3000 PRODUCT FAMILIES SERVICE MANUAL—ALLISON 4 th GENERATION
6. Install a dial indicator to read up and down
shaft movements.
7. You may need to place a shim or a smooth
washer on the output shaft to get true readings.
8. Bottom the output shaft by applying downward
force while slightly rotating the output yoke.
9. The shaft is bottomed when the dial indicator
shows no more down movement. Zero the dial
indicator at this point.
10. Using a chain hoist and a scale, apply an up-
ward force of 734–778 N (165–175 lbs) on the
output shaft. While force is applied, slightly
rotate the yoke.
11. Check the dial indicator for movement.
12. If the indicator readings are not within the spec-
ified limits, add or remove shims and check pre-
load again. End play must be 0.025–0.127 mm
(0.001–0.005 inch).
13. If the indicator readings are within the speci-
fied limits, coat both sides of washer 80 with
sealant and install the washer. Repeat Step (5)
from above.
q. Disassembly of C7 Control Valve Body
(Foldout 14)
1. Begin C7 valve body disassembly by removing
pins 34 and 40 securing the C7 signal valve so-
lenoid 35 and C7 control valve 31 in body 30.
Remove the pins by driving them out from the
top toward the bottom (machined face).
2. Remove stop 33, spring 32, and valve 31 from
body 30.
3. Remove solenoid 35 and O-rings 36 and 37.
4. Remove solenoid regulator valve 38.
5. Check the valves and bores for wear, scoring,
and damage.
r. Assembly of C7 Control Valve
Body Assembly (Foldout 14)
1. Insert solenoid regulator valve 38 in the bore of
body 30 and inspect for smooth movement.
2. Inspect solenoid filter screen for damage or de-
bris.
5–34 Copyright © 2005 General Motors Corp.
3. Replace solenoid O-rings 36 and 37 during
overhaul.
4. Insert solenoid 35 into valve body 30.
5. Insert valve 31, followed by spring 32 and
valve stop 33.
6. Push in on stop 33 to compress spring 32 and
insert a small cylindrical punch through the top
hole in body 30 to hold these parts in position.
7. Install pin 34 by starting it in the hole opposite
where the punch has been inserted. Tap the pin
into position. The punch will be displaced as
the pin is installed.
8. Install pin 40 which retains solenoid 35. Insert
the smooth (not ridged) end of the pin into the
mating hole at the bottom face of body 30. Tap
the pin into position flush with the bottom of
body 30. Use a small diameter punch to
slightly countersink pin 40.
s. Assembly of Transfer Case Module
(Foldouts 12, 13, 14)
1. Lube bearing cups 17, 37, and 78 (Foldout 13),
installed in front transfer case housing 14.
2. One side of drive gear 19 has a shorter shoul-
der than the other side. Install drive gear 19 so
that the side with the shorter shoulder is toward
the front of the transmission.
3. Install idler gear 39 with its threaded hole to-
ward the front of the transmission.
4. Install driven gear 80 into front transfer case 14
in the same orientation as it was removed.
5. Install output speed sensor 45 (Foldout 14).
6. Install two bolts 46 and tighten them to
24–29 N·m (18–21 lb ft).
7. Install C7 control valve body assembly 29.
8. Install six bolts 41, and tighten them to
24–29 N·m (18–21 lb ft).
9. Install new transfer case gasket 16
(Foldout 13).
10. Install rear transfer case 2 (Foldout 14) onto
the front transfer case. If necessary, use soft
face mallet to seat the case half.