PREVENTIVE MAINTENANCE

to prevent air pressure buildup within the transmission preparations have been made before conducting the
and must be kept clean and open. transmission stall test.
1. The manufacturer concurs with performing a
b. Maintenance full-throttle transmission stall test.
1. The amount of dust and dirt encountered will 2. The engine programmable parameter for 0 rpm
determine the frequency of breather cleaning. transmission output speed is set higher than the
Use care when cleaning the transmission value expected at transmission stall speed.
exterior. Spraying steam, water, or cleaning 3. The vehicle is in an area in which a transmis-
solution directly at the breather can force the sion stall test can be safely performed.
water or cleaning solution into the
4. Make sure the fuel control linkage goes to full
transmission.
throttle and does not stick when released.
2. Always use a properly sized wrench to remove 5. Make sure the engine air induction system and
or replace the breather. Pliers or a pipe wrench exhaust system have no restrictions.
can crush or damage the breather’s stem and 6. Install a temperature gauge with the probe in
produce metal chips which could enter the the transmission converter out (to cooler) line.
transmission. Allison DOC™ displays sump temperature
only.
2–14. TRANSMISSION STALL TEST 7. Perform a Cold Check of the transmission fluid
AND NEUTRAL COOL-DOWN level and adjust as necessary.
CHECK 8. Connect Allison DOC™ to the vehicle
a. Purpose. Stall testing is performed to determine diagnostic data connector or install an accurate
if a vehicle performance complaint is due to an engine tachometer (do not rely on the vehicle
or transmission malfunction. Stall testing is a trouble- tachometer).
shooting procedure only—never perform a stall test as 9. Install wheel chocks.
a general examination or during routine maintenance.
10. A driver is in the driver’s position.
Transmission stall speed is the maximum engine rpm 11. The vehicle’s service/park brakes are fully ap-
attainable when the engine is at full throttle and the plied.
torque converter turbine is not moving, or “stalled.”
After a transmission stall test, compare the actual full
throttle engine speed at torque converter turbine stall WARNING!
with specifications established by the vehicle manu- To help avoid personal injury, such as burns,
facturer. from hot transmission fluid and/or to help avoid
equipment damage, do not stall the torque con-
verter for more than ten seconds maximum and
NOTE: monitor transmission fluid temperature. Imme-
Engine speed data can be obtained from the vehicle diately return the engine to idle if converter out
(to cooler) temperature exceeds 150ºC (300ºF).
manufacturer, or from the equipment dealer or dis-
Operating the transmission at high engine power
tributor. Some engine manufacturers provide a at transmission stall or near stall conditions
programmable parameter to limit engine speed causes a rapid rise in the transmission fluid tem-
when the transmission output speed is 0 rpm, such perature. The fluid in the transmission torque
as at a stop. This parameter should be set to a higher converter is absorbing all of the engine power
value than the expected transmission stall speed be- and the vehicle cooling system cannot dissipate
fore performing a stall test. the excessive heat load. Extended operation un-
der high heat load conditions causes transmis-
sion and cooling system damage, and can
b. Stall Testing Preparation. If a transmission stall possibly fail hydraulic lines causing leaking high
test is to be performed, make sure the following temperature fluid.

