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Manual
2005 OCTOBER
SM4014EN
Allison Transmission
ALLISON 4TH GENERATION CONTROLS
VOCATIONAL MODELS
4000 EVS
4000 HS
4000 MH
4000 RDS
4000 SP
4000 TRV
4500 EVS
4500 HS
4500 RDS
4500 SP
4700 EVS
4700 RDS
4700 SP
4800 EVS
4800 SP
B 500
T 425
T 450
T 525
INTRODUCTION
ELECTRONIC CONTROL UNIT AND DIAGNOSTIC DATA READER/TOOL
DISPLAYS AND BUTTON NAMES
(Up), (Down),
Shift Selector, Allison DOC button, and display names are printed in bold capital letters
MODE, MONITOR, SELECT, etc.
Transmission range shifts are indicated by the letter or number on the shift selector, in bold text, followed by the
name of the range in parenthesesD (Drive), N (Neutral), etc.
References to diagnostic messages displayed are printed within double quotation marks (OL, OK, etc.).
TRADEMARK USAGE
The following trademarks are the property of the companies indicated:
Allison DOC (Allison Diagnostic Optimized Connection Tool) is a trademark
NOTE:
This publication is revised periodically to include improvements,
new models, special tools, and procedures. A revision is indicated
by the date on the title page. Check with your Allison
Transmission service outlet for the currently applicable
publication. Additional copies of this publication may be
purchased from authorized Allison Transmission service outlets.
Look in your telephone directory under the heading of
TransmissionsTruck, Tractor, etc.
ii
CAUTION:
is used when an operating procedure, practice,
etc., which, if not strictly observed, could result
in damage to or destruction of equipment.
NOTE:
is used when an operating procedure, practice, etc.,
is essential to highlight.
iii
LIST OF WARNINGS
This manual contains the following Warnings
IT IS YOUR RESPONSIBILITY TO BE FAMILIAR WITH ALL OF THEM.
If you leave the vehicle and the engine is running, the vehicle can move suddenly and you
or others could be injured. If you must leave the engine running, do not leave the vehicle
until you:
Put the transmission in N (Neutral)and
Apply the parking brake and emergency brakes and make sure they are properly
engagedand
Chock the wheels and take any other steps necessary to keep the vehicle from moving.
Avoid contact with the hot fluid or the hot sump when draining transmission fluid. Direct
contact with the hot fluid or the hot sump may result in bodily injury.
DO NOT conduct a converter stall test until the following actions are taken. The parking
brake and/or emergency brakes must be set and properly engaged and the wheels must be
chocked. Warn personnel to keep clear of the vehicle and its travel path. Failure to do so
can cause serious injury.
Use appropriate safety equipment such as safety glasses, safety shoes, and gloves.
Do not burn discarded Teflon seals; toxic gases are produced by burning Teflon.
Never dry bearings by spinning them with compressed air. A spinning bearing can
disintegrate, allowing balls or rollers to become lethal flying projectiles. Also, spinning a
bearing without lubrication can damage the bearing.
DO NOT disconnect the hydraulic fluid line between the accumulator and the retarder
until air and hydraulic pressure have been bled from the retarder.
PREVENT PERSONAL INJURY: Use proper tools and lifting equipment when installing
or removing a transmission from the repair stand. Transmission dry weights are as
follows:
4000 and 4500 Models
Base transmission
377 kg (831 lbs)
With PTO provision
405 kg (893 lbs)
With retarder
411 kg (906 lbs)
With retarder and PTO provision
439 kg (968 lbs)
4700 and 4800 Models
Base transmission
With PTO provision
With retarder
With retarder and PTO provision
With retarder, PTO, and integral
retarder sump cooler
iv
LIST OF WARNINGS
This manual contains the following Warnings
IT IS YOUR RESPONSIBILITY TO BE FAMILIAR WITH ALL OF THEM.
Get help when lifting the control module. Assistance from a hoist or another person may
be required. The control module weighs approximately 25 kg (55 lb).
Get help when lifting the retarder module. Assistance from a hoist or another person may
be required. The retarder module weighs approximately 34 kg (75 lb).
Get help when lifting the C6 adapter housing module. Assistance from a hoist or another
person may be required. The C6 adapter housing module weighs approximately 68 kg
(150 lb).
Carefully release spring force. Piston springs are highly compressed. Personal injury can
occur if the spring force is not controlled.
Piston springs are highly compressed. Be extremely careful during removal and
installation. Personal injury can occur if the spring force is not controlled.
Place the P3 planetary assembly on its side to avoid possible injury while disassembling
the planetary.
INTRODUCTION
NOTES
vi
TABLE OF CONTENTS
Paragraph
Page
Paragraph
Page
vii
Page
Paragraph
Page
31. SCOPE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
213. BREATHER
a. Location And Purpose. . . . . . . . . . . . . . . 28
b. Maintenance . . . . . . . . . . . . . . . . . . . . . . 29
214. TRANSMISSION STALL TEST AND
NEUTRAL COOL-DOWN CHECK
a. Purpose . . . . . . . . . . . . . . . . . . . . . . . . . . 29
b. Stall Testing Preparation. . . . . . . . . . . . . 29
c. Performing a Transmission Stall Test . 210
d. Driving Transmission Stall Test . . . . . . 210
e. Driving Transmission Stall Test
Preparation . . . . . . . . . . . . . . . . . . . . . . 210
f. Performing a Driving Transmission
Stall Test . . . . . . . . . . . . . . . . . . . . . . . . . 211
g. Neutral Cool-Down Procedure. . . . . . . 211
h. Transmission Stall Test Results . . . . . . 211
215. READING CLUTCH PRESSURES
a. Purpose . . . . . . . . . . . . . . . . . . . . . . . . .
b. Transmission And Vehicle Preparation .
c. Recording Data . . . . . . . . . . . . . . . . . . .
d. Comparing Recorded Data
To Specifications. . . . . . . . . . . . . . . . . .
212
212
212
213
a. Disassembly . . . . . . . . . . . . . . . . . . . . . 217
b. Assembly. . . . . . . . . . . . . . . . . . . . . . . . 218
TABLE OF CONTENTS
Paragraph
Page
Paragraph
Page
ix
Page
Paragraph
Page
e. Disassembly Of Retarder
Stator Assembly . . . . . . . . . . . . . . . . . . 522
f. Assembly Of Retarder Stator . . . . . . . . 523
g. Assembly Of P3 Planetary
Carrier Assembly . . . . . . . . . . . . . . . . . 523
h. Assembly Of Retarder Housing
Assembly. . . . . . . . . . . . . . . . . . . . . . . . 523
i. Assembly Of The Retarder Valve Body. 524
519
520
517
517
517
517
518
TABLE OF CONTENTS
Paragraph
Page
Paragraph
Page
xi
Page
Paragraph
xii
Page
1
2
3
3,A
3,B
3,C
EXPLODED VIEWS
Foldout
4,A
4,B
5,A
5,B
6,A
6,B
7
8
9,A
9,B
9,C
10,A
10,B
10,C
10,D
11,A
11,B
12,A
12,B
12,C
13
xiii
xiv
SCOPE OF MANUAL
T 400 Series:
T 425
T 450
T 525
b. Illustrations
1. The text is supported with line drawings and
cross-sectional views. Overhaul procedures are
illustrated by line drawings. Cross-sections
show the relationship of assembled parts.
Cross-sections, exploded views, and a
hydraulic schematic (transmission in Neutral)
are on foldout pages in the back of the manual.
2. Illustrations show correct procedures for all
modelsincluding models not illustrated.
c. Maintenance Information. Each task described
in this manual has been successfully completed by
service organizations and individuals. Not every
service organization or individual possesses the
required special tooling, training or experience to
perform all described tasks. However, any task may be
performed if the following conditions are met:
1. The organization or individual has the
required knowledge of the task through:
Formal instruction at Allison Transmission
11
PTO PROVISION
(TOP RIGHT POSITION)
SHIPPING
BRACKET (3)
MOUNTING
PAD
FEEDTHROUGH
HARNESS
CONNECTOR
ENGINE SPEED
SENSOR
TURBINE SPEED
SENSOR
OUTPUT SPEED
SENSOR
COOLER PORTS
FILL TUBE
NAMEPLATE
V07319.01.00
Figure 11. 4000 Product Family Transmission With PTO Provision (Except 4700 and 4800 Models)Right-Rear View
FEEDTHROUGH
HARNESS
CONNECTOR
MOUNTING PAD
(BOTH SIDES)
PTO PROVISION
(BOTTOM LEFT POSITION)
MAIN-PRESSURE TAP
COOLER PORTS
V06830.01.00
Figure 12. 4000 Product Family Transmission With PTO Provision (Except 4700 and 4800 Models)Left-Rear View
12
GENERAL INFORMATION
FILL TUBE
PTO PROVISION
(TOP RIGHT POSITION)
RETARDER
FEEDTHROUGH HARNESS
CONNECTOR
TORQUE CONVERTER
MODULE
NAMEPLATE
TURBINE-SPEED SENSOR
ENGINE-SPEED SENSOR
MOUNTING PAD
V07320.01.00
Figure 13. 4000 Product Family With PTO Provision and Retarder (Except 4700 and 4800 Models)Right-Front View
MOUNTING PAD
OUTPUT-SPEED
SENSOR
PTO PROVISION
(BOTTOM LEFT POSITION)
RETARDER
MAIN-PRESSURE TAP
COOLER PORTS
ACCUMULATOR PORT
V07334.01.00
Figure 14. 4000 Product Family With PTO Provision and Retarder (Except 4700 and 4800 Models)Left-Rear View
13
C6 ADAPTER
HOUSING
RETARDER
OUTPUT
FLANGE
MOUNTING PAD
PTO PROVISION
MOUNTING PAD
V07333.01.00
Figure 15. 4000 Product Family With PTO Provision and Retarder (4700 and 4800 Models)Left-Rear View
PTO PROVISION
(TOP RIGHT POSITION)
C6 ADAPTER
HOUSING
MOUNTING PAD
TURBINE
SPEED SENSOR
FILL T UBE
OUTPUT
SPEED SENSOR
NAMEPLATE
V07332.01.00
Figure 16. 4000 Product Family With PTO Provision (4700 and 4800 Models)Right-Rear View
14
GENERAL INFORMATION
12.
SUPPLEMENTARY
INFORMATION
13.
ORDERING PARTS
14.
GENERAL DESCRIPTION
Model number
Control Module
Serial number
Output Module
Data code
TransID number
LTURAL
IMP
MO
BIL
E , A E ROSPACE
AN
RICU
T WORKERS O
F
UT
TRANSMISSION
IDENTIFICATION
NUMBER
AG
EN
DATA CODE
EM
self-diagnostic capabilities
UNITED A
ICA
ER
AM
00A00
ENGINEERING FEATURE
CONFIGURATION
NUMBER FIELD
TIDA
S/N
XXXXXXXXXX
SERIAL NUMBER
V09468.01.01
15
MAJOR COMPONENTS
b. Torque Converter
1. The torque converter includes a lockup clutch
and torsional damper for direct and smooth
transfer of engine power.
2. Torque converter models available are:
Torque Converter Model
TC 521
TC 531
TC 541
TC 551
TC 561
c. Power Takeoff. Direct, engine-driven PTO
gearing is available at two positions, except in the
4000 HS.
d. Main Housing and Gear Module. The Main
Housing and Gear Module include:
Main Housing
Oil pump charging system
Three planetary gear sets
16
Sensors
Wiring harness (customer-furnished)
Engine adaptation
Control module
Shift selector
16.
BUS
EVS
HS
MH
RDS
SP
TRV
7 or 8
5
0
Bus Series
Emergency Vehicle Service
Highway Series
Motorhome Series
Rugged Duty Series
Specialty Series
Truck Recreational Vehicle Series
Widest Ratio Coverage (WRC)
Wide Ratio (WR)
Close Ratio (CR)
GENERAL INFORMATION
CR/WR
Maximum
Forward
Ranges
PTO
Retarder
Deep
Sump
Shallow
Sump
OLS
4000 EVS
CR
STD
OPT
STD
OPT
STD
4000 HS
CR
N/A
OPT
STD
N/A
STD
4000 MH
CR
OPT
OPT
STD
OPT
STD
4000 RDS
CR
STD
OPT
STD
N/A
STD
4000 SP
CR
STD
OPT
STD
OPT
STD
4000 TRV
CR
OPT
OPT
STD
N/A
STD
4500 EVS
WR
STD
OPT
STD
OPT
STD
4500 HS
WR
N/A
OPT
STD
N/A
STD
4500 RDS
WR
STD
OPT
STD
N/A
STD
4500 SP
WR
STD
OPT
STD
OPT
STD
4700 EVS
WR
STD
OPT
STD
OPT
STD 1
4700 RDS
WRC
STD
OPT
STD
N/A
STD 1
4700 SP
WRC
STD
OPT
STD
N/A
STD
4800 EVS
WRC
STD
OPT
STD
OPT
STD 1
4800 SP
WRC
STD
OPT
STD
N/A
STD
B 500
CR
OPT
OPT
STD
OPT
STD
T 425
CR
OPT
OPT
STD
OPT
STD
T 450
CR
OPT
OPT
STD
OPT
STD
T 525
CR
OPT
OPT
STD
OPT
STD
Vocational
Model
17.
EXPLODED
(DISASSEMBLED) VIEWS
18.
DIAGNOSIS
NOTE:
Refer to Allison 4th Generation Controls
Troubleshooting Manual (TS3989EN) for in-depth
troubleshooting procedures.
17
MONITOR
1
P
18
19.
GENERAL INFORMATION
4. Coat all exposed, unpainted surfaces with
preservative grease such as petrolatum
(MIL-C-11796, Class 2).
CAUTION:
If the unit does not have a converter-out temperature gauge, do not stall the converter.
19
Range
Close-Ratio
Wide-Ratio
Widest-Ratio Coverage
First . . . . . . . . . . . . . . . . . . . . . . . . .
3.51:1
4.70:1
7.63
Second . . . . . . . . . . . . . . . . . . . . . . .
1.91:1
2.21:1
3.51
Third . . . . . . . . . . . . . . . . . . . . . . . .
1.43:1
1.53:1
1.91
Fourth . . . . . . . . . . . . . . . . . . . . . . .
1.00:1
1.00:1
1.43
Fifth . . . . . . . . . . . . . . . . . . . . . . . . .
0.74:1
0.76:1
1.00
Sixth. . . . . . . . . . . . . . . . . . . . . . . . .
0.64:1
0.67:1
0.74
Seventh . . . . . . . . . . . . . . . . . . . . . .
0.64
Reverse . . . . . . . . . . . . . . . . . . . . . .
4.80:1
5.55:1
4.80:1
110
GENERAL INFORMATION
Table 11. Specifications and Data Chart* (contd)
HYDRAULIC SYSTEM:
Fluid type . . . . . . . . . . . . . . . . . . . . TranSyndTM, MIL-PRF-2104, MIL-PRF-46167, MIL-PRF-21260,
DEXRON-III, C-4 (refer to Paragraph 210.)
