be repaired using a
G. Inspect the C2 drive hub
Manual Spring Data Charts for soft stone or crocus cloth. Inspect
internal and external housing splines
spring specifications and splines for step wear, twisting,
and the hub splines for step wear,
identification. chips, burrs and signs of battering.
twisting, chips, burrs and signs of
Replace the gear if damage cannot be
D. Inspect the P1 drive flange for battering. Replace the assembly if
repaired using a soft stone or crocus
internal and external spline step damage cannot be repaired using a
cloth.
wear, burrs, chips, distortion and soft stone or crocus cloth. Maximum
signs of discoloration. Replace the F. Inspect the thrust washer allowable hub spline wear is 0.38
flange if it is cracked or if it has between the C2 drive hub and P1 mm (0.015 inch). Maximum
damage which cannot be repaired sun gear for scoring, burrs, nicks, allowable clutch spline step wear is
using a soft stone or crocus cloth. cracks, distortion and signs of 0.100 mm (0.004 inch).
overheating. Replace the thrust
H. The C2 balance piston includes
washer if damage cannot be repaired
a bonded seal. Replace the piston
using a soft stone or crocus cloth.
during overhaul.
Replace the thrust washer if any of

C3 AND C4 CLUTCH PACK COMPONENTS
B. C3/C4 Return
C. C3 Spring
Backplate Assemblies
D. C4
E. C3/C4
Backplate
Clutch
Pistons
A. C3/C4 Clutch
Packs
A. Inspect all friction plate friction plates which have been crocus cloth. Replace the plate if
contact faces for excessive wear, exposed to water and/or glycol. any tangs are broken, bent or
embedded metal particles, cracking Friction material which is loose or otherwise distorted. Minimum
and distortion. Inspect the plate flaking indicates that the plates allowable plate thickness is
splines for burrs, cracks and have been exposed to glycol and/or 2.440 mm (0.0961 inch). Maximum
damaged spline teeth. Replace the water. Reference SIL 18-TR-98, allowable coning is 0.40 mm
plate if spline damage cannot be Rev. A for details. (0.016 inch).
repaired using a soft stone or crocus
NOTE: Battered and worn spline B. Inspect the C3 and C4 clutch
cloth. Minimum allowable friction return spring plates for cracks,
teeth may be an indicator of
plate thickness is 2.375 mm (0.0935 chips, burrs, bends and distortion.
driveline issues. Replace the clutch
inch). Minimum allowable oil Replace the plate if damage cannot
plates and check the driveline.
groove depth is 0.20 mm (0.008 be repaired using a soft stone or
inch). Maximum allowable coning Inspect reaction plate contact crocus cloth. Replace the spring
is 0.225 mm (0.009 inch). surfaces for chips, cracks, grooves, assembly if springs are broken,
scoring and signs of discoloration. cracked, permanently set, showing
NOTE: Anti-freeze (glycol) and/or Inspect reaction plate tangs for signs of wear due to rubbing or
water will adversely affect the chips, cracks and signs of battering. showing signs of discoloration.
bonding agent between the friction Replace the plate if damage cannot (continued)
material and steel core. Replace any be repaired using a soft stone or

(continued) C3 AND C4 CLUTCH PACK COMPONENTS
C3/C4
Return Spring
Assembly
and Plate
Updates -
Reference
SIL 1-1K2K-04
Updates Aid
The Assembly
Process.
C. Clutch Plate
Thickness and
Coned Plate
Coning
Check Using
Feeler Gauge
Flat Plate
Thickness
Reference the Service Manual Replace any thrust plates showing

Spring Data Charts for spring signs of excessive or uneven wear,
specifications and identification. gouges, scoring or cracks. Calculate
Minimum allowable backplate thrust plate thickness following the
thickness is 3.110mm (0.1224 inch). Service Manual guidelines.
Maximum allowable backplate Minimum allowable thrust plate
coning is 0.40mm (0.016 inch). thickness is 3.00mm (0.1181 inch).
C. Inspect the C3 clutch D. Inspect the C4 clutch
backplate. Replace the backplate if backplate. Replace the backplate if Calculate thrust
has burrs, scoring or other damage has burrs, scoring or other damage plate thickness
which cannot be repaired using a which cannot be repaired using a following Service
soft stone or crocus cloth. Replace
soft stone or crocus cloth. Replace Manual guidelines.
the backplate if it is cracked or
the backplate if it is cracked or
broken. Check the backplate for
coning. Replace the backplate if broken. Check the backplate for
E. C3 and C4 clutch pistons
any coning is detected. Minimum coning. Replace the backplate if any
include a bonded seal. Replace
allowable backplate thickness is coning is detected. Minimum
the pistons during overhaul.
15.325mm (0.6033 inch). allowable backplate thickness is
15.40mm (0.6063 inch).