Copyright © 2005 General Motors Corp. 2–9

 4000 PRODUCT FAMILIES SERVICE MANUAL—ALLISON 4 th GENERATION

8. Record converter out (to cooler) temperature.

WARNING!
9. Reduce engine speed to idle and shift the trans-
To help avoid personal injury and equipment mission to N (Neutral).
damage while conducting a transmission stall
test, the vehicle must be positively prevented 10. Raise engine speed to 1200–1500 rpm for
from moving. Apply the parking brake, the ser- two minutes to cool the transmission fluid.
vice brake, and chock the wheels securely. Warn 11. At the end of two minutes, record converter out
personnel to keep clear of the vehicle and its
(to cooler) temperature.
travel path.
d. Driving Transmission Stall Test
c. Performing a Transmission Stall Test
1. Start the engine. While in neutral let the trans- NOTE:
mission warm to normal operating tempera- If the vehicle is equipped with a smoke controlled or
ture: an emission controlled engine or engine control
— Sump temperature: 71–93ºC (160–200ºF) programming inhibits engine acceleration, the
— Converter out temperature: 82–104ºC following transmission stall test procedure can be
(180–220ºF) used.
2. Perform a Hot Check of the transmission fluid
level and adjust as necessary. CAUTION:
3. Turn OFF all engine accessories.
To help avoid personal injury and/or equipment
4. Use Allison DOC™ For PC–Service Tool to damage, a driving transmission stall test must be
select fourth range. Using fourth range reduces performed by a trained driver and a qualified
the torque imposed on the transmission and technician.
driveline. Do not perform a transmission stall
test in Reverse. e. Driving Transmission Stall Testing Prepara-
tion. If a transmission stall test is to be per-
CAUTION: formed, make sure the following preparations
To help avoid transmission or driveline damage, have been made before conducting the transmis-
full throttle transmission stall tests must never be sion stall test.
performed in reverse range (all models) or low 1. The manufacturer concurs with performing a
ranges (7-speed models). full-throttle stall test.
5. Notify personnel in the area to keep clear of 2. Engine programmable parameter for 0 rpm
the vehicle. output speeds are set higher than value ex-
6. Slowly increase engine rpm until engine speed pected for stall speed.
stabilizes.
3. The vehicle is in an area in which a transmis-
7. Record engine speed. sion stall test can be safely performed.
CAUTION: 4. Make sure the fuel control linkage goes to full
The transmission stall test procedure causes a throttle and does not stick when released.
rapid rise in transmission fluid temperature that 5. Inspect the engine air induction system and ex-
can damage the transmission. Never maintain a
haust system for restrictions.
stall condition once engine speed stabilizes or
converter out (to cooler) temperature exceeds 6. Perform a Cold Check of the transmission fluid
150ºC (300ºF). During a stall condition, con- level and adjust as necessary.
verter out temperature rises much faster than in-
ternal (sump) temperature. Never use sump fluid 7. Install a temperature gauge with the probe in
temperature to determine the length of the stall the transmission converter out (to cooler) line.
condition. If the stall test is repeated, do not let Allison DOC™ displays sump temperature
the engine overheat. only.

2–10 Copyright © 2005 General Motors Corp.

 PREVENTIVE MAINTENANCE
8. Install an accurate tachometer (do not rely on 11. Raise engine speed to 1200–1500 rpm for two
the vehicle tachometer). minutes to cool the transmission fluid. At the
end of two minutes, record converter out (to
9. Connect Allison DOC™ to the vehicle diag- cooler) temperature
nostic data connector.

f. Performing a Driving Transmission Stall Test g. Neutral Cool-Down Check Procedure

1. Start the engine while in Neutral and let the 1. At the end of two minutes, converter out (to
transmission warm to normal operating tem- cooler) fluid temperature should return to
perature within normal operating temperature range.
— Sump temperature:
71–93ºC (160–200ºF) 2. If the transmission fluid does not cool within
— Converter out temperature: two minutes, the cause could be a stuck torque
82–104ºC (180–220ºF) converter stator or an issue with the transmis-
sion cooler, lines, or fittings.
2. Perform a Hot Check of the transmission fluid
level and adjust as necessary.
h. Transmission Stall Test Results
3. Turn OFF all engine accessories.
4. While located in isolated area, begin the driv-
ing transmission stall test. NOTE:
5. Select a hold range that will limit road speed Environmental conditions, such as ambient
(usually 2nd or 3rd range). Never perform a temperature, altitude, engine accessory loss
driving stall test in Reverse or Low range variations, etc., affect engine performance/power.
(7-speed models). Due to such conditions, stall speed can vary from
6. Operate the engine at 100 percent full throttle, specification by +/-150 rpm and still be accepted as
maximum governed speed. within published stall speed.

7. With the engine at maximum governed speed,

begin gradually applying the vehicle service If engine speed with the transmission stalled is more
brakes while maintaining 100 percent full than 150 rpm below the stall speed specified, an en-
throttle. gine issue is indicated.
8. When the vehicle comes to a complete stop,
record engine speed. If engine speed with the transmission stalled is more
than 150 rpm above specification, a transmission issue
CAUTION: is indicated.
The transmission stall test procedure causes a Conditions that can exist to cause stall speed to be
rapid rise in transmission fluid temperature that
150 rpm above specification could be:
can damage the transmission. Never maintain a
stall condition once engine speed stabilizes or
converter out (to cooler) temperature exceeds — Transmission fluid cavitation or aeration.
150ºC (300ºF). During a stall condition, con- Verify proper fluid level using the oil level
verter out temperature rises much faster than in- sensor, if equipped, or dipstick.
ternal (sump) temperature. Never use sump fluid
— Slipping clutch.
temperature to determine the length of the stall
condition. If the stall test is repeated, do not let — Torque converter malfunction.
the engine overheat.
— Sticking/damaged torque converter valve
9. Record converter out (to cooler) temperature. A low stall speed that is at least 33 percent lower than
10. Reduce engine speed to idle and shift the trans- the published stall speed could indicate an engine is-
mission to N (Neutral). sue or a freewheeling stator in the torque converter.

Copyright © 2005 General Motors Corp. 2–11