Filters, main and lube . . . . . . . . . . . Dual integral, replaceable cartridge type
4000 PRODUCT FAMILY SIZES:
With PTO drive
with retarder and integral retarder sump cooler. . . . . . . . . . 469 kg (1032 lb)
4700/4800 Models
With PTO drive
4700/4800 Models
Without PTO drive
111
112
SECTION
PREVENTIVE
2PREVENTIVE
MAINTENANCE
MAINTENANCE
21.
SCOPE
22.
PERIODIC INSPECTION
AND CARE
NOTE:
The oil level sensor compensates for transmission
CAUTION:
DO NOT pressure-wash the transmission
electrical connectors. Water and detergent cause
the electrical contacts to corrode and become
faulty.
1. Clean and inspect the exterior of the
transmission at regular intervals. Severity of
service and operating conditions determine the
frequency of inspections.
2. Inspect the transmission for:
Loose boltstransmission and mounting
components.
Fluid leaksrepair immediately.
Loose, dirty, or improperly adjusted throttle
sensor linkage.
Damaged or loose fluid hoses.
24.
electrical harnesses.
Bent, worn or out-of-phase driveline
23.
IMPORTANCE OF PROPER
FLUID LEVEL
NOTE:
The Allison 4th Generation Controls full-function
pushbutton and lever shift selectors can display two
characters at one time. One character is displayed
under the SELECT label and one under the
MONITOR label.
21
CAUTION:
NOTE:
The TCM may delay the fluid level check until the
following conditions are met:
The fluid temperature is above 60C (140F)
22
Cause of Code
PREVENTIVE MAINTENANCE
NOTE:
26.
25.
CAUTION:
DO NOT start the engine until the presence of
sufficient transmission fluid has been confirmed.
Remove the transmission fluid dipstick and be
sure the static fluid level is near the HOT FULL
mark.
a. Purpose. The purpose of the Cold Check is to
determine if the transmission has enough fluid to be
operated safely until a Hot Check can be made.
b. Cold Check Procedure
WARNING!
If you leave the vehicle and the engine is running,
the vehicle can move suddenly and you or others
could be injured. If you must leave the engine
running, do not leave the vehicle until you have
completed all of the following procedures:
23
WARNING!
If you leave the vehicle and the engine is running,
the vehicle can move suddenly and you or others
could be injured. If you must leave the engine
running, do not leave the vehicle until you have
completed all of the following procedures:
CAUTION:
An accurate fluid level check cannot be made
unless the engine is idling (500800 rpm) in
N (Neutral), the transmission fluid is at the
proper temperature, and the vehicle is on a level
surface.
a. Purpose. The purpose of the Hot Check is to
determine if the transmission has enough fluid to be
operated safely.
CAUTION:
Containers or fillers that have been used for
antifreeze or engine coolant solution must
NEVER be used for transmission fluid.
Antifreeze and coolant solutions contain ethylene
glycol which, if put into the transmission, can
cause clutch plate failure.
Prevent foreign material from entering the
transmission by using clean containers, fillers, etc. Lay
the dipstick in a clean place while filling the
transmission.
Calibration level marking
locations with respect to
transmission control module
splitline and fill tube
SCALE NONE
HOT
ADD
DIMENSION A
SEE CHART
BELOW
Sump temperature
DIMENSION C
24
COLD
ADD
82104C (180220F)
132.6 mm
(5.22 in.)
COLD
FULL
DIMENSION B
Converter-out temperature
FILL
TUBE
HOT
FULL
b. Procedure
28.
106.7 mm
(4.20 in.)
76.2 mm
(3.00 in.)
66.0 mm
(2.60 in.)
V02511.00.01
PREVENTIVE MAINTENANCE
29.
FLUID RECOMMENDATIONS
a. Fluid Type
1. The hydraulic fluids (oils) used in Allison
transmissions directly affect transmission
performance, reliability, and durability.
Recommended fluids for 4000 Product Family
applications are TranSyndTM, or other TES-295
fluid, and DEXRON-III. Type C-4 fluids are
also approved.
2. Some DEXRON-III fluids are also qualified
as Type C-4 fluids. To be sure the fluid is
qualified for use in Allison transmissions, look
for a DEXRON-III or Type C-4 fluid license,
or approval numbers on the fluid container, or
consult the lubricant manufacturer. Fluid types
such as Type F, and universal farm fluids may
or may not be properly qualified to use in your
Allison transmission. Consult your Allison
Transmission dealer or distributor before using
any fluid types except those fluids qualified for
use in Allison transmissions.
CAUTION:
Disregarding minimum fluid temperature limits
can result in transmission malfunction or
reduced transmission life.
3. When choosing the optimum viscosity grade of
fluid to use, duty cycle, preheat capabilities,
and/or geographical location must be taken
into consideration. Table 21 lists the
minimum fluid temperatures at which the
transmission may be safely operated. Preheat
with auxiliary heating equipment or by running
the equipment or vehicle with the transmission
in N (Neutral) for a minimum of 20 minutes
before attempting range operation.
Viscosity Grade
SAE 0W-20* or
TranSyndTM
DEXRON-III
SAE 10W
SAE 15W-40W
SAE 30W
SAE 40W
30
22
25
20
15
0
10
13
4
5
32
50
25
26
Main
12,000 Miles
(20 000 km)
6 Months
500 Hours
Internal
Overhaul
Lube/
Auxiliary
12,000 Miles
(20 000 km)
6 Months
500 Hours
Fluid
25,000 Miles
(40 000 km)
12 Months
1000 Hours
Main
25,000 Miles
(40 000 km)
12 Months
1000 Hours
Internal
Overhaul
GENERAL VOCATION
Filters
Lube/
Auxiliary
25,000 Miles
(40 000 km)
12 Months
1000 Hours
Overhaul
75,000 Miles
(120 000 km)
36 Months
3000 Hours
150,000 Miles
(240 000 km)
48 Months
4000 Hours
75,000 Miles
(120 000 km)
36 Months
3000 Hours
Overhaul
50,000 Miles
(80 000 km)
24 Months
2000 Hours
Overhaul
50,000 Miles
(80 000 km)
24 Months
2000 Hours
150,000 Miles
(240 000 km)
48 Months
4000 Hours
50,000 Miles
(80 000 km)
24 Months
2000 Hours
50,000 Miles
(80 000 km)
24 Months
2000 Hours
75,000 Miles
(120 000 km)
36 Months
3000 Hours
Local conditions, severity of operation or duty cycle may require more or less frequent fluid change intervals that differ from the
published recommended fluid change intervals of Allison Transmission. Transmission protection and fluid change intervals can be optimized
by the use of fluid analysis. Filters must be changed at or before recommended intervals.
Severe Vocation: All Retarders, On/Off Highway, Refuse, Transit, and Intercity Coach with duty cycle greater than one (1) stop per mile.
General Vocation: Intercity Coach with duty cycle less than or equal to one (1) stop per mile and all other vocations.
Overhaul
Schedule 3. Recommended Fluid and Filter Change Intervals (TranSynd/TES 295 Fluid)
2 inch Control Module (1.75 inch approximately)Requires Filter Kit P/N 29540493
75,000 Miles
(120 000 km)
36 Months
3000 Hours
NOTE: Change fluid/filters after recommended mileage, months, or hours have elapsed, whichever occurs first.
50,000 Miles
(80 000 km)
24 Months
2000 Hours
75,000 Miles
(120 000 km)
36 Months
3000 Hours
Schedule 2. Recommended Fluid and Filter Change Intervals (TranSynd/TES 295 Fluid)
4 inch Control Module (3.5 inch approximately)Requires Filter Kit P/N 29540494
Flushing Machines are not recommended due to inconsistencies in removing 100 percent of the used fluid.
NOTE: The following recommendations in Schedule 2 are based upon the transmission containing 100 percent of TranSynd fluid.
4000 Product Family Filter change intervals in Schedule 2 and 3 are only valid with the use of Allison Transmission Gold series filters.
Fluid
12,000 Miles
(20 000 km)
6 Months
500 Hours
SEVERE VOCATION
Filters
Schedule 1. Recommended Fluid and Filter Change Intervals (Non-TranSynd/Non-TES 295 Fluid)
PREVENTIVE MAINTENANCE
Limit
Viscosity
CAUTION:
If excessive metal contamination has occurred,
replace the oil cooler and visually inspect all
bearings in the transmission.
Metal particles in the fluid (except for the minute
particles normally trapped in the oil filter) may
indicate internal transmission damage. When these
particles are found in the sump, the transmission must
be disassembled and closely inspected to find the
source. Metal contamination requires complete
transmission disassembly. Clean all internal and
external hydraulic circuits, cooler, and all other areas
where the particles could lodge.
a. Water
NOTE:
If only filters are being replaced, do not drain the
fluid.
a. Drain Fluid
WARNING!
Avoid contact with the hot fluid or the hot sump
when draining transmission fluid. Direct contact
with the hot fluid or the hot sump may result in
bodily injury.
1. Drain the transmission when the fluid is at
operating temperature7193C (160200F).
Hot fluid flows quicker and drains more
completely.
2. Remove the drain plug from the control
module and allow the fluid to drain into a
suitable container.
3. Examine the fluid
Paragraph 211.
as
described
in
27
CAUTION:
c. Refill Transmission
CAUTION:
Do not use the bolts to draw filter covers to the
sump. This can damage the covers, seals, or sump.
3. Install filter 1 and cover 5 assemblies into the
filter compartment. Index each filter/cover
assembly to the holes in the channel plate/
sump. Push the filter/cover assemblies in by
hand to seat the seals.
LUBE
MAIN
Capacity*
PTO Provision
48.0 liters
51.0 quarts
No PTO Provision
45.0 liters
48.0 quarts
PTO Provision
41.0 liters
43.0 quarts
No PTO Provision
38.0 liters
40.0 quarts
Non-retarder
1.0 liter
1.1 quart
1
2
3
4
5
6
Remote
Accumulator
0.5 liter
0.5 quart
213.
MAIN
BREATHER
V07321.02.00
PREVENTIVE MAINTENANCE
to prevent air pressure buildup within the transmission
and must be kept clean and open.
b. Maintenance
1. The amount of dust and dirt encountered will
determine the frequency of breather cleaning.
Use care when cleaning the transmission
exterior. Spraying steam, water, or cleaning
solution directly at the breather can force the
water or cleaning solution into the
transmission.
3. The vehicle is in an area in which a transmission stall test can be safely performed.
4. Make sure the fuel control linkage goes to full
throttle and does not stick when released.
WARNING!
To help avoid personal injury, such as burns,
from hot transmission fluid and/or to help avoid
equipment damage, do not stall the torque converter for more than ten seconds maximum and
monitor transmission fluid temperature. Immediately return the engine to idle if converter out
(to cooler) temperature exceeds 150C (300F).
Operating the transmission at high engine power
at transmission stall or near stall conditions
causes a rapid rise in the transmission fluid temperature. The fluid in the transmission torque
converter is absorbing all of the engine power
and the vehicle cooling system cannot dissipate
the excessive heat load. Extended operation under high heat load conditions causes transmission and cooling system damage, and can
possibly fail hydraulic lines causing leaking high
temperature fluid.
29
WARNING!
To help avoid personal injury and equipment
damage while conducting a transmission stall
test, the vehicle must be positively prevented
from moving. Apply the parking brake, the service brake, and chock the wheels securely. Warn
personnel to keep clear of the vehicle and its
travel path.
CAUTION:
To help avoid transmission or driveline damage,
full throttle transmission stall tests must never be
performed in reverse range (all models) or low
ranges (7-speed models).
5. Notify personnel in the area to keep clear of
the vehicle.
6. Slowly increase engine rpm until engine speed
stabilizes.
7. Record engine speed.
CAUTION:
The transmission stall test procedure causes a
rapid rise in transmission fluid temperature that
can damage the transmission. Never maintain a
stall condition once engine speed stabilizes or
converter out (to cooler) temperature exceeds
150C (300F). During a stall condition, converter out temperature rises much faster than internal (sump) temperature. Never use sump fluid
temperature to determine the length of the stall
condition. If the stall test is repeated, do not let
the engine overheat.
210
NOTE:
If the vehicle is equipped with a smoke controlled or
an emission controlled engine or engine control
programming inhibits engine acceleration, the
following transmission stall test procedure can be
used.
CAUTION:
To help avoid personal injury and/or equipment
damage, a driving transmission stall test must be
performed by a trained driver and a qualified
technician.
e. Driving Transmission Stall Testing Preparation. If a transmission stall test is to be performed, make sure the following preparations
have been made before conducting the transmission stall test.
1. The manufacturer concurs with performing a
full-throttle stall test.
2. Engine programmable parameter for 0 rpm
output speeds are set higher than value expected for stall speed.
3. The vehicle is in an area in which a transmission stall test can be safely performed.
4. Make sure the fuel control linkage goes to full
throttle and does not stick when released.
5. Inspect the engine air induction system and exhaust system for restrictions.
6. Perform a Cold Check of the transmission fluid
level and adjust as necessary.
7. Install a temperature gauge with the probe in
the transmission converter out (to cooler) line.
Allison DOC displays sump temperature
only.
PREVENTIVE MAINTENANCE
8. Install an accurate tachometer (do not rely on
the vehicle tachometer).
9. Connect Allison DOC to the vehicle diagnostic data connector.
f. Performing a Driving Transmission Stall Test
1. Start the engine while in Neutral and let the
transmission warm to normal operating temperature
Sump temperature:
7193C (160200F)
Converter out temperature:
82104C (180220F)
2. Perform a Hot Check of the transmission fluid
level and adjust as necessary.
NOTE:
CAUTION:
10. Reduce engine speed to idle and shift the transmission to N (Neutral).
211
C3
C5
NOTE:
Determine if there are diagnostic codes set that are
related to the transmission difficulty you are
evaluating. Proceed to make mechanical
preparations for reading clutch pressures only after
codes have first been evaluated.
b. Transmission and Vehicle Preparation
CAUTION:
Be sure that the hydraulic fittings have the same
thread as the plugs removed (716-20 UNF-2A).
These fittings must be straight thread, O-ring
style. Failure to use properly threaded fittings
will damage the control module.
1. Remove the plug from the pressure tap and
install a hydraulic fitting and a pressure gauge
or transducer at each location where
measurement is desired (refer to Figure 23 or
Figure 24). Pressure gauge set J 26417-A is
available for this purpose. Refer to Table 25
for pressure levels expected.
2. Provide for engine speed to be monitored. (The
Allison DOC For PCService Tool may be
used.)
3. Be sure that transmission sump fluid
temperature can be measured. (The Allison
DOC For PCService Tool may be used.)
4. Be sure that the transmission has enough fluid
for cold operation until an operating
temperature fluid level can be set.
212
LU
MAIN
C2
C4
C1
V07322.00.02
PREVENTIVE MAINTENANCE
2. Operate the transmission at the conditions
shown in Table 25 and record engine speed,
transmission sump fluid temperature, main
pressure, and clutch pressures in the ranges
where a problem is suspected.
d. Comparing Recorded Data To Specifications
1. Be sure that engine speed and transmission
sump fluid temperatures were within the
values specified in Table 25.