MAIN HOUSING
A. Main Housing G. Speed Sensor

Bore
J. Identification B. Front
Plate Sealing I. Filltube C. Rear
Surface Bore Sealing
Surface
H. Selector
D. PTO Shaft Bore
Mounting
Pads E. Electrical
Rear Connector
Front
View Bore
View
F. Splines
A. Inspect the main housing for C. Inspect the sealing surface at E, G, H, I. Inspect machined
impact damage, chips and cracks. the rear of the main housing for bores for nicks, burrs, scratches,
Inspect threaded holes for damage, nicks, burrs, scratches, scoring and scoring and other damage which
stripping and cracking. Replace the other damage which might cause might cause improper sealing or
main housing if damage cannot be improper sealing or component component seating. Replace the
repaired. seating. Replace the housing if housing if damage cannot be
damage cannot be repaired using a repaired using a light stone or
B. Inspect the sealing surface and light stone or crocus cloth. crocus cloth.
machined bore at the front of the (continued)
main housing for nicks, burrs, D. Inspect the PTO mounting pad
scratches, scoring and other damage surfaces for nicks, burrs, scratches,
which might cause improper sealing scoring and other damage which
or component seating. Replace the might cause improper sealing or
housing if damage cannot be PTO seating. Replace the housing if
repaired using a light stone or damage cannot be repaired using a
crocus cloth. light stone or crocus cloth.

Inspect the flat sealing surface (continued) MAIN HOUSING
and the machined bore at the
front of the main housing.
Oil Passage Detail - Exhaust Oil Passage Detail -

Front View To Sump Rear View
C3 Torque N/A
Spline Converter
Clutch
C3 C4 C4
Feed Main Spline Feed C5
Spline
Control
Main
From
Exhaust Filter
To Sump Suction Knockdown Park Pawl C5 Main
Control Support
Overdrive Feed Connector
C2 Main To Pin Bore
Exhaust C1 Exhaust Filter Bore
Exhaust Backfill
Backfill
Oil Passage Detail - Bottom View
Torque
F. Inspect splines for step wear, Control Main Converter
twisting, chips, burrs and signs of From Filter Clutch
Control Apply C5 / Exhaust
battering. Replace the main housing Backfill
Main To
if damage cannot be repaired using
Filter
a soft stone or crocus cloth.
J. The identification plate Knockdown
contains information necessary to Overdrive
perform service work on the Main
transmission. The model number, C5
serial number, electronic "E" C1 / Exhaust Feed
number and date of manufacture Backfill
Exhaust
are included, as well as individual
To Sump
component group numbers which Suction
are used to identify specific
components used to build each C2 / Exhaust
major section of the transmission. Backfill
Remove and reattach the plate if it
is not securely riveted to the Exhaust
transmission main housing. C3 / Exhaust C4 Feed
Backfill
C5 CLUTCH PACK COMPONENTS
B. C5
Piston
C. C5
Backplate D. C5 Return
Spring
Assembly
A. C5 Clutch
Pack
A. Inspect friction plate contact NOTE: Anti-freeze (glycol) and/or be repaired using a soft stone or
faces for excessive wear, embedded water will adversely affect the crocus cloth. Replace the plate if
metal particles, cracking and bonding agent between the friction any tangs are broken, bent or
distortion. Inspect the plate splines material and steel core. Replace any otherwise distorted. Maximum
for burrs, cracks and damaged friction plates which have been allowable coning is 0.295mm
spline teeth. Replace the plate if exposed to water and/or glycol. (0.0116 inch). Minimum allowable
spline damage cannot be repaired Friction material which is loose or plate thickness is indicated in the
using a soft stone or crocus cloth. flaking indicates that the plates chart below.
Minimum allowable friction plate have been exposed to glycol and/or
Part Minimum ID
thickness is 2.375mm (0.0935 inch). water. Reference SIL 18-TR-98, Rev. Number Thickness Number
Minimum allowable oil groove A for details.
depth is 0.20mm (0.008 inch). 29536481 1.935 mm 1
Maximum allowable coning is Inspect reaction plate contact (0.0762 inch)
0.225mm (0.009 inch). surfaces for chips, cracks, grooves, 29536482 2.435 mm 2
scoring and signs of overheating. (0.0959 inch)
NOTE: Battered and worn spline Inspect reaction plate tangs for
teeth may be an indicator of 29536483 2.935 mm 3
chips, cracks and signs of battering.
(0.1156 inch)
driveline issues. Replace the clutch Replace the plate if damage cannot
plates and check the driveline.
(continued)