LOCKUP
PRESSURE TAP
C6 PRESSURE TAP
(On left side of
adapter housing,
near the bottom)
MAIN
C4
C1
C5
C3
C2
MAIN
LUBE
DRAIN PLUG
OIL FILTER
COVERS
LUBE PRESSURE
TAP
CLUTCH PRESSURE
TAPS
V05596.01.00
213
214
580620
Neutral
Main Mod OFF
Neutral
Main Mod ON
Reverse
Main Mod OFF
Reverse
Main Mod ON
Low C (4000 7-Speed)
Main Mod OFF
Low C (4000 7-Speed)
Main Mod ON
1C
Main Mod OFF
1C
Main Mod ON
2C
Main Mod OFF
2C
Main Mod ON
Range
C1, C4
C1, C4
C1, C5
C1, C5
C1, C6
C1, C6
C3, C5
C3, C5
C5
C5
Clutches
Applied
15152055
(220300)
13101725
(190250)
14502055
(210300)
11701585
(170230)
12401725
(180250)
8701340
(125195)
12401725
(180250)
8701340
(125195)
12401725
(180250)
8701340
(125195)
Main
kPa (psi)
14402055
(210300)
12351725
(180250)
13752055
(200300)
10951585
(160230)
11651725
(170250)
7951340
(115195)
11651725
(170250)
7951340
(115195)
11651725
(170250)
7951340
(115195)
Range Clutch*
kPa (psi)
3.5 min
(0.5 min)
3.5 min
(0.5 min)
3.5 min
(0.5 min)
3.5 min
(0.5 min)
3.5 min
(0.5 min)
3.5 min
(0.5 min)
3.5 min
(0.5 min)
3.5 min
(0.5 min)
3.5 min
(0.5 min)
3.5 min
(0.5 min)
Lockup Clutch*
kPa (psi)
* To pass this specification, measured clutch pressures must be within 75 kPa (10 psi) of actual measured main pressure and still be within the minimum and maximum value of
this specification.
Engine
rpm
Transmission Model/Test
Type
Pressure Specifications
17801820
C3, C5
C1, C6
1C
2C
2L
3C
3L
4C
4L
5C
5L
6C
6L
C5
C5
Clutches
Applied
Neutral
Main Mod OFF
Neutral
Main Mod ON
Reverse
Range
18052055
(260300)
14151725
(205240)
18052055
(260300)
15501795
(225260)
15501795
(225260)
15501795
(225260)
10801365
(155200)
15501795
(225260)
10801365
(155200)
15501795
(225260)
10801365
(155200)
15501795
(225260)
10801365
(155200)
13451590
(195230)
10351235
(150180)
Main
kPa (psi)
17302055
(250300)
13401725
(195240)
17302055
(250300)
14751795
(215260)
14751795
(215260)
14751795
(215260)
10051365
(145200)
14751795
(215260)
10051365
(145200)
14751795
(215260)
10051365
(145200)
14751795
(215260)
10051365
(145200)
12701590
(185230)
9601235
(140180)
Range Clutch*
kPa (psi)
160240
(2335)
160240
(2335)
160240
(2335)
160240
(2335)
160240
(2335)
160240
(2335)
160240
(2335)
160240
(2335)
160240
(2335)
125200
(1830)
125200
(1830)
125200
(1830)
125200
(1830)
125200
(1830)
125200
(1830)
Lockup Clutch*
kPa (psi)
* To pass this specification, measured clutch pressures must be within 75 kPa (10 psi) of actual measured main pressure and still be within the minimum and maximum value of
this specification.
Engine
rpm
Transmission Model/Test
Type
Pressure Specifications
PREVENTIVE MAINTENANCE
215
2. Housing:
Filler pipe seal damaged or missing
Filler pipe bracket dislocated
Oil cooler connector fittings loose or
damaged
Output shaft seals worn or damaged
Pressure port plugs loose
Porous casting
3. Converter end:
Converter seal damaged
damage)
Garter spring missing from seal
Converter leak in weld area
Damaged or missing converter O-ring seal
Porous casting
NOTE:
A dye and black light kit is available for finding
leaks. Refer to the manufacturers directions when
using the kit. Refer to kit directions for the color of
the fluid and dye mix.
Plugged breather
Water or coolant in fluidfluid will appear
milky
Incorrect electronic fluid level indication
Drain-back holes plugged
216
PREVENTIVE MAINTENANCE
5. Gaskets:
damaged threads
Warped flanges or sealing surface
Scratches, burrs, or other damage to a
sealing surface
Damaged or worn gasket
damaged
Loose or worn bearing causing excess seal
wear
e. Repairing the Leak. Once the leak has been
located and traced to its source, repair the leaking
components. If a gasket is replaced, but the sealing
flange is bent, the new gasket will not repair the leak.
The bent flange must also be repaired.
6. Seals:
Fluid level/pressure is too high
Improper installation
Cracks in component
3
1
2
4
5
6
7
8
V06834.01.00
Figure 25. Output Flange and Oil Seal (Except 4700 and 4800 Models)
217
Item
Paragraph
PTO(s)
42b
42c(2)
42c(3)
42c(7)
Control Module
42f
3
1
2
4
5
6
7
8
V05578.01.00
Figure 26. Output Flange and Oil Seal (4700 and 4800 Models)
218
SCOPE
32.
WARNING!
Use appropriate safety equipment such as safety
glasses, safety shoes, and gloves.
CAUTION;
Caustic cleaning compounds will damage some
transmission parts. Use only mineral spirits to
clean transmission parts.
120 cm
(48 in.)
200 cm
(78 in.)
OIL DRAIN
60 cm
(24 in.)
OIL DRAIN
(BOTH SIDES)
10x10 cm
(4x4 in. LEGS)
STEEL TOP
TROUGH
16-GAUGE SHEET STEEL
35 mm (112 in.) DEEP
35 mm (112 in.) WIDE
5x15 cm
(2x6 in. BOARD)
FOR TOP FRAME
AND LEG BRACKETS
V00660.02
31
6
11
7
10
14
12
15
13
17
18
19
16
22
21
20
23
26
24
27
25
28
31
29
V06922.02.00
32
30
3
29
4
5
J 33884
J 35923-2
J 35924
J 35926
J 37030-1
J 37030-2
J 37030-3
J 37031-A
J 37032
J 37033
J 37034
NA
19
7
24
17
18
20
22
9
10
15
Seal Remover
Pressure Gauge Set
Overhaul Stand
Valve Body Parts Tray Set (includes
J 33163-1 and J 33163-2)
Pressure Switch Test Block
C1 Spring Compressor (use with J 37030-3)
Main-Pressure Spring Remover/Installer
Transmission Holding Bracket
C2 Spring Compressor (use with J 37030-3)
C5 Spring Compressor (use with J 37030-3)
C1, C2, and C5 Spring Compressor Tool Base
Output Seal Installer
Input Seal Installer
Output Bearing Cup Installer (use with J 37034)
Output Bearing Installer/Drive Sleeve
J 37035
11
J 37036
12
J 37038
21
J 37040
J 37041
J 38548
J 38564
J 39534
J 39949
J 39954
J 41445
J 41462
J 42048
J 46150
J 47942
13
14
27
25
26
8
16
23
6
28
30
31
Reference
Paragraph
514c,e; 516a,c
217b; 53b; 55e; 56b,c; 57b;
510b; 511b; 514g; 516e
217a; 55b; 56a; 514c; 516a
215b
42a; 62a
518a
NA
57a,b
518e,h
42a; 62a
57a,b
514e,f; 516c,d; 517c
57a,b; 514e,f; 515f; 516c,d
62q,s
55e; 56c
514f,h; 515g,h
55e; 56b,c; 514f,g,h; 515g,h,i,j;
516d,e,f; 517d,e,f
514c,h; 515c,j; 516a,f; 517a,f;
62q,r,s,t
57b; 511b; 514g; 516e
55e; 56b, c; 510b
57b
55d; 56b
53b; 62v
42g
NA
53b
56c
42a; 62a
56a,b
514c,h; 515c,j
62z
518c,j
We believe this source and its tools to be reliable. These tools may be available from other manufacturers. General
Motors does not endorse, indicate any preference for, or assume any responsibility for the products or tools from
these firms, or for any such items that may be available from other sources.
**
33
10
9
23
11
14
24
17
16
15
25
12
19
18
20
13
21
V06923.02.00
34
22
Kent-Moore
Tool No.**
J 3940
J 8092
J 24171-A
J 35923-4
J 35926-A
Figure 33
Item
Number
1
2
3
11
13
J 35926-UPD
NA
J 37030-2
J 37030-3
J 37032
J 37033
J 37034
10
11
4
5
9
J 37035
J 37036
6
8
J 41445
J 42048
J 43020
J 43023
J 43024 -A
J 43025
J 43046
J 43047
J 43202
J 43278
12
23
15
16
17
18
19
20
21
7
J 43922
J 43975
22
14
J 46150
J 47942
24
25
Description
Bearing Race Remover
Drive Handle
Seal Remover
Spring Compressor Tool Base
Transmission Lifting Bracket (modified to lift
4700 and 4800 models)
Modification Template (used to modify J 35926 to
become J 35926-A)
C5 Spring Compressor
C1, C2, and C5 Spring Compressor Tool Base
Input Seal Installer
Output Bearing Cup Installer
Output Bearing Installer/Drive Sleeve
Spanner Nut Torque Tool Set
Turbine Shaft Bushing/Output Bushing/P2 Carrier
Bushing Installer
Transmission Holding Bracket
Retarder Flow Valve Spring Compressor
P3 Planetary Lifting Ring
P4 Planetary Bushing Installer
Output Shaft Seal Installer
C5 Return Spring
Torque Wrench Adapter
Bearing Installer/Remover
Output Shaft Bearing Installer
Output Shaft Holding Tool
Reference
Paragraph
515d,f; 517c
217b; 515i; 517e
217a; 515c; 517a
513d,e; 517d
42a; 62a
NA
515f,g; 517c
515f,g; 517c
NA
516d; 517d
513d,e,f; 515g,h,i,j;
517d,e,f; 62r,t
515c,j; 517a,f; 62r,s,t
515i; 517e
42a; 62a
515c,j
42n; 62k
513f
217b; 62r,t
513d,e; 517d
42m; 62l
513d,e
515i; 517e
514h; 515j; 516f;
517a,f; 62r,t
Measuring Blocks And Straight Edge
62m,n
4700 and 4800 Model Tool Kit (Includes the following NA
special tools: J 43020, J 43023, J 43024, J 43025,
J 43046, J 43047, J 43202, J 43278, and J 43922)
Slinger Installer
62z
Valve Body Spring Compressor
518c,j
We believe this source and its tools to be reliable. These tools may be available from other manufacturers. General
Motors does not endorse, indicate any preference for, or assume any responsibility for the products or tools from these
firms, or for any such items that may be available from other sources.
**
35
REPLACEMENT PARTS
CAUTION:
Seal all openings and the breather before steam
cleaning the transmission. The material on
friction-faced clutch plates, the bonding agent,
and clutch housing machined surfaces can be
damaged by water, steam cleaning, or
unapproved solvents and detergents. Use only
mineral spirits to clean friction-faced clutch
plates and clutch housings.
1. Clean all metallic transmission parts, except
bearings and friction-faced clutch plates, by
steam cleaning or with mineral spirits. Do not
use caustic soda solution for steam cleaning. If
steam cleaning, do not allow steam or water to
enter the transmission. Clean friction-faced
clutch plates and bearings with mineral spirits
only.
2. Dry all parts, except bearing assemblies, with
compressed air. To prevent rust, lubricate
steam-cleaned parts as soon as they are dry.
WARNING!
Do not burn discarded Teflon seals; toxic gases
are produced by burning Teflon.
34.
CAREFUL HANDLING
WARNING!
35.
d. Inspecting Bearings
CAUTION:
If excessive metal contamination has occurred,
replacement of all bearings is recommended.
1. Inspect bearings for rough rotation. Replace a
bearing if its rotation is still rough after
cleaning and lubrication.
2. Inspect bearings for scored, pitted, scratched,
cracked, or chipped races, and for excessive
roller or ball wear. Replace the bearing if any
of these defects are found.
3. Inspect a defective bearings bore and mating
shaft for grooved, burred, or galled conditions
that indicate the bearing has been turning in the
bore or on the shaft. If shaft or bore damage
cannot be repaired with crocus cloth, replace
the defective part.
4. When removing a bearing, do not apply
pressure across the balls. This can cause
brinelling and bearing failure.
be installed.
Do not remove the grease in which new
37
CAUTION:
When removing a defective bushing, do not
damage the bushing bore.
2. Replace bushings that are out-of-round, deeply
scored, or excessively worn. Inspect parts
mated to bushings to be sure they are not
damaged or worn beyond use.
3. Inspect thrust washers for distortion, scores,
burrs, and wear. Replace a thrust washer if
defective or worn.
h. Inspecting Sealrings and Gaskets
1. Inspect piston sealrings and lip-type seals for
nicks, cuts, tears, splits, and pattern damage. A
damaged seal can indicate rough or sharp
edges in piston grooves or on a mating surface
that could damage a new seal.
2. Inspect piston sealring grooves for nicks, burrs,
dents, or displaced metal that could damage
the new seal. Remove raised metal, sharp
edges, burrs, or nicks with a soft stone and
crocus cloth. Thoroughly clean all residue
from the piston before assembly.
3. Replace all composition gaskets.
4. Inspect hook-type sealrings for wear, broken
hooks, and distortion. Install a new hook-type
sealring if the old ring shows any wear on its
outside diameter, or if there is excessive side
wear. Install a new sealring if there is wear on
the sealring outside diameter mating surface.
5. Inspect clutch housing sealing surfaces for
nicks, burrs, dents, or displaced metal that
could interfere with mating parts or damage
the piston seal. Remove raised metal, sharp
edges, burrs, or nicks with a soft stone and
crocus cloth. Thoroughly clean all residue
from the housing before assembly.
6. Measure butt-joint sealring end gap by
inserting the sealring into its respective sealing
bore. Use a feeler gauge to measure end gap.
Discard sealrings that do not meet
specifications. Refer to Table 71, Wear Limits
Data, in Section 7.
38
LEVEL SURFACE
36.
ASSEMBLY PROCEDURES
CLUTCH PLATE
39
h. Butt-Joint Sealrings
CAUTION:
CAUTION:
Teflon
Do not use
tape on threaded parts
where slivers can enter the transmission and
cause a malfunction.
Improperly installed plugs or fittings can
cause leakage and cracked housings.
Threaded plugs in 4000 Product Family transmissions
are the straight-thread, O-ring type. Be sure that the
O-ring is in like-new condition and tighten all plugs to
the torque value specified in the assembly procedure or
in the exploded views.
f. Coated Threaded Fasteners. Control module
bolts are manufactured with a band of sealant on the
threads. Coated bolts may be reused, however repeated
removal and installation may reduce the effectiveness
of the coating. If fluid leaks are detected around the
bolts, replace the coated bolts. Do not attempt to
re-apply a sealing compound. The coated bolts sizes
are M10 x 1.5 x 55 mm and M10 x 1.5 x 100 mm.
g. Lip-Type Oil Seals
1. When replacing lip-type seals, make sure the
spring-loaded lip is toward the fluid to be
sealed (toward the inside of the unit). Coat the
inside of the seal with high temperature grease
(MIL-G-3545A or equivalent) to protect the
seal during shaft installation and to provide
lubrication during initial operation.
2. The circumference of some seals is precoated
with a dry sealant. The sealant is usually
colored for easy identification. Precoated seals
do not require any additional sealant before
installation.
310
37.
REMOVING TRANSMISSION
FROM VEHICLE (Figure 35)
NOTE
A significant amount of fluid may drain from a
hydraulic hose when it is disconnected from the
transmission.
4. Disconnect all hydraulic hoses from the
transmission. If a retarder is installed,
disconnect the accumulator line from the
retarder housing. Remove the hoses from the
vehicle if they interfere with the transmission
removal. Plug all openings to keep dirt from
entering the hydraulic system.
5. If an integral cooler is used, drain coolant from
the cooler and disconnect coolant hoses.
Remove the hoses from the vehicle if they
interfere with transmission removal. Plug all
openings to keep dirt from entering the cooling
system.
b. Disconnecting Controls
a. Drain Fluid
WARNING!
Avoid contact with the hot fluid or the hot sump
when draining transmission fluid. Direct contact
with the hot fluid or the hot sump may result in
bodily injury.
1. Drain the transmission fluid before removing
the transmission from the vehicle. The
transmission fluid should be warm to promote
complete drainage.
2. Remove the drain plug from the control
module. Examine the drained fluid for evidence
of contamination (see Paragraph 211).
Reinstall the drain plug. If the drain plug
threads are damaged, see Paragraph 212 for
corrective action.
3. Remove transmission fill tube if it interferes
with transmission removal.
transmission
WARNING!
DO NOT disconnect the hydraulic fluid line
between the accumulator and the retarder until
air and hydraulic pressure have been bled from
the line.
311
OUTPUT
SPEED
SENSOR
REAR
COOLER
PORTS
FRONT COOLER
PORTS (OPTIONAL)
FRONT
ACCUMULATOR LINE
(RETARDER ONLY)
TURBINE
SPEED SENSOR
RIGHT SIDE
V07323.01.00
38.
WEAR LIMITS
39.
SPRING SPECIFICATIONS
310.
312
TORQUE SPECIFICATIONS
SCOPE
Title
Tools and Equipment
Replacement Parts
Careful Handling
Cleaning and Inspection
Removing Transmission From Vehicle
Wear Limits Data
Spring Data
42.
DISASSEMBLY OF
TRANSMISSION
WARNING!
PREVENT PERSONAL INJURY
Use proper tools and lifting equipment when
installing or removing a transmission from the
repair stand.
Transmission dry weights are as follows:
4000 Product Family (except 4700 and 4800
models)
Base Transmission
377 kg (831 lb)
With PTO Provision
405 kg (893 lb)
With Retarder
411 kg (906 lb)
With PTO and Retarder 439 kg (968 lb)
4000 Product Family (4700 and 4800 models)
Base Transmission
493 kg (1087 lb)
With PTO Provision
521 kg (1149 lb)
With Retarder
527 kg (1162 lb)
With PTO and Retarder 555 kg (1224 lb)
41
2
4
3
1
2
4
V06836
20
ENGINE
SPEED
SENSOR
2
TURBINE 1
SPEED
SENSOR
7
5
9
OUTPUT
SPEED
SENSOR
15
13
16
10
11
17
18
19
12
14
V06837.03.00
42
TRANSMISSION DISASSEMBLY
7. Remove bolt 4, retainer 3, speed sensor 2, and
O-ring 1 from the converter housing module
(engine speed sensor), main housing module
(turbine speed sensor), and rear cover or
retarder (output speed sensor). Refer to Figure
43 for sensor locations.
d. Removal of Integral Oil Cooler (Figure 44)
1. Remove two bolts 11 and seventeen bolts 12.
Remove cover 13, gasket 14, and two
O-rings 10.
2. Remove plate assembly 9 and four O-rings 8.
ENGINE
SPEED SENSOR
OUTPUT
SPEED SENSOR
TURBINE
SPEED SENSOR
V09786.00.00
3
1
11
4
5
8
2
6 7
8
19
18 17
19
18 17
11
15
9
10
10
16
11
12
14
13
11
V06843
43
WARNING!
Get help when lifting the control module.
Assistance from a hoist or another person may be
required.
The
control
module
weighs
approximately 25 kg (55 lb).
1. Remove forty-three bolts 3 and 4 retaining
control module 1 to the main housing module,
including the bolts retaining the filter covers.
2. Loosen control module 1 by applying pressure
at the reinforced tabs or use jack bolts, inserted
into the control module bolt holes that bottom
against the main housing module.
3. Remove covers and filters if a handhold is
needed to remove the control module.
4. Remove control module assembly 1 and
gasket 2.
44
4
V09785.00.00
TRANSMISSION DISASSEMBLY
located on the main housing (Figure 46,
View D). Insert a heel bar into a torque
converter housing bolt hole. Insert two bolts
into the flexplate adapter bolt holes. Then
place a screwdriver at an angle to prevent
converter rotation (Figure 46, View C).
5. Using converter bolt tool J 38564, remove
bolt 3.
6. Remove selective shim 4 located under bolt 3
(Figure 46, View A).
5
1
RESTRICT MOVEMENT
USE HOIST AND SLING
J 38564
VIEW A
VIEW B
LOCKUP
PRESSURE
TAP
VIEW C
VIEW D
VL06840.01.00
45
NOTE:
Proceed to Paragraph 42 sub-paragraph shown
below by output module configuration and model.
NOTE:
Seven converter housing retaining bolts 3 are
removed from inside converter housing 1. Use
mechanical fingers or a similar tool to remove these
bolts.
WARNING!
Get help when lifting the retarder module.
Assistance from a hoist or another person may be
required. The retarder module weighs
approximately 34 kg (75 lb).
1
3
V07335
2
2
1
2
8
7
4
6
3
6 5
2
5
5
3
OR
3
V06844
Figure 48. Removal of Retarder Module (Except 4700 and 4800 Models)
46
TRANSMISSION DISASSEMBLY
1
4
2
4
4
4
3
5
7
4
7
9
6
9
OR
7 8
V06845
WARNING!
Get help when lifting the retarder module.
Assistance from a hoist or another person may be
required. The retarder module weighs
approximately 34 kg (75 lb).
2. Thread an M14 eye bolt into the retarder
output shaft and lift retarder module 5 from
main housing module 1.
3. Remove retarder gasket 3 from main housing
module 1 or from retarder module 5.
1
2
V06846
47
WARNING!
Get help when lifting the C6 adapter housing
module. Assistance from a hoist or another
person may be required. The C6 adapter housing
module weighs approximately 68 kg (150 lb).
1
2
4
V05580
J 43046
4
4
4
BOLT,
METRIC HEAVY
(5) MARKED 5
4
4
5
5
5
V05374
V07494
48
TRANSMISSION DISASSEMBLY
n. Removal of P3 Planetary Module
(4700 and 4800 Models) (Figure 414)
2
3
4
5
1
J 43020
C5
2
3
V05375
1
CLOSE RATIO MODELS
3
V01737.00.06
E01271.01
49
CAUTION:
Always remove the turbine speed sensor before removing the rotating clutch module to
avoid possible damage to the turbine speed
sensor.
When you remove rotating clutch module 1,
carefully place it on the workbench and prevent it from rolling off the bench.
3. Using a hoist and an M16 eye bolt, lift turbine
shaft and rotating clutch module 1 (Figure 419)
from the main housing module and place it on
the workbench.
2
3
CAUTION:
Make sure the main housing module is
horizontal when removing the C3/C4 clutch
assembly.
1
V01272
1
3
E01273.01
410
E01274.01
SCOPE
52.
GENERAL INFORMATION
FOR MODULE REBUILD
Description
Tools, Equipment
Replacement Parts
Careful Handling
Cleaning and Inspection
Assembly Procedures
Wear Limits Data
Spring Data
53.
51
Roller to be installed in
small end of cam pocket
STATOR CAM
CAUTION:
When installing thrust bearings, make sure that
the locating lip on either the inner or outer thrust
bearing race is not preventing the race from
contacting the thrust surface of the mating part.
Failure to do this leads to premature thrust
bearing failure and incorrect shim selection to
maintain proper internal part clearance.
6. Install thrust bearing assembly 18.
7. If removed, press a new bushing 8 into cover 7
bushing bore using J 39949 bushing installer
and J 8092 drive handle.
8. Install new sealring 16 onto turbine hub and
insert turbine assembly 17 into the new
bushing and inspect for freedom of rotation.
52
V01360.03.00
MODULE REBUILD
DRIVE TANG SURFACE
THRUST
SURFACE
OF
TURBINE
HUB
DIM.
DIM.
THRUST
SURFACE
OF
TURBINE
HUB
J 38548
E02517.01
NOTE:
Use P/N
Shim Thickness
29503879
29503880
29503881
53
TORQUE CONVERTER
HOUSING MODULE
(Models Without PTO Provision)
40
40
340
20
68
450
110
230
CAUTION:
Use the correct wrench size to avoid crushing the
vent assembly.
CAUTION:
Use the correct wrench size to avoid crushing the
vent assembly.
2. Install breather assembly 2. Torque breather
assembly to 1216 Nm (912 lb ft).
TORQUE CONVERTER
HOUSING MODULE
(Models With PTO Provision)
CAUTION:
Use the correct wrench size to avoid crushing the
vent assembly.
54
55.
CAUTION:
Oil pump drive hub 13 can be incorrectly
installed backwardsposition the oil pump
drive hub tangs toward the oil pump.
2. Install oil pump drive hub 13 into PTO gear 12,
aligned with hub tangs toward the oil pump.
3. Insert sealring 14 into the sealing bore of pump
housing 10 (Foldout 6,A) and measure end gap
with feeler gauges. Sealring end gap must be
1.181.66 mm (0.0470.065 inch). Refer to
Paragraph 36h.
MODULE REBUILD
4. Remove sealring 14 (Foldout 5,B) from the
seal bore and install the sealring onto PTO
gear 12.
e. Assembly of Bearing Retainer Assembly
(Foldout 5,B)
1. If removed, install bushing 6 using a press, and
tools J 37038 and J 8092.
2. Install sealring 9 onto bearing retainer 7. Install
oil seal 4 using a press, and tools J 37032 and
J 37034.
3. Insert sealring 8 into the sealing bore in PTO
gear 12 and measure the end gap using feeler
gauges. Sealring end gap must be 1.181.66 mm
(0.0470.065 inch). Refer to Paragraph 36h.
4. Remove sealring 8 from sealing bore and
install the sealring onto bearing retainer 7.
f. Assembly (Foldout 5,B)
1. Using a mallet, lightly tap PTO gear
assembly 10 into converter housing 19 until
the gear assembly is seated.
2. Use guide bolts to install bearing retainer
assembly 3, rocking the retainer while
installing it.
3. Install eleven bolts 2 to hold bearing retainer
assembly 3 and PTO gear assembly 10 to
housing 19. Tighten the bolts to 5161 Nm
(3845 lb ft).
4. If used, install PTO covers 25 or 28 and
gaskets 26 or 29 using ten bolts 24 or 27 in
the cover. Tighten the bolts to 5161 Nm
(3845 lb ft).
5. Install engine speed sensor assembly 15 and
engine speed sensor retaining bolt 18. Tighten
the bolt to 2429 Nm (1821 lb ft).
CAUTION:
Use the correct wrench size to avoid crushing the
breather.
6. Install breather 20. Tighten the breather to
1216 Nm (912 lb ft).
56.
55
PUMP
HOUSING
MAX DEPTH OF
GEAR CAVITY
19.04 mm (0.75 in.)
PUMP
HOUSING
DRIVE
GEAR
MAX SIDE
CLEARANCE
0.10 mm (0.004 in.)
DRIVEN GEAR
V02518
V01899.01
PUMP
HOUSING
MAX ID OF
GEAR CAVITY
150.25 mm (5.915 in.)
V02519
V01277.01
PUMP HOUSING
DRIVEN GEAR
MODULE REBUILD
14. Remove fourteen bolts 14 retaining the wear
plate 13 to front support 20. Remove wear
plate 13.
15. If damaged, remove roller bearing 26 from
front support 20 using a drift and hammer.
16. Measure the OD of front support sleeve 21.
Minimum diameter is 119.81 mm (4.717 inch).
Also inspect for wear. If worn or damaged, remove front support sleeve 21 from front support 20.
17. If damaged, remove dowel pins 19 from front
support 20.
18. If worn or damaged, remove ground sleeve 16
or 17 by pressing ground sleeve from front
support 20.
19. Compress spring 22, using tool J 41462, until
load is removed from dowel pin 24. Remove
dowel pin 24 and carefully release the load on
spring 22 by rotating the handle on tool
J 41462 in the counter-clockwise direction.
When spring 22 has reached its free length, remove tool J 41462. Remove spring 22 and ball
23 from the front support 20.
57
DOWEL PIN
14.5 mm
(0.57 in.)
GROUND SLEEVE
INSTALL
REMOVE
SPLINE OD T.I.R.
0.30 mm
(0.012 in.)
E
SECTION E-E
BOTTOM
VIEW A
RELIEF VALVE
BORE
VIEW B
To install, align flat on
ground sleeve with arrow
on front support.
20
VIEW C
V01344.00.04
58
57.
MODULE REBUILD
6. Measure the wear surface thickness of C2
clutch backplate 39. Minimum thickness
allowed is 7.90 mm (0.311 inch). Measure
flatness of the backplate. Maximum allowable
distortion is 0.15 mm (0.006 inch).
7. Remove C2 clutch packseven friction plates
38 and seven steel reaction plates 37.
8. Measure the thickness of each friction plate 38.
Minimum thickness allowed is 2.92 mm
(0.115 inch). Measure the oil groove depth and
cone of each friction plate. Minimum groove
depth allowed is 0.20 mm (0.008 inch).
Maximum cone allowed is 0.25 mm (0.010 inch).
depth allowable is 0.20 mm (0.008 inch). Maximum cone allowed is 0.25 mm (0.010 inch).
14. Measure the thickness of each steel reaction
plate 31. Minimum allowable thickness is
2.41 mm (0.095 inch). Maximum cone allowable is 0.25 mm (0.010 inch).
15. Measure the wear surface thickness and cone
of C1 clutch apply plate 29 and backplate 32.
Minimum thickness allowed is 5.90 mm
(0.232 inch) and 9.90 mm (0.390 inch), respectively. Measure flatness of the C1 clutch apply
plate and backplate. Maximum allowable distortion is 0.15 mm (0.006 inch).
from
turbine
shaft
59
J 37030-3
HANDLE
HANDLE
FLAT WASHER
FLAT WASHER
BEARING
J 35923-2
BEARING
J 35923-2
VIEW A
VIEW B
J 37030-3
VIEW C
VIEW D
ALIGNMENT SLOTS
V06847.02.00
WARNING!
Carefully release spring force. Piston springs are
highly compressed. Personal injury can occur if
the spring force is not controlled.
22. Release spring force by rotating handle in
counterclockwise direction. Remove handle,
flat washer, bearing, and J 35923-2 tool.
23. Remove balance piston 26, sealring 27, and
C1 spring assembly 25.
24. Install tools J 37030-3, J 37030-1, J 35923-2
(Figure 59, View B), bearing, washer, and
handle. Tighten tool and remove internal retaining ring 22. Remove tools after relieving
spring force.