Inspect the piston
internal and
external sealring
grooves.
C5 Friction Plate Update -
2WD C5 Piston 4WD C5 Piston Current Friction Plates

(100%) (70%) Have Sunburst Pattern.
B. Inspect the C5 clutch piston C. Inspect the C5 clutch D. Inspect the C5 clutch return
for burrs, chips and cracks. Inspect backplate. Replace the backplate if spring plate for cracks, chips,
the internal and external sealring it has burrs, scoring or other burrs, bends and distortion.
grooves for burrs, chips and cracks. damage which cannot be repaired Replace the plate if damage cannot
Replace the piston if damage using a soft stone or crocus cloth. be repaired using a soft stone or
cannot be repaired using a soft Replace the backplate if it is crocus cloth. Replacethe assembly
stone or crocus cloth. cracked or broken. Check the springs if broken, cracked,
backplate for coning. Replace the permanently set, showing signs of
backplate if any coning is detected.
wear due to rubbing or showing
Minimum allowable backplate
signs of discoloration. Reference the
thickness is 17.90mm (0.7047 inch).
Service Manual Spring Data Charts
for spring specifications and
C. Clutch Plate identification.
Thickness and
Coned Plate
Coning
Check Using
Feeler Gauge
Flat Plate
Thickness

PARK PAWL COMPONENTS
B. Pawl Support
Pin
A. Park
Pawl
H. Spherical
Pin C. Pawl
Return
Spring
G. Detent
Lever
E. Apply
Assembly
D. Apply
F. Selector Guide
Shaft
I. Selector
Shaft Nut
Park pawl
seated in the
P3 carrier
cogs.
A. Inspect the park pawl contact damage or if it
faces for cracks, step wear, impact does not quickly
damage and signs of battering. recoil when
Inspect the park pawl pivot bore released.
for burrs, nicks, scoring and out-of-
round. Replace the park pawl if any D. Inspect the
damage is detected. apply guide for
grooves, scoring
B. Inspect the park pawl support and deformities. Inspect the park pawl contact surfaces.
pin for burrs, nicks, scoring and Replace the guide
grooves. Replace the pin if it if damage cannot
doesn’t fit securely in the rear cover be repaired using
or main housing or if it has damage a soft stone or
which cannot be repaired using a crocus cloth.
soft stone or crocus cloth. (continued)
C. Inspect the park pawl return
spring for damaged coils. Replace
the spring if it has any signs of

(continued) PARK PAWL COMPONENTS
Inspect the apply

Indexing
assembly spring
Tang
rollers and
indexing tang.
Inspect the
detent lever Slots
slots and Spring
detent teeth.
Detent
Teeth Rollers
Inspect the
selector shaft for
Mushroomed mushrooming in
Areas the indicated
areas. Avoid
NSBU damage
by removing
mushrooming
prior to switch
Selector removal or
E. Inspect the slotted end of the selector shaft if Shaft installation.
apply assembly for burrs, chips and damage cannot
cracks. Inspect the indexing tang be repaired using a soft stone or H. Inspect the spherical pin for
for cracks and burrs. Inspect the crocus cloth, or if the shaft is bent. nicks, burrs and deformities.
spring for bent, cracked or broken Replace the pin if it is bent or if it
NOTE: Burrs or raised metal on the has damage which cannot be
coils. Inspect the rollers for scoring,
burrs and pitting. The rollers selector shaft flats (where the repaired using a soft stone or crocus
should fit securely in the retainer selector lever seats) may cause cloth.
and should roll freely without damage to the NSBU switch and
selector seal if not removed or I. Inspect the selector shaft nut
binding or sticking. Replace the
repaired. threads for stripping and damage.
assembly if damage cannot be
Inspect the nut shoulder for burrs
repaired using a soft stone or crocus G. Inspect the detent lever slots and deformities which might
cloth. for burrs, chips and cracks. Inspect prevent proper seating. Replace the
F. Inspect the selector shaft for the detent teeth for impact damage, nut if damage cannot be repaired
burrs, chips and cracks. Inspect the step wear, bends and cracks. using a soft stone or crocus cloth.
shaft flats for chips, burrs and Replace the detent lever if damage
nicks. Inspect the shaft threads for cannot be repaired using a soft
stripping and damage. Replace the stone or crocus cloth.

SPEED SENSORS
Speed sensor
retainer
orientation is
critical for
proper
operation.
A. Sensor
Body
C. Sensor
Connector and
Terminals B. Sensor
D. O-Ring Retainer
A. Inspect the sensor body for C. Inspect the connector body for D. Replace the sensor O-ring if it
chips, cracks and broken pieces. cracks and impact damage. Inspect is fretted or if it does not properly
Replace the sensor if any damage is the locking tangs for damage which fit on the sensor or in the sensor
detected. might prevent proper harness bore.
connector installation and seating.
B. Inspect the sensor retainer for Replace the sensor if any damage is NOTE: During installation, sensors
cracks, bends and deformities. detected. Inspect the terminals for must be properly and thoroughly
Sensor retainer orientation is any damage which might prevent seated in their bores before
critical to proper sensor and proper seating with mating installing retaining bolt. Improper
electronic control operation. Do not terminals. Reference the installation can cause sensor
attempt to reposition the sensor in Troubleshooting Manual TS3192 for damage and erratic speed sensor
the retainer. terminal replacement procedures signals which can affect shift
and ohmmeter pin-out checks. quality.

NEUTRAL START BACKUP (NSBU) SWITCH
First
Current
Version
Version
NSBU switch
evolution from left
to right - earliest
to current single-
connector
version.
P/N 12450016 P/N 29540193 P/N 29541852
NSBU Switch Improvements - Reference SILs 32-1K2K-01 and 14-1K2K-03
Current NSBU Switch Is A Single Connector Design. (continued)

NEUTRAL START BACKUP (NSBU) SWITCH (continued)
A. Switch
Body
B. Connector
D. Retainer
C. Splash
Shield
Current
switch A. Inspect the switch body for C. Inspect the splash shield for
backside cracks, bends and impact damage. cracks, bends and deformities.
view. Replace the switch if any damage is Replace the switch assembly if the
detected. splash shield is damaged.
B. Inspect the connector body for D. Inspect the splash shield
cracks and impact damage. Inspect retainer for cracks and deformities.
the locking tangs for damage which The retainer is non-serviceable and
might prevent proper harness is included with a new switch.
connector installation and seating. Switches which are reused can be
Replace the switch if any damage is installed without the retainer (the
detected. Inspect the terminals for selector lever and nut will retain
any damage which might prevent the shield).
proper seating with mating
terminals. Reference
Troubleshooting Manual TS3192 for
terminal replacement procedures
and ohmmeter pin-out checks.

WEAR LIMITS AND SPRING DATA
7–1. WEAR LIMITS DATA

A. Maximum Variations. Wear limits information meet the load height speciÞcations according to Table
in this Section are the maximum wear at which 7–2, Spring Data.
components are expected to function satisfactorily.
B. Inspection. Inspection criteria (load vs. height)
Table 7–1 lists the Wear Limits Data.
and identiÞcation characteristics of the springs are pre-
B. Cleaning and Inspection. Parts must be clean to sented in Table 7–2. The Spring Data are keyed to the
permit effective inspection for wear or damage. Refer exploded views (Foldouts 5 through 20) in the back of
to Section 3. this manual.
7–2. SPRING DATA NOTE:

A. Spring Replacement. Replace springs if there When more than one spring part number is listed
are signs of overheating, wear due to rubbing adjacent for the same location, refer to the latest edition of
parts, or permanent set. Discard springs which do not Parts Catalog PC3062EN to determine which
spring is used in your specific assembly number.
Table 7–1. Wear Limits Data Wear Limit

Description mm (inches)
TORQUE CONVERTER MODULE
Maximum Torque Converter End Play—Used 1.015 0.0400
Maximum Torque Converter End Play—New 0.762 0.0300
Converter Pump Hub:
Minimum OD 58.250 2.2933
Minimum Distance Between Flats 51.816 2.0400
Cover Pilot, Minimum OD 43.080 1.6960
FRONT SUPPORT AND OIL PUMP MODULE
Charging Pump:
Bushing, Maximum ID
The pump bushing must have a complete burnt-orange color
58.458 2.3015
Teßon® coating. If any portion of the Teßon® coating is worn
and bronze material is visible, replace the pump.
Gear Cavity, Maximum Depth 24.940 0.9819
Gear Cavity, Maximum ID 109.191 4.2989
Driven Gear, Max. Diametric Clearance w/ Pump Body 0.204 0.0080
Driven Gear, Maximum Tooth Clearance w/ Crescent 0.455 0.0179
Driven Gear, Minimum OD 108.987 4.2908
Wear Plate, Minimum Thickness 2.950 0.1161
Gear-to-Wear Plate, Maximum Side Clearance 0.064 0.0025
Drive Gear, Maximum Distance Between Flats 52.165 2.0537
Drive Gear, Side Clearance 0.066 0.0026
WEAR LIMITS AND SPRING DATA (continued)
Table 7–1. Wear Limits Data (cont’d) Wear Limit