510
MODULE REBUILD
29. Remove piston sealrings 16 and 17 from
hub 13.
30. Separate C1 piston 24 and sealring 23 from C2
piston 19 and sealring 18 by tapping lightly on
the C1 piston.
b. Assembly Foldout 6,B)
1. If removed during disassembly, install
bushing 12 into drive hub assembly 11 using
tools J 37040 and J 8092.
2. Install piston sealring 16 on hub assembly 13
and piston sealring 18 into C2 piston 19. Install
piston sealring 17 on rotating clutch hub
assembly 13 and piston sealring 23 onto C1
piston 24.
3. With a mallet, lightly tap C2 piston 19 (with
sealring 18) onto hub assembly 11.
4. Align notch on C1 piston with any lubrication
orifice on the rotating drive hub. With a mallet,
lightly tap C1 piston 24 (with sealring 23) onto
the center of C2 piston 19 and over rotating
clutch hub assembly 13.
5. Install rotating clutch drum 9 over hub
assembly 11 and C1/C2 pistons 24 and 19.
6. Install C2 spring assembly 20. Align the spring
assembly with the rotating clutch hub 36 tangs
and the splines on the C2 piston 19. The C2
spring assembly must make contact with the
bottom of the slots in the C2 piston. If the spring
assembly does not reach the bottom, remove the
C2 spring assembly and re-index it in the next
spline on the rotating drum 9. Repeat this
process until the C2 spring assembly is in the
proper position.
7. Install C2 spring plate 21. Index the spring
plate with the drive hub tangs and the splines
on the C2 piston.
8. Place the rotating clutch on tool base J 37030-3
so that the rotating drum is supported by tool
tangs. Install tool J 37030-1 (Figure 59, View
B), J 35923-2, that includes the bearing,
washer, and handle. Tighten tool to compress
C2 spring assembly 20, and install retaining
ring 22. Remove tools.
9. Install sealring 27 onto balance piston 26.
CAUTION:
Be sure that thrust bearings are assembled to
function correctly. Make sure that the locating
lip on either the inner or outer thrust bearing
race is not preventing the race from contacting
the thrust surface of the mating part. Failure to
do this leads to premature thrust bearing failure
and incorrect shim selection to maintain proper
internal part clearance.
16. Install thrust bearing 14 onto the rotating
clutch hub assembly 13.
17. Install C1 clutch pack (Figure 510)one
clutch apply plate 29, seven friction plates 30,
six steel reaction plates 31, and one
backplate 32. Install clutch plates alternately,
starting with a friction plate 30. Install C1 retaining ring 33.
18. Install C1 drive hub 34. Be sure that the drive
hub passes over the external splines of all
seven plates 30.
19. Install a thrust bearing 35 on each side of C2
drive hub 36, and install this assembly over C1
drive hub 34.
511
58.
a. Disassembly (Foldout 7)
NOTE:
When replacing a nameplate, keep the original
identification plate. Stamp the information from the
original identification plate onto the replacement
identification plate.
1. Replace a damaged nameplateremove
retaining rivet 24 and nameplate 23.
2. Inspect the inner C5 clutch plate splines of
main housing 31. Maximum allowable spline
wear is 1.15 mm (0.045 inch).
3. Remove fourteen bolts 2 retaining the C3
backplate assembly 3 and C3 clutch housing
assembly 11.
assembly 3.
Remove
C3
BACKPLATE
V05566.00.01
512
backplate
MODULE REBUILD
12. Inspect six thrust plates 12 in C3 housing 13.
Minimum allowable thrust plate 12 thickness
at the contact surface is 2.82 mm (0.111 inch).
Maximum allowable distortion of backplate 4
is 0.15 mm (0.006 inch). Maximum stepwear
of 0.13 mm (0.005 inch) is allowed. If replacement is necessary, remove the thrust plates. Inspect splines in C3 clutch housing 13.
Maximum spline wear allowed is 1.15 mm
(0.045 inch).
13. Remove C4 clutch packsix steel reaction
plates 14 and five friction plates 15.
14. Measure the thickness and cone of each friction plate 15. Minimum allowable thickness is
3.485 mm (0.137 inch). Maximum allowable
cone is 0.25 mm (0.010 inch).
16. Remove piston return plate assembly 16. Inspect plate 16. Minimum allowable thickness
of plate 23 is 4.91 mm (0.193 inch)
b. Assembly (Foldout 7)
1. Install piston 17 into C4 housing 18.
2. Install piston return plate assembly 16.
59.
a. Disassembly (Foldout 8)
513
52.98 mm
(2.085 in.)
35.92 mm
(1.414 in.)
V02524
514
MODULE REBUILD
slots in the planetary, and retain them with oilsoluble grease.
3. Slide the pinion gear and bearing assemblies
into the side of the P1 planetary carrier
between the thrust washers.
4. Repeat the procedure for the five remaining
pinion gears.
5. Install six spindles 6 so the lower step is
positioned for proper installation of indexing
ring 5.
6. Install indexing ring 5 and retaining ring 4.
7. If components were replaced, measure pinion
end play. Pinion end play must not exceed
0.94 mm (0.037 inch). Measure all six pinion
gears.
8. Install P2 ring gear 15 over P1 planetary
carrier assembly 3.
9. Install internal retaining ring 2 into P2 ring
gear 15, connecting P1 planetary carrier
assembly 3 and the P2 planetary ring gear.
CAUTION:
Be sure that thrust bearings are assembled to
function correctly. Make sure that the locating
lip on either the inner or outer thrust bearing
race is not preventing the race from contacting
the thrust surface of the mating part. Failure to
do this leads to premature thrust bearing failure
and incorrect shim selection to maintain proper
internal part clearance.
10. Install thrust bearing assembly 14 on P1 planetary carrier assembly 3.
CAUTION:
If the wear on the indexing ring is minor, flip it
over to get a fresh reaction point for the spindle.
Replace the indexing ring if both corners of the
indexing ring are worn. Failure to take corrective
action may allow the spindle to rotate which may
reduce or shut off lubrication to the pinion
bearings and thrust washers.
3. Install four spindles 13 so the lower step is
positioned for proper installation of indexing
ring 5.
4. Install indexing ring 5 and internal retaining
ring 4.
515
DIMENSION A
VIEW A
VIEW B
V06848
516
MODULE REBUILD
4. If components were replaced, measure pinion
end play. Pinion end play must not exceed
0.94 mm (0.037 inch). Measure all four pinion
gears 9.
NOTE:
Do not install shim locating ring 6 or selective
shim 12 until final transmission assembly.
Measurement for selective shim is performed during
final buildup.
J 35923
J 43025
V05581
517
NOTE:
Ball bearing assembly 26 is properly seated when it is
against the shoulder at the bottom of the bearing
bore and is 1.573.35 mm (0.0620.132 inch) below
the machined face of the adapter housing at the top
of the bearing bore.
4. Press ball bearing assembly 26 into C6 adapter
housing assembly 21 until it is properly seated.
J 37034
J 43047
V05583
J 35923-4
J 37034
J 43047
V05584
V05582
518
MODULE REBUILD
5. Install piston ID lip-type sealring 20 onto C5
piston 18. Install external sealring 19 onto C5
piston 18.
6. Align the tang on the back of the C5 clutch
piston 18 with the notch in the C6 adapter
housing 22 before installing C5 clutch piston
18. Install C5 clutch piston 18 into C6 adapter
housing module 14. Use a rubber mallet to seat
the piston.
7. Place spring return assembly 17 in C6 adapter
housing assembly 21. Use alignment notch to
guide installation.
WARNING!
Piston springs are highly compressed. Be
extremely careful during installation. Personal
injury can occur if the spring force is not
controlled.
8. Place retaining ring 16 in C6 adapter housing
assembly 21.
9. Compress spring and retainer assembly 17
using J 35923-4 tool base, washer, bearing,
handle, and piston spring compressor J 43025.
Install retaining ring 16 and slowly release the
spring force (Figures 517 and 518).
J 35923-4
J 35923
J 43025
V05582
V05581
519
NOTE:
For 4700 and 4800 models with a retarder,
proceed to Paragraph 515.
For 4700 and 4800 models without a retarder,
proceed to Paragraph 517.
J 37034
J 43023
520
MODULE REBUILD
1,000,000
SENSOR RESISTANCE ()
100,000
10,000
1,000
100
10
1
40
14
68
122
40
10
20
50
176
230
284
338
392
80
110
140
170
200
TEMPERATURE
V04641.01
NOTE:
CAUTION:
Temperature
(C)
40
20
110
Temperature
(F)
40
68
230
521
WARNING!
Place the P3 planetary assembly on its side to
avoid possible injury while disassembling the
planetary.
1. Remove retaining ring 11 and thrust washer 10
from P3 planetary carrier assembly 3.
NOTE:
For 4500 models (wide ratio) transmissions,
skip to Step (3).
For close ratio models, proceed with Step (2).
2. On a close ratio transmission, remove output
shaft assembly 4. Inspect the splines on output
shaft assembly 4. Maximum spline wear
allowed is 0.38 mm (0.015 inch).
3. If replacement is necessary, remove cone and
roller bearing assembly 17.
522
WARNING!
Piston springs are highly compressed. Be
extremely careful during removal and
installation. Personal injury can occur if the
spring force is not controlled.
2. Remove C5 clutch piston 21 from retarder
stator 25 by compressing spring and retainer
assembly 20 using J 37030-3 tool base, washer,
bearing, handle, and piston spring compressor
J 37030-2. Remove retaining ring 19 and
slowly release the spring force.
MODULE REBUILD
5. Install two roller bearing assemblies 15 into
the center of pinion gear 14.
WARNING!
Piston springs are highly compressed. Be
extremely careful during installation. Personal
injury can occur if the spring force is not
controlled.
523
NOTE:
Delay installing output oil seal assembly 60.
12. Install valve plug 49 and retaining ring 50.
NOTE:
When installing the Belleville washer, be sure that
the concave side of the washer at the inside diameter
contacts the inner race of the bearing and that the
anti-rotation tang engages the drilled hole in the P3
carrier. Tilt the Belleville washer, tang toward the
bearing, to engage the tang into the hole.
8. Install Belleville washer 58.
CAUTION:
Over-tightening bearing retainer locknut 59 will
damage cone and roller bearing assemblies 17
and 57 and cups 24 and 51.
9. Lubricate output shaft threads and install
locknut 59 so that the Verspel buttons are in
contact with the Belleville washer 58. Replace
current locknut if it does not exhibit 3 Nm
(7.5 lb ft) of running torque.
10. Using special tools J 37035 and J 43278, with
the torque wrench and breaker bar positioned
as shown in Figure 521, rotate the torque
wrench clockwise to tighten bearing retainer
locknut 59 to 185200 Nm (137147 lb ft).
Locknut torque values are for bench assembly
only. If the output module is mounted on the
transmission, tighten the bearing retainer
locknut to 7488 Nm (5564 lb ft).
11. Support retarder housing 41 so that the turning
torque of the P3 carrier assembly 3 can be
measured after installation of bearing retainer
locknut 59. Use tool J 37035 to measure turning torque. Maximum turning torque is 3 Nm
(27 lb inch).
524
MODULE REBUILD
6. Install guide pin 76 into the retarder control
body 75.
7. Install retarder control valve cover gasket 87
and retarder control valve cover 88 on
frontside and separator plate 63 on backside of
retarder control valve body 75.
8. Install O-ring 91 and pressure tap plug 92.
Tighten the plug to 1013 Nm (710 lb ft).
9. Install retarder control body assembly 65, nine
bolts 93, and three bolts 89 that retain it to retarder housing 41. Tighten bolts to 2429 Nm
(1821 lb ft).
CAUTION:
Be sure to remove speed sensor 46. Failure to
remove the speed sensor will result in equipment
damage.
1. Remove output speed sensor bolt 49, sensor
retainer 48, and output speed sensor
assembly 46 from the retarder housing. Remove
O-ring 47 and discard. Measure output speed
sensor resistance (speed sensor resistance
varies by temperature).
Resistance
(Ohms)
Temperature
(C)
Temperature
(F)
250
40
40
340
20
68
450
110
230
Remove
Remove
retarder
only if
NOTE:
Output seal 45 must be removed before retainer
locknut 44 can be removed.
525
526
WARNING!
Piston springs are highly compressed. Be
extremely careful during removal and
installation. Personal injury can occur if the
spring force is not controlled.
2. Remove C5 clutch piston 10 from retarder
stator housing 14 by compressing piston return
spring and retainer assembly 9 using J 37030-3
tool base, washer, bearing, handle, and piston
spring compressor J 37030-2. Remove
retaining ring 8 and slowly release the spring
force.
3. Remove external sealring 11 from C5 clutch
piston 10.
4. Remove internal lip-type sealring 12 from C5
clutch piston 10.
5. If replacement is necessary, remove roller
bearing cup 13 using bearing tool J 3940.
g. Assembly of Retarder Stator (Foldout 10,D)
1. If removed, install bearing cup 13 using
bearing tool J 37033 and drive sleeve J 37034.
2. Install internal lip-type sealring 12 onto C5
clutch piston 10. Install external sealring 11
onto C5 clutch piston 10.
3. Align the tang notch on the back of the C5
clutch piston with the tang on the retarder
stator before installing C5 clutch piston 10 into
retarder stator 14. Install C5 clutch piston 10
into retarder stator 14.
MODULE REBUILD
4. Install spring and retainer assembly 9, aligning
the tab in the spring and retainer assembly with
the notch in retarder stator 14.
WARNING!
Piston springs are highly compressed. Be
extremely careful during installation. Personal
injury can occur if the spring force is not
controlled.
5. Compress piston return spring and retainer
assembly 9 using J 37030-3 tool base, washer,
bearing, handle, and piston spring compressor
J 37030-2. Install external retaining ring 8 and
slowly release the spring force.
CAUTION:
Over-tightening bearing retainer locknut 44 will
damage roller bearings 6 and 42 and bearing
cups 13 and 41. If the torque wrench and breaker
bar positions in Figure 524 are reversed, the
bearing retainer locknut will be overtorqued. Be
sure wrenches are positioned ONLY as shown in
Figure 524.
527
NOTE:
Delay installing output oil seal assembly 45 until
final assembly.
6. Install plug 39 and retaining ring 40.
7. If removed, install spring pin 27 into retarder
valve 26 and insert into valve bore. Install
spring 25, O-ring 24, and plug 23. Use J 42048
to compress plug 23 and install retaining
ring 22.
8. Install output speed sensor assembly 46, with
new O-ring 47, and output speed sensor bolt 49.
Tighten the bolt to 2429 Nm (1821 lb ft).
9. Carefully install temperature sensor assembly 35
into retarder housing 31. Install temperature
sensor retainer 37 and retainer bolt 38. Tighten
the bolt to 2429 Nm (1821 lb ft).
10. If removed, install brass washer 30 onto tachograph plug 29. Install plug 29 into retarder
housing 31. Tighten plug 29 to 6067 Nm
(4549 lb ft).
528
250
40
40
340
20
68
450
110
230
MODULE REBUILD
2. If used, remove the tachograph sensor. If
present, remove plug 29 and washer or
O-ring 28.
3. If not previously removed, remove output
seal assembly 40 using seal removal tool
J 24171-A.