Front Support and Ground Sleeve:
Ground Sleeve, Maximum ID at Turbine Shaft Sealring Bore 45.450 1.7894
No visible No visible
Ground Sleeve, Maximum Spline Wear wear allowable wear allowable
Ground Sleeve Bushing, Maximum ID 33.820 1.3315
Thrust Washer 1.49 0.059
ROTATING CLUTCH MODULE
Rotating Clutch Housing:
Bushing, Maximum ID 78.170 3.0776
Rotating Seal Bore, Maximum ID 74.050 2.9154
C1 Friction Plates:
Maximum Cone 0.255 0.0100
Minimum Thickness 2.375 0.0935
Minimum Oil Groove Depth 0.200 0.0079
C1 Steel Reaction Plate:
C1 Backplate:
Minimum Thickness (Selective)
Part # 29532420 11.400 0.4688
Part # 29538521 11.840 0.4661
Part # 29538522 12.280 0.4835
Part # 29538523 12.730 0.5012
Part # 29538524 13.180 0.5189
Part # 29538525 13.630 0.5366
C2 Friction Plates:
Turbine Shaft Bushing, Maximum ID 20.117 0.7920
Thrust Washer 2.59 0.102
(continued) WEAR LIMITS AND SPRING DATA

MAIN HOUSING MODULE
C3/C4 Friction Plate:
C3/C4 Steel Reaction Plate:
C3/C4 Spring Plate:
C3 Backplate:
Thrust Plate Inner Rim, Minimum Thickness 3.000 0.1181
C4 Backplate:
C5 Friction Plate:
Minimum Thickness (Selective)
Part # 29536481 1.935 0.0762
Part # 29536482 2.435 0.0959
Part # 29536483 2.935 0.1156
C5 Backplate:
P1 Ring Gear, Maximum Spline Wear (Notching) Detectable Detectable
Main Housing Clutch Plate, Spline Wear (Notching) 1.150 0.0450

WEAR LIMITS AND SPRING DATA (continued)

PLANETARY GEAR MODULE
P1 Carrier Assembly:
Pinion Gear, Maximum End Play 1.010 0.0400
Thrust Washer, Minimum Thickness 1.490 0.0590
Main Shaft:
Pilot, Minimum OD (Turbine Shaft and Output Shaft) 19.987 0.7869
Journal, Minimum OD (P2 Carrier Bushing) 36.405 1.4333
REAR COVER MODULE
Output Shaft Bushing (2WD and 4WD), Maximum ID 20.070 0.7940
Output Shaft (2WD and 4WD), Minimum Bearing Surface OD 44.978 1.7708
Parking Pawl Gear Wear 0.000 0.0000
OUTPUT YOKE
Output Seal Surface, Minimum OD 65.080 2.5622

Table 7–2. Spring Data
Spring Approx. Free
Length Under Load
Color No. Wire Dia. OD Length
Foldout Ref. Spring Part No. Code Coils mm (in.) mm (in.) mm (in.) mm (in.) N (lb) min.
6, 13 12, 4 C3/C4 Return Spring 29531046 No code 8.78* 1.588* 12.00* 31.89** 24.81** 162.00–187.60**
Assembly (0.0625) (0.472) (1.256) (0.977) (36.42–42.17)
9 22 Main Pressure 29531017 No Code 11.87 2.77 22.61 73.74 41.50 231.56–255.94
Regulator (0.109) (0.890) (2.903) (1.634) (52.06–57.54)
9 11 Converter Relief 29541296 No Code 12.18 1.42 13.46 44.85 22.84 45.10–55.44
(0.056) (0.529) (1.766) (0.899) (10.14–12.46)
(continued) WEAR
9 14 Converter Flow 29540523 Light Blue 6.79 1.60 16.10 31.43 17.05 54.23–73.89
(0.063) (0.634) (1.237) (0.671) (12.19–16.61)
9 7 Lube Regulator 29541228 No Code 12.38 1.47 11.70 39.22 24.05 55.99–72.00
(0.058) (0.464) (1.544) (0.946) (12.59–16.19)
ALLISON
9 19 C1 Clutch BackÞll 29542713 No Code 7.24 0.81 11.25 27.25 11.05 10.41–13.09
(0.032) (0.443) (1.073) (0.435) (2.34–2.94)
10 16 C2 Return Spring 29536104 No Code 5.77* 1.143* 10.05* 19.60** 15.90** 652.5–770.9**
Assembly (0.0450) (0.396) (0.772) (0.626) (146.7–173.3)
10 25 C1 Return Spring 29536198 No Code 7.99* 1.295* 9.17* 19.49** 15.62** 941.2–1126.4**
Assembly (0.0510) (0.361) (0.767) (0.615) (211.6–253.2)
19B, 19C 14, 6 Control Main/Control 29541153 No Code 11.85 1.50 14.00 40.62 22.11 45.86–50.68
Relief (0.059) (0.551) (1.599) (0.870) (10.31–11.39)
TRANSMISSION
19C 3 Exhaust BackÞll 29531161 Orange Stripe 11.35 0.90 12.60 22.54 16.16 2.537–3.003
(0.035) (0.496) (0.887) (0.636) (0.570–0.675)
19C 11, 17, 28 A, B, and F Trim 29536313 No Code 7.44 0.76 9.80 20.15 9.44 8.14– 9.70
(0.030) (0.386) (0.793) (0.372) (1.83–2.18)
19C 13 A Trim 29537230 No Code 7.21 1.30 15.20 23.25 13.37 18.69–21.35
(0.051) (0.598) (0.915) (0.526) (4.20–4.80)
19B 4, 8, 11 C, D, and E Shift 29531176 No Code 11.55 1.00 11.00 29.29 14.26 14.61–16.59
TECHNICIANS’
(0.039) (0.433) (1.153) (0.561) (3.28–3.73)
16A 5 C5 Return Spring 29531134 No Code 7.8* 1.702* 13.5* 31.40** 21.60** 1454.6–1620.2**
Assembly (0.0670) (0.531) (1.236) (0.850) (327.0–364.2)
GUIDE
16A 4 Park Pawl Return 29531147 No Code 6 0.75 8.70 29.55 41.75 11.3–14.9
(0.030) (0.343) (1.161) (1.644) (2.5–3.3)
LIMITS AND SPRING DATA
63
* Individual Springs
** For the complete Spring Assembly
NOTES

TORQUE CONVERTER MODULE
Allison Transmission
General Motors Corporation
Indianapolis, IN 46206-0894
1-800-252-5283
www.allisontransmission.com
 2005 General Motors Corporation. (5/05)

GN4062EN
GUIDE
TECH
GN4062EN
(5/05)

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TECHNICIANS’ GUIDE

INSPECTION AND ANALYSIS OF THE

Glossary Of Terms . . . . . . . . . . 2 P2 Planetary and

ALLISON TRANSMISSION TECHNICIANS’ GUIDE i

Abrade - Scrape off Metal Transfer - Metal from one

Burr - Sharp metal extending Score - Deep scratch

Cone - A shape whose base is a Spalled - Damage characterized by

Gall - Wear between

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The Technicians’ Guide is

General Rework Guidelines

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Check gears for

A. Inspect gears for damaged or

Inspect splined parts

A. Inspect splined parts for 0.38 mm (0.015 inches) if not

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A & B. Replace the bearing if any C. Replace the bearing if any

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General Bearing Handling When immersing in solvent, place

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A. Inspect retaining rings for Examine retaining

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A. Replace thrust washers if they

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B. Measure reaction plate

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Reference the Service

A. Inspect springs for permanent

Inspect springs for signs of

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Reverse Modulated Main

General Valve Body

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Identification Detail: Exhaust

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Identification Detail: Identification Detail:

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A. Valves must be free of nicks, B. Valve bores must be free of

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Identification Detail: Not Reference the

TCM And Calibrations Have Evolved

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Main Oil Passage Detail

D. Inspect the filter attachment F. Inspect the input speed sensor

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B. Machined Standard Park Brake B. Machined Sealing,

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E. Inspect the selective shim for

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P1 Ring Assembled P1 Planetary

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A. Inspect the splines where the assembly if damage cannot be

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F. Inspect the carrier bushing for G. Thrust bearings are located

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1K 2K Technician's Guide

1K 2K Technician's Guide