NOTE:
Output seal 40 must be removed before retainer
locknut 39 can be removed.
4. Remove bearing retainer locknut 39 using
special tool J 37035.
NOTE:
b. Disassembly of P3 Planetary Carrier
Assembly (Foldout 10,A)
WARNING!
529
WARNING!
WARNING!
CAUTION:
If the wear on the indexing ring is minor, flip it
over to get a fresh reaction point for the spindle.
Replace the indexing ring if both corners of the
indexing ring are worn. Failure to take corrective
action may allow the spindle to rotate which may
reduce or shut off lubrication to the pinion
bearings and thrust washers.
MODULE REBUILD
NOTE:
Replacement indexing rings should look like the
example in Figure 512. The ring is stamped with
HD5. Replacement spindles should look like the
example in Figure 512. The spindle has a 2
stamped on the rear end.
6. Install four pinion spindles 14 so the lower step
is positioned for proper installation of indexing
ring 10.
7. Install indexing ring 10. Install internal
retaining ring 9.
8. If components were replaced, measure pinion
end play. Pinion end play must not exceed
0.94 mm (0.037 inch). Measure all four pinion
gears.
f. Completion of Rear Cover Assembly
(Foldout 10,A)
NOTE:
When installing the Belleville washer, make sure
that the concave side of the washer at the inside
diameter contacts the inner race of the bearing and
that the anti-rotation tang engages the drilled hole
in the P3 carrier. Tilt the Belleville washer, tang
toward the bearing, to engage the tang into the hole.
J 37035-1
CAUTION:
Over-tightening bearing retainer locknut 39 will
damage cone and roller bearing assemblies 19
and 37 and cups 26 and 36.
4. Lubricate the output shaft threads and install
locknut 39 so that the Vespel buttons are in
V00223.00.03
531
NOTE:
Output seal 29 must be removed before retainer
locknut 28 can be removed.
WARNING!
Piston springs are highly compressed. Be
extremely careful during removal and
installation. Personal injury can occur if the
spring force is not controlled.
1. Remove C6 clutch piston 13 from rear
cover 18 by compressing C5 piston spring and
retainer assembly 12 using J 37030-3 tool
base, washer, bearing, handle, and piston
spring compressor J 37030-2. Remove
retaining ring 11 and slowly release the spring
force.
2. Remove external sealring 14 from C6 clutch
piston 13.
3. Remove internal sealring 15 from C6 clutch
piston 13.
4. If replacement is necessary, remove bearing
cup 16 using bearing tool J 3940.
d. Beginning Rear Cover Assembly
(Foldout 10,B)
1. If removed, install bearing cup 16 using
bearing tool J 37033, and bearing cup 21 using
bearing tool J 37033 and drive sleeve J 37034.
2. Install internal sealring 15 onto C6 clutch
piston 13. Install external sealring 14 onto C6
clutch piston 13.
V05598
532
MODULE REBUILD
4. Install C5 piston spring and retainer assembly
12, aligning the tab in the spring and retainer
assembly with the notch in rear cover 18.
J 37034
WARNING!
Piston springs are highly compressed. Be
extremely careful during installation. Personal
injury can occur if the spring force is not
controlled.
J 43202
V05586
CAUTION:
Over-tightening bearing retainer locknut 29 will
damage roller bearings 9 and 27 and bearing
cups 16 and 21. If the torque wrench and breaker
bar positions in Figure 525 are reversed, the
bearing retainer nut will be overtorqued. Be sure
wrenches are positioned ONLY as shown in
Figure 525.
533
control module parts during removal, cleaning, inspection, and installation. Keep them in
clean containers until they are installed.
Control valve module assembly springs and
NOTE:
Delay installing output oil seal assembly 29.
J 43278
J 37035
a. Removal of Filters
V05589.00.01
534
MODULE REBUILD
c. Disassembly of the Solenoid Valve Body
bolts
46
from
standoff
V09556.00.00
535
WARNING!
Valve springs are highly compressed. Be extremely careful during disassembly. Personal injury can occur if the spring force is not
controlled.
10. Remove PCS3 80, two O-rings 81 and 82,
valve 83, and spring 84.
11. Remove PCS4 85, two O-rings 86 and 87,
valve 88, and spring 89.
12. Remove Main Mod solenoid 90 and two
O-rings 91 and 92.
13. Measure resistance of each solenoid by using
chart in Figure 520.
d. Disassembly of C6 Control Valve Body
NOTE:
C6 control valve body is only in 4700 and 4800 model transmissions.
1. Remove four bolts 154 remove C6 valve body
bracket 153, spring 152, accumulator 151, and
valve body 156.
2. Remove pin 158 for C6 Enable solenoid 160.
Remove nut 164 and plate 163, remove C6 enable solenoid 160, two O-rings 161 and 162,
valve 159, and spring 157.
3. Remove screw 171 and bracket 170. Remove
C6 Clutch solenoid 167, O-rings 168 and 169,
valve 166, and spring 165.
536
WARNING!
Valve springs are highly compressed. Be extremely careful during disassembly. Personal injury can occur if the spring force is not
controlled.
9. Install spring compressor J 35924 (Figure 527).
Compress spring 106, remove valve retention
pin 104, and carefully remove compressor
J 35924 after turning handle counterclockwise
to release spring force.
10. Remove stop 107, spring 106, and main regulator valve 105.
11. Remove valve retention pin 111.
12. Remove clip 110, spring 109, and control main
valve 108.
13. Remove valve retention pin 120.
14. Remove stop 119, spring 118, and C2 latch
valve 117.
MODULE REBUILD
3. Install drain plug 141. Tighten plug to
2532 Nm (1824 lb ft).
4. If removed, install two pins 139.
5. Install gasket 137 and separator plate 136.
h. Assembly of the Main Valve Body
1. Install converter regulator
spring 130, and stop 131.
valve
129,
18. Install main valve body assembly 95 onto seperator plate 136, channel plate gasket 137, and
channel plate assembly 138.
19. Install solenoid separator plate 93 onto main
valve body assembly 115.
537
NOTE:
C6 control valve body is only available in 4700 and
4800 model transmissions.
1. Install spring 157, valve 159, two O-rings 161
and 162, C6 enable solenoid 160, solenoid protective plate 163, push-on nut 164, and solenoid retention pin 158 into C6 valve body 156.
2. Install spring 165, valve 166, two O-rings 168
and 169, solenoid 167, bracket 170 and secure
to C6 valve body 156 with screw 171.
3. Install accumulator plug 151 and spring 152 into
C6 valve body 156.
4. Position C6 control valve body assembly 155
onto separator plate 136, channel plate
assembly 137, and channel plate assembly 138.
5. Install bracket 153 and four bolts 154. Tighten
the bolts to 1013 Nm (710 lb ft).
j. Assembly of the Solenoid Valve Body
1. Install Main Mod solenoid 90, two O-rings 91
and 92.
2. Install spring 89, valve 88, O-rings 86 and 87
and PCS4 85.
3. Install spring 84, valve 83, two O-rings 81 and
and 82, and PCS3 80.
538
SCOPE
Description
32
Tools, Equipment
33
Replacement Parts
34
Careful Handling
36
Assembly Procedures
NOTE:
All parts must be cleaned and lubricated before
assembly.
E01274.01
62.
ASSEMBLY OF TRANSMISSION
CAUTION:
Before beginning assembly, attach bracket
J 41445 and holding fixture J 35926 to the main
housing. Use a hoist to mount the fixture and
housing on repair stand J 29109.
CAUTION:
E01273.01
61
NOTE:
2
3
E01271.01
1
1
C5
2
3
E02516.01
V01272
62
TRANSMISSION ASSEMBLY
2. Measure dimension A, from top of the straight
edge to the selective shim thrust surface on the
main shaft bearing spacer.
3. Measure dimension B, thickness of straight
edge. Subtract dimension B from dimension
Athe remainder is dimension C.
4. Place the retarder or rear cover module output
end down (facing the bench top). Install an
uncompressed gasket on the retarder or rear
cover mounting surface and place a straight
edge across the P3 planetary carrier.
5. Measure dimension D, from top of the straight
edge to the gasket.
6. Measure dimension E from the top of the
straightedge to the thrust bearing contact
surface on the P3 planetary carrier. Subtract
dimension E from dimension Dthe
remainder is dimension F.
7. Dimension G is the remainder of C minus F
and determines the thickness of the selective
shim.
8. Install the proper thickness selective shim and
the thrust bearing.
V01737.00.06
BEARING AND
SHIM REMOVED
STRAIGHT EDGE
DIM. A
UNCOMPRESSED
GASKET IN PLACE
STRAIGHT EDGE
DIM. E
DIM. B
DIM. C
DIM. F
DIM. D
RETARDER
MODEL
NONRETARDER
MODEL
USE P/N
SHIM ID
29501117
1 NOTCH
29501118
2 NOTCHES
29501119
3 NOTCHES
29501120
4 NOTCHES
DIM. G
6.8447.113 mm
0.2700.280 in.
7.1147.383 mm
0.2810.290 in.
7.3847.484 mm
0.2910.295 in.
USE P/N
SHIM ID
29501121
5 NOTCHES
29501122
6 NOTCHES
29512774
0 NOTCHES
V03210.01.00
Figure 67. Main Shaft Selective Shim Measurement for 4000 Product FamilyClose Ratio
63
CAUTION:
BEARING AND
SHIM REMOVED
STRAIGHT EDGE
DIM. A
UNCOMPRESSED
GASKET IN PLACE
STRAIGHT EDGE
DIM. E
DIM. B
DIM. C
DIM. F
DIM. D
RETARDER
MODEL
NONRETARDER
MODEL
USE P/N
SHIM ID
29503218
1 NOTCH
29503219
2 NOTCHES
29503220
3 NOTCHES
29503221
4 NOTCHES
DIM. G
5.6545.923 mm
0.2240.233 in.
5.9246.193 mm
0.2340.244 in.
6.1946.380 mm
0.2450.254 in.
USE P/N
SHIM ID
29503222
5 NOTCHES
29503223
6 NOTCHES
29503224
7 NOTCHES
V03211.01.00
Figure 68. Main Shaft Selective Shim Measurement for 4000 Product FamilyWide Ratio
64
TRANSMISSION ASSEMBLY
k. Installation of P3 Planetary Module (4700 and
4800 Models With Retarder) (Figure 69)
1. Thread special tool J 43020 onto P3 Planetary
Module 2 and use chain hoist to install P3
Planetary Module 2 in Main Housing
Module 1.
2. Install P4 shaft flange 3.
NOTE:
Do not install shim locating ring or selective shim
until final transmission assembly. Measurement for
selective shim is performed during final buildup.
CAUTION:
Over-tightening bolt 3 will damage the bolt. Use
the torque formula in Figure 612 to find the
correct torque value to apply to bolt 3.
3. Install fourteen bolts 3 through C6 adapter
housing module 4 into main housing 1. Tighten
bolts in a star pattern using special tool J 43046
and torque wrench to produce 100120 Nm
(7488 lb ft) at the bolt (Figure 611). Use the
formula in Figure 612 to find the correct
torque wrench value that will apply to the
required torque bolt 3.
1
J 43046
2
3
4
WARNING!
Get help when lifting the C6 adapter housing
module. Assistance from a hoist or another
person may be required. The C6 adapter housing
module weighs approximately 68 kg (150 lb).
5
V05374
J 43046
2
3
4
5
J 43020
V05590
V05375
65
BOLT
(C6 adapter housing
to main housing)
A
TORQUE WRENCH
J 43046
Tw
Ta
CLOCKWISE
ROTATION
L
C6 ADAPTER HOUSING
TOP VIEW
L
L+A
L = Effective length of torque wrench
A = Effective length of special tool
Tw = Torque applied at the wrench (adjusted torque value to be applied with wrench)
Ta = Torque applied at the bolt (ACTUAL torque value specified by service manual)
Tw = Ta X
V05591
66
DIM. B
STRAIGHT EDGE
J 43922
GASKET
INSTALLED
STRAIGHT EDGE
J 43922
DIM. A
DIM. C
MEASURING
BLOCK (2), J 43922
DIM. E
DIM. F
DIM. D
No Gasket
SUPPORTS
USE P/N
SHIM ID
29530516
29530517
1 NOTCH
29530518
2 NOTCHES
29530519
3 NOTCHES
29530520
4 NOTCHES
29530521
5 NOTCHES
29530522
6 NOTCHES
29530523
7 NOTCHES
29530524
8 NOTCHES
V05380.00.03
Figure 613. P3 Planetary Shim Measurement (4700 and 4800 Models With Retarder)
67
DIM. B
STRAIGHT EDGE
J 43922
GASKET
INSTALLED
STRAIGHT EDGE
J 43922
DIM. A
DIM. C
MEASURING
BLOCK (2), J 43922
DIM. E
DIM. F
DIM. D
No Gasket
SUPPORTS
USE P/N
SHIM ID
29530516
29530517
1 NOTCH
29530518
2 NOTCHES
29530519
3 NOTCHES
29530520
4 NOTCHES
29530521
5 NOTCHES
29530522
6 NOTCHES
29530523
7 NOTCHES
29530524
8 NOTCHES
V05612.00.03
Figure 614. P3 Planetary Shim Measurement (4700 and 4800 Models With Rear Cover)
68
TRANSMISSION ASSEMBLY
3. Thread an M14 eye bolt into the retarder output shaft and lift retarder module 1 onto main
housing module 8. If used, install the rear support bracket.
WARNING!
Get help when lifting the retarder module.
Assistance from a hoist or another person may be
required. The retarder module weighs
approximately 34 kg (75 lb).
2
2
1
2
8
7
4
6
3
6 5
2
5
5
3
OR
3
V06844
69
NOTE:
DO NOT reuse a tang once it has been bent. Use a
new locknut retainer 43 (Foldout 10,A).
J 37034
J 43024
V05594
4
2
4
4
4
3
5
7
4
7
9
8
6
6
OR
7 8
V06845
Figure 617. Installation of Retarder and Output Shaft Module (4700 and 4800 Models)
610
TRANSMISSION ASSEMBLY
s. Installation of Rear Cover Module
(Except 4700 and 4800 Models) (Figure 618)
1. Install guide bolts to ease rear cover 2
installation and keep gasket 1 in place.
2. Install a NEW rear cover gasket 1 on main
housing 4.
3. Place rear cover module 2 on main housing 4
using a hoist and sling as a lifting fixture.
Install rear support bracket 3 (Foldout 10,B), if
used.
4. Install nineteen bolts 3 (Figure 618).
Tighten bolts to 100120 Nm (7488 lb ft).
CAUTION:
Do not reuse a tang once it has been bent. Install
a new locknut retainer 38 (Foldout 10,A).
6. Install output shaft oil seal 5 (Figure 618)
using tool J 37031.
CAUTION:
Do not reuse a tang once it has been bent. Install
a new locknut retainer 28 (Foldout 10,D).
4
1
3
2
V06867
611
1
2
J 43278
J 37035
6
7
5
V05589.00.01
V05580
4
4
J 37034
4
J 43024
4
4
BOLT,
METRIC HEAVY
(5) MARKED 5
4
4
5
5
V05595
V07494
612
TRANSMISSION ASSEMBLY
u. Installation of Converter Housing Module
(Figure 623)
1. Install guide bolts to ease converter housing 1
installation and keep gasket 2 in place.
2. Position the transmission input end up. Install a
NEW converter housing gasket 2 on main
housing module 4.
3. Lower converter housing 1 onto main
housing 4. If the transmission is PTO
equipped, rotate the PTO drive gear to align the
gear tangs with the charging pump.
4. Install seven bolts 3 into the inside of converter
housing 1. Use mechanical fingers, or a similar
tool, when installing these bolts.
5. Remove the two guide bolts and install the
remaining bolts 3. Tighten all bolts 3 to 5161 Nm
(3845 lb ft).
V06868
613
5
1
RESTRICT MOVEMENT
USE HOIST AND SLING
J 38564
VIEW A
VIEW B
VIEW C
VIEW D
Figure 624. Torque Converter Module Installation and Selective Shim Measurement
614
VL06869.01.00
TRANSMISSION ASSEMBLY
NOTE:
Dimension C shown in Table 61 includes a
correction due to internal deflection caused by the
2734 Nm (2025 lb ft) bolt torque applied to gauge
J 38548. Correct torque value is critical to selection
of the proper shim.
6. Measure from top of tool J 38548 to face of
turbine shaft and record it as dimension B
(Figure 624, View D). Subtract dimension B
from dimension A to determine dimension C.
(Dimension A is the height of tool J 38548,
100.00 mm; 3.937 inch.)
Use P/N
ID
No.
29505688
29505681
29505682
29505683
29505684
29505685
29505686
29507793
29507794
615
NOTE:
Apply transmission fluid to the control module bolts
as they are installed. This will provide lubrication
during the installation and tightening and prevent
thread seizure.
WARNING!
Get help when lifting the control module.
Assistance from another person may be
required. The control module weighs
approximately 25 kg (55 lb).
4
V09785.00.00
616
against
the
TRANSMISSION ASSEMBLY
6. Install the remaining seven bolts 7 into cooler
housing 3. Tighten nine bolts 7 to 5161 Nm
(3845 lb ft).
10. Install two headless guide bolts into each manifold to cooler mating surface.
11. Install gaskets 6 over the headless guide bolts.
WARNING!
To help avoid personal injury, securely support
the cooler in its installed position before
installing the bolts retaining the cooler to the
manifold. The cooler weighs 30 kg (64 lb); use
care when handling the cooler.
12. Install cooler 7 over the headless guide bolts
and install two M10 x 1.5 x 60 bolts 1 so that
the cooler is retained to the cooler manifold.
Do not install bolts into the inlet or outlet hose
adapter bolt holes. Tighten bolts finger tight.
4
3
1
11
4
5
8
2
6 7
8
19
18 17
19
18 17
11
15
9
10
10
16
11
12
14
13
11
V06843
617
1. If
not
previously
installed,
install
transmission breather 20. Tighten breather to
1216 Nm (912 lb ft).
20
ENGINE
SPEED
SENSOR
2
TURBINE 1
SPEED
SENSOR
7
5
9
OUTPUT
SPEED
SENSOR
15
13
16
10
11
17
18
19
12
14
V06837.03.00
618
TRANSMISSION ASSEMBLY
ab. Removal of Transmission From Repair Stand
WARNING!
NOTE:
2
4
3
1
2
4
V06836
619
620
NOTE:
72.
SPRING DATA
Description
Foldout 4,B
mm
(inches)
66.91
2.634
10
12
6.53
0.257
14
0.51
0.020
14
8.51
0.335
0.38
0.015
15
0.15
0.006
15
11.79
0.464
18
66.69
2.626
19
61.77
2.432
24
9.45
0.372
36
88.99
3.504
89.19
3.511
14, 18
Foldout 5,B
6
8, 14
1.18
0.047
8, 14
1.66
0.065
0.31
0.012
13
71
Description
mm
(inches)
Foldout 6,A
89.19
3.511
9, 10
19.04
0.750
9, 10
150.25
5.915
9, 10, 11
0.30
0.012
9, 10, 13
0.10
0.004
11
0.15
0.006
12
66.93
2.635
66.67
2.625
0.13
0.005
119.81
4.717
16, 17
16, 17, 20
20
25
1.00
0.040
25
1.44
0.056
36.14
1.423
Foldout 6,B
0.65
0.026
1.01
0.039
0.38
0.015
12
120.27
4.735
29
5.90
0.232
29, 39
0.15
0.006
30, 38
0.25
0.010
30, 38
2.92
0.115
30, 38
0.20
0.008
31, 37
0.25
0.010
31, 37
2.41
0.095
32
9.90
0.390
0.38
0.015
7.90
0.311
34, 36
39
72
Description
mm
(inches)
0.13
0.005
0.15
0.006
2.82
0.111
0.38
0.015
8, 21, 29
0.25
0.010
8, 21, 29
3.485
0.137
4.00
0.157
9, 20, 30
0.25
0.010
9, 20, 30
3.25
0.128
11, 23
4.91
0.193
19, 28
1.15
0.045
1.15
0.045
5, 18
7
8, 21
43
Foldout 8
7, 8
52.98
2.085
7, 8
35.92
1.414
7, 8
0.38
0.015
0.94
0.037
89.32
3.516
Foldout 9,A
P1 PLANETARY MODULE
10, 13
1.40
0.055
10, 13
0.12
0.005
0.38
0.015
0.94
0.037
53.23
2.096
15
Foldout 9,B
P2 PLANETARY MODULE
9, 12
1.40
0.055
9, 12
0.12
0.005
0.38
0.015
15
73
Description
Foldout 9,C
(inches)
0.94
0.037
1.40
0.055
0.12
0.005
27
3.24
0.128
0.25
0.010
28
3.68
0.145
32
0.94
0.037
38
113.33
4.462
40
1.40
0.055
40
0.12
0.005
0.94
0.037
27, 28
Foldout 10,A
36.14
1.423
0.38
0.015
15, 18
1.40
0.055
15, 18
0.12
0.005
Foldout 10,B
REAR COVER AND OUTPUT SHAFT MODULE (47000 and 4800 models)
36.14
1.423
0.38
0.015
0.94
0.037
36.14
1.423
Foldout 10,C
13, 16
1.40
0.055
13, 16
0.12
0.005
27, 30
139.72
5.501
0.38
0.015
29
74
mm
Description
Foldout 10,D
mm
(inches)
36.14
1.423
0.38
0.015
139.72
5.501
0.38
0.015
85.0
3.346
16, 19
18
Foldout 12,A
1, 4, 5, 6, 9,
10, 11, 12
75
76
Ref.
26
22
20
25
25
10
22
17
22
12
20
35
25
70
Foldout
4,B
6,A
6,B
6,B
6,B
9,C
10,A
10,B
10,C
10,D
10,C
10,D
10,C
Exhaust Backfill
C5 Return
C5 Return
C5 Return
C5 Return
C5 Return
C4 Return
C3 Return
C1 Return
C1 Return
C2 Return
Main Relief
Stator
Spring
23049391 No Code
29515692 No Code
29515692 No Code
29503036 No Code
29503036 No Code
29503036 No Code
29503036 No Code
29530488 No Code
29542504 Pink
29542504 Pink
29537301 No Code
29509453 No Code
29505719 No Code
29507709 No Code
29501300 No Code
Part No.
Color
Code
20.40
11.4
11.4
12*
12*
12*
12*
11.6*
13.8
13.8
11.8*
12*
11.5*
10
N/A
No. of
Coils
N/A
17.96
(0.707)
19.06*
(0.750)
16.0*
(0.630)
16.8*
(0.661)
15.0*
(0.590)
15.0*
(0.590)
17.00*
(0.669)
17.00*
17.00*
17.00*
17.00*
36.17
(1.424)
36.17
(1.424)
8.00
(0.315)
3.25
(0.128)
2.04*
(0.080)
2.10*
(0.083)
2.17*
(0.085)
2.10*
(0.083)
2.10*
(0.083)
2.03*
(0.080)
2.10*
(0.083)
2.10*
(0.083)
2.10*
(0.083)
2.10*
(0.083)
4.12
(0.162)
4.12
(0.162)
0.61
(0.024)
Spring
OD
mm (in.)
N/A
Wire Dia
mm (in.)
29.2
(1.15)
114.3
(4.500)
114.3
(4.500)
57.3*
(2.26)
57.3*
(2.26)
57.3*
(2.26)
57.3*
(2.26)
53.80
(2.11)
55.55*
(2.187)
55.55*
(2.187)
52.89*
(2.082)
57.53*
(2.265)
70.76*
(2.786)
18.2
(0.716)
91.1
(3.587)
91.1
(3.587)
37.6
(1.48)
37.6
(1.48)
37.6
(1.48)
37.6
(1.48)
37.7
(1.48)
39.25
(1.545)
39.25
(1.545)
34.5
(1.358)
34.8
(1.37)
28.2
(1.110)
40.7
(1.60)
5.7
(0.224)
17.8
(0.70)
52.4
(2.06)
mm
(in.)
2.67
(0.60)
213.3
(47.95)
213.3
(47.95)
3086**
(693.8)
3086**
(693.8)
3086**
(693.8)
3086**
(693.8)
3611**
(811.8)
143.5**
(32.3)
143.5**
(32.3)
4893**
(1100.0)
4649**
(1045.4)
5185**
(1165.6)
474
(106.5)
0.9
(0.2)
N
(lb)
Approx.
Free
Length
mm (in.)
Ref.
59
78
67
85
74
50
130
123
175
180
100
112
134
Foldout
10,D
10C
10D
10C
10D
11
11
11
11
11
11
11
11
Converter Regulator
Control Main
Connector Flow
C6 Clutch
C6 Enable
C2 Latch
C1 Latch
Accumulator
Relay Valve
Relay Valve
Regulator Valve
Regulator Valve
Exhaust Backfill
Spring
12.19
(0.480)
7.43
(0.293)
16.26
(0.640)
11.43
(0.450)
10.75
(0.423)
11.05
(0.435)
14.10
(0.555)
14.8
(0.583)
11.00
(0.433)
0.97
(0.038)
0.97
(0.038)
0.97
(0.038)
0.97
(0.038)
0.94
(0.037)
1.37
(0.054)
1.32
(0.052)
1.22
(0.048)
0.67
(0.026)
1.37
(0.054)
1.83
(0.072)
1.53
(0.060)
Lt. Green/
10.45
Silver
Lt. Green/
10.45
Silver
Lt. Green/
10.45
Silver
Lt. Green/
10.45
Silver
Dk. Green
15.90
Dk. Blue
29507456 Pink
29542926 Orange
23049326 No Code
29542936 No code
29542949 No code
29542929 Blue
8678805
29529310
29529310
29529310
29529310
10.20
10
10
6.90
11
12
12.19
(0.480)
12.19
(0.480)
12.19
(0.480)
8.00
(0.315)
0.61
(0.024)
20.40
23049391 No Code
Part No.
No. of
Coils
Spring
OD
mm (in.)
Color
Code
Wire Dia
mm (in.)
30.3
(1.19)
44.6
(1.76)
42.1
(1.66)
6.5
(0.26)
16.71
(0.658)
41.3
(1.63)
46.2
(1.82)
30.82
(1.213)
38.15
(1.502)
38.15
(1.502)
38.15
(1.502)
38.15
(1.502)
29.2
(1.15)
Approx.
Free
Length
mm (in.)
22.8
(0.90)
24.2
(0.95)
17.0
(0.67)
3.45
(0.14)
12.84
(0.506)
19.0
(0.75)
29.2
(1.15)
18.20
(0.717)
17.70
(0.697)
17.70
(0.697)
17.70
(0.697)
17.70
(0.697)
18.2
(0.716)
mm
(in.)
53.759.3
(12.113.3)
131145
(29.532.6)
49.260.2
(11.0613.53)
3.24.2
(0.720.94)
18.1421.86
(4.084.91)
64.178.3
(14.417.6)
16.718.9
(3.754.25)
27.59
(6.20)
14.70
(3.31)
14.70
(3.31)
14.70
(3.31)
14.70
(3.31)
2.67
(0.60)
N
(lb)
77
78
79
104
108
71
76
84
89
66
11
11
11
11
11
11
11
11
TCC
PCS4
PCS3
PCS2
PCS1
Main Regulator
Lube Regulator
Diagnostic
Spring
* Individual Springs
** For the complete Spring Assembly
OD at larger end
Ref.
Foldout
29542938 No Code
29542936 No Code
29542936 No Code
29542936 No Code
29542936 No code
23049327 Red
29542941 No Code
Part No.
Color
Code
15
13
No. of
Coils
Spring
OD
mm (in.)
10.50
(0.433)
11.10
(0.437)
22.0
(0.866)
11.05
(0.435)
11.05
(0.435)
11.05
(0.435)
11.05
(0.435)
11.05
(0.435)
Wire Dia
mm (in.)
1.30
(0.039)
1.22
(0.048)
2.87
(0.113)
0.67
(0.026)
0.67
(0.026)
0.67
(0.026)
0.67
(0.026)
0.67
(0.026)
6.5
(0.26)
6.5
(0.26)
6.5
(0.26)
6.5
(0.26)
6.5
(0.26)
98.5
(3.88)
46.3
(1.82)
27.03
(1.06)
Approx.
Free
Length
mm (in.)
3.45
(0.14)
3.45
(0.14)
3.45
(0.14)
3.45
(0.14)
3.45
(0.14)
54.6
(2.15)
23.5
(0.93)
15.49
(1.02)
mm
(in.)
3.24.2
(0.720.94)
3.24.2
(0.720.94)
3.24.2
(0.720.94)
3.24.2
(0.720.94)
3.24.2
(0.720.94)
305337
(68.675.8)
46.551.3
(10.511.5)
2.45
(0.78)
N
(lb)
OWNER ASSISTANCE
dealer
Type and make of vehicle/equipment
Transmission model number, serial number,
history
Step ThreeIf you are still not satisfied after contacting the Regional Customer Support Manager, present
the entire matter to the Home Office by writing to the
following address:
Allison Transmission
Manager, Warranty Administration
P.O. Box 894, Mail Code 462-470-PF9
Indianapolis, IN 46206-0894
The inclusion of all pertinent information will assist
the Home Office in expediting the matter.
When contacting the Home Office, please keep in
mind that ultimately the problem will likely be resolved at the distributorship or dealership utilizing
their facilities, equipment, and personnel. Therefore, it
is suggested that Step 1 be followed when experiencing a problem.
Your purchase of an Allison Transmission product is
greatly appreciated, and it is our sincere desire to
assure complete satisfaction.
81
SERVICE LITERATURE
(Table 81)
Literature
Number
GN3433EN
GN2055EN
OM3749EN
OM3656EN
OM3750EN
OM4119EN
OM3349EN
OM3752EN
OM3753EN
OM3654EN
MT4015EN
MT4085EN
PC2456EN
CD2456EN
PO4016EN
SM4014EN
TS3989EN
SA2229EN
82
F OLDOUT 1
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
10
11
12
13
14
26
25
24
23
22
21
20
19
18
17
16
15
V05513.01.02
F OLDOUT 2
1
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
28
10
11
12
13
14
15
Lockup clutch/damper
Converter turbine
Converter stator
Converter pump
Charging oil pump
Front support
Breather
Main housing
Main shaft
C3 clutch
C4 clutch
P2 sun gear
C5 clutch
P3 sun gear
Output shaft
Rear cover
C5 piston
P3 module
Oil level sensor
Control module
P2 module
P1 module
C2 clutch
C1 clutch
Turbine shaft
PTO drive gear
Ground sleeve
Converter housing module
28
27
26
25
24
23
22
21
Foldout 2. 4500 Model (Wide Ratio) Transmission With PTO ProvisionCross Section
20
19
18
17
16
V05515.01.02
F OLDOUT 3
1
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
10
11
12
13
14 15
16
17
27
Foldout 3.
26
25
24
23
22
21
20
19
18
V05514.01.01
Foldout 3,A
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
28
29
30
31
32
33
34
35
Foldout 3,A
Lockup clutch/damper
Converter turbine
Converter stator
Converter pump
Charging oil pump
Front support
Main housing
Main shaft
C3 clutch
C4 clutch
P2 sun gear
Shim
C5 clutch
P3 sun gear
C5 piston assembly
C6 adapter housing module
C6 clutch
P4 ring gear
Rear cover
Output shaft
C6 piston
P4 planetary
P4 sun gear
Selective shim
P4 shaft flange
P3 planetary
Oil level sensor
Control valve assembly
P2 planetary
P1 planetary
C2 clutch
C1 clutch
Turbine shaft
Converter ground sleeve
Converter housing
F OLDOUT 3,A
1
35
34
10
11
12
13
14
15
33
16
25
32
31
30
29
28
27
26
17
18
24 23 22
19
20
21
V05265.05.00
Foldout 3,B
Foldout 3,B
Lockup clutch/damper
Converter turbine
Converter stator
Converter pump
Charging oil pump
Front support
Main housing
Main shaft
C3 clutch
C4 clutch
P2 sun gear
Shim
C5 clutch
P3 sun gear
C5 piston assembly
C6 adapter housing module
C6 clutch
P4 ring gear
Retarder stator
Retarder rotor
Retarder and output shaft module
Output shaft
C6 piston
P4 planetary
P4 sun gear
Selective shim
P4 shaft flange
P3 planetary
Control valve assembly
P2 planetary
P1 planetary
C2 clutch
C1 clutch
Turbine shaft
Converter ground sleeve
Converter housing
F OLDOUT 3,B
1
36
35
10
11
12
13
14
15
34
16
27
33
32
31
30
29
28
Foldout 3,B. 4700 and 4800 Model Transmission With RetarderCross Section
17
18
26 25 24
19
20
21
22
23
V09805.00.00
Foldout 3,C
Foldout 3,C
Lockup clutch/damper
Converter turbine
Converter stator
Converter pump
Charging oil pump
Front support
Oil vent assembly
Main housing
Main shaft
C3 clutch
C4 clutch
P2 sun gear
Shim
C5 clutch
P3 sun gear
C5 piston assembly
C6 adapter housing module
C6 clutch
P4 ring gear
Retarder stator
Retarder rotor
Retarder and output shaft module
Output shaft
C6 piston
P4 planetary
P4 sun gear
Selective shim
P4 shaft flange
P3 planetary
Control valve assembly
P2 planetary
P1 planetary
C2 clutch
C1 clutch
Turbine shaft
PTO drive gear
Converter ground sleeve
Converter housing
F OLDOUT 3,C
1
38
37
36
35
34
10
11 12
13
33
14
15
16
29
32
31
17
28
18
27
30
Foldout 3,C. 4700 and 4800 Model Transmission With Retarder and PTO ProvisionCross Section
19
26
20
25
21
22
23
24
V05646.05.00
F OLDOUT 4,A
3
2
4
5
6
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
28
29
30
31
32
33
34
35
36
37
38
39
40
41
Flexplate
Flexplate
Bolt, M8 x 1.25 x 25 (28), A
Flexplate adapter assembly
Ring gear
Flexplate adapter
Wear plate
Bolt, 516-18 x 2 (6), A
Bolt, M8 x 1.25 x 25 (12), A
Flexplate assembly
Bolt plate (6)
Flexplate
Flexplate
Bolt, M8 x 1.25 x 25 (16 or 28), A
Flexplate adapter assembly
Ring gear
Flexplate adapter
Wear plate
Bolt (2), A
Torque
A
Nm
2429
lb ft
1821
8
9
10
11
13
12
14
15
16
17
18
20
19
21
22
23
24
25
26
27
28
31
32
33
29
34
30
35
36
37
38
39
40
41
L00182
F OLDOUT 4,B
1
2
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
28
29
30
31
32
33
34
10
4
11
5
12
16
13
17
15
18
19
21
22
23
24
26
27
14
28
Torque
A
B
C
Nm
5060
3035
2429
lb ft
3744
2226
1821
29
25
30
31
20
32
33
34
V06850.01.00
Foldout 5
3 Converter housing
5 O-ring
6 Bushing
7 Bearing retainer
8 Sealring
9 Sealring
Nm
1216
2429
5161
Foldout 5
Nm
5161
2429
1216
lb ft
3845
1821
912
F OLDOUT 5
A
B
1
1
4
24
25
26
6
7
8
4
9
20
15
10
10
16
11
9
7
17
18
12
21
13
11
14
23
19
22
29
28
27
V05395
V03918.02
Foldout 6
A
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
Torque
A
Nm
5161
lb ft
3845
B
1
2
3
4
5
6
Foldout 6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
28
29
30
31
32
33
34
35
36
37
38
39
40
41
42
43
F OLDOUT 6
A
3
4
8
5
7
12
11
10
13
21
14
22
15
23
10
16
17
18
24
11
19
25
12
13
16
20
26
15
27
28
14
17
29
33
18
20
30
34
19
31
35
36
21
35
37
25
26
38
32
23 22
24
39
40
41
42
V02818.01
43
V06870.01.00
F OLDOUT 7
2
4
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
28
29
30
31
32
33
34
35
36
37
Nm
5161
2429
1
5
6
7
8
14
11
15
9
29
10
12
26
16
27
13
17
25
28
34
37
18
35
23 24
36
lb ft
3845
1821
33
22
31
21
19
20
30
32
V04763.06.00
F OLDOUT 8
WIDE RATIO
4
1
5
2
6
1
1
1
1
1
1
1
1
2
Wide Ratio
3
4
5
6
7
Close Ratio
3
4
5
6
7
8
CLOSE RATIO
4
1
5
2
6
V06878
Foldout 9
1 P1 planetary module
1 P2 planetary module
2 Retaining ring
4 Retaining ring
5 P1 indexing ring
5 P2 indexing ring
7 P2 planetary carrier
8 P1 planetary carrier
8 Bushing
9 P1 carrier bushing
15 P2 ring gear
Foldout 9
F OLDOUT 9,A,B
A
1
2
14
15
3
5
4
5
6
7
7
15
8
9
14
6
9
13
10
10
11
11
12
12
13
V06852
V03630.01
F OLDOUT 9,C
1 P3 carrier module
25 O-ring, 8.92 ID
3 P3 indexing ring
4 P3 planetary carrier
5 P4 shaft flange
29 C6 backplate
30 P4 sun gear
31 Thrust bearing
32 P4 carrier assembly
18 Piston
19 Piston OD sealring
20 Piston ID lip-type sealring
21 Adapter housing assembly
22 Adapter housing
23 Plug assembly (2), B
13
10
8
35 Indexing ring
20
12
19
6
8
15 Piston assembly
18
15
17
4
14
16
12
3
11
38 P4 carrier bushing
26
27
21
28
24
25
23
25
24
30
29
46 P4 ring gear
31
32
43
Nm
100120
1013
44
lb ft
7488
710
46
45
47
33
34
37
35
39
38
36
48
49
41
42
40
V06854.01.00
Foldout 9,C. P3 Planetary Module and C6 Adapter Housing Module (4700 and 4800 Models)Exploded View
F OLDOUT 10,A
1 Rear cover gasket
25 Internal sealring
3 Washer
28 Brass washer
29 Tachograph plug, C
7 Bushing
30 Rear cover
8 Output shaft
21
12 Thrust washer
38 Belleville washer
20
24
11 P3 planetary carrier
23
33 O-ring
1
22
10 P3 indexing ring
19
35
25
32
26
34
27
41
33
30
9
10
31
11
29
28
12
13
31
Torque
A
B
C
D
Nm
100120
2429
6067
7488
lb ft
7488
1821
4549
5565
14
36
15
16
37
17
38
18
39
40
V06856.01.00
F OLDOUT 10,B
1 Rear cover gasket
2
7 Bushing
8 Output shaft
9 Roller bearing assembly
8
9
11
14 External sealring
12
13
14
10
18 Rear cover
23
15
19 Tachograph plug, B
22
16
20 Washer
24
17
30
25
18
26
27
19 20
28
27 Belleville washer
28 Bearing retainer locknut
29
21
Nm
100120
6067
2429
lb ft
7488
4450
1821
V06858.01.00
Foldout 10B. Rear Cover and Output Shaft Module (4700 and 4800 Models)Exploded View
32 Retaining ring
33 Valve plug
34 O-ring
5 Bushing
35 Valve spring
6 Output shaft
36 Retarder valve
37 Spring pin
8 P3 indexing ring
9 P3 planetary carrier
39 Tachograph plug, A
10 Thrust washer
40 Washer
41 Retarder housing
42 Gasket
43 Cover
46 O-ring
47 Retainer
49 Valve plug
50 Retaining ring
21 C5 clutch piston
54 O-ring
25 Retarder stator
26 O-ring
27 Retarder sealring
58 Belleville washer
29 Rotor assembly
30 Retarder sealring
Foldout 10,C
63 Separator plate
91 O-ring
92 Pressure tap plug, F
68 O-ring
69 Spring
70 Exhaust backfill valve
72 Solenoid
97 Gasket
73 O-ring seal
98 Jumper manifold
74 O-ring
77 Regulator valve
78 Spring
79 Straight thread plug assembly
80 O-ring
81 Straight thread plug
82 Straight thread plug assembly
83 Straight thread plug
Torque
A
B
C
D
E
F
G
Nm
6067
2429
1215
*
100120
1013
5161
lb ft
4549
1821
911
*
7488
710
3845
84 O-ring
85 Spring
86 Relay valve
Foldout 10,C
F OLDOUT 10,C
1
17
19
20
21
18
22
3
2
4
23
24
25
6
7
8
26
9
10
11
12
13
14
15
65
16
66 67
68
69
71 70
62
48
52
27
45
72
73
74
47
46
90
89
64
91
92
93
75
61
88
28
87
63 76
54 55 56
30
29
38
39
41
49
40
50
51
37
86
77
78
79
80
81
53
85 82
84
83
57
58
59
31
35
32
36
33
34
60
42
43
44
96
94
91
95
100
97
101
98
99
V06859.01.01
F OLDOUT 10,D
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
28
29
30
31
32
33
34
35
36
37
38
39
40
41
42
43
44
45
46
47
48
49
50
51
52
53
54
55
56
57
58
59
60
61
62
63
64
65
66
67
68
69
70
71
72
73
74
75
76
77
78
79
80
81
82
83
84
85
86
87
88
89
90
Nm
1215
6067
*
2429
100120
1013
5161
lb ft
911
4549
*
1821
7488
710
3845
1
4
3
5
6
9
10
7
11
2
12
13
14
15
54
55 56
57
58
60 59
38
20
16
35
61
62
63
51
37
36
50
79
78
53
80
81
82
64
77
17
76
52 65
47 48 49
19
18
28
29
31
39
30
40
75
66
68 67
69
70
46
41
27
74 71
73
72
42
43
44
21
25
22
26
23
24
45
32
33
34
89
88
86
83
90
84
85
Foldout 10D. Retarder and Output Shaft Module (4700 and 4800 Models)Exploded View
87
V06860.01.01
51
52
53
54
55
56
57
58
59
60
61
62
63
64
65
66
67
68
69
70
71
72
73
74
75
76
77
78
79
80
81
82
83
84
85
86
87
88
89
90
91
92
93
94
95
96
97
98
99
Foldout 11
Retention pin 3 OD 43
Lube regulator valve
Spring
Valve stop
Retention pin 5 OD x 43
Main regulator valve
Spring
Valve stop
Control main valve
Spring
Clip
Retention pin, 2.5 OD x 40
Solenoid assembly
O-ring
O-ring
Control valve body
Spring pin, 5 OD x 55
C2 latch valve
Spring
Valve stop
Retention pin, 5 OD x 43
Exhaust backfill valve
Spring
Valve stop
Retention pin, 5 OD x 43
C1 latch valve
Spring
Valve stop
Retention pin, 5 OD x 43
Converter regulator valve
Spring
Valve stop
Retention pin 3 OD x 43
Bolt M6 x 1.0 x 45 (2), A
Oil level sensor assembly
Ferrule Viton (2)
Separator plate
Channel plate gasket
Channel plate assembly
Dowel pin (2)
Channel plate
Oil drain plug assembly, D
O-ring
Pressure tap plug assembly
Foldout 11
144
145
146
147
148
149
150
151
152
153
154
155
156
157
158
159
160
161
162
163
164
165
166
167
168
169
170
171
172
173
174
O-ring
Pressure tap plug (9), A
Filter cover (2)
Filter cover gasket (2)
O-ring (2)
O-ring (2)
Oil filter (2)
Accumulator plug
Accumulator spring
Accumulator retaining bracket
Bolt, M6 x 1.0 x 60 (4), A
C6 clutch body assembly
C6 clutch body
Spring
Retention pin 2.5 OD x 30
C6 enable valve
Solenoid assembly
O-ring
O-ring
Solenoid protective plate
Push-on nut
Spring
C6 clutch trim valve
Solenoid assembly
O-ring
O-ring
Solenoid retaining bracket
Screw
Case gasket
Bolt, M10 x 1.5 x 55 (34), E
Bolt, M10 x 1.5 x 100 (25, 4 inch sump), E
Torque
Nm
lb ft
A
B
C
D
E
1013
58
2.53.5
2532
5161
710
46
2231 lb inch
1824
3845
F OLDOUT 11
1 (Cont'd)
93
99
95
98
10
9
96
100
128
11
132
8
12
104
43
44
39
42
103
101
107
135
106
111
14
133
134
102
124
120
94
97
110
105
46
109
45
40 41
108
13
112
3
30
129
38
26
6
5
126
23
36
34
33
123
117
118
20
19
119
18
150
16
17
31
116
122
24
32
172
121
21
22
35
115
127
15
25
114
125
131
29
28
27
37
113
130
136
137
149
57
54
47
154
62
48
55
64
49
66
53
56
67
139
146
151
68
51
140
69
70
91
92
61
72
157
73
74
59
85
86
60
76
87
159
160
161
75
171
158
162
141
89
143
88
80
155
156
71
90
81
170
167
82
84
83
138
147
152
52
58
153
65
50
148
63
169
168
163 164
166
78
144
142
145
165
79
77
173
V09483.00.00
174
V09482.00.00
Foldout 12
1 Output flange
3 Slinger
14 Straight fitting
4 Output flange
5 Output flange
6 Output flange
18 PTO gasket
8 Slinger
9 Output yoke
10 Output yoke
21 Hose assembly
11 Output yoke
12 Dropbox coupling
13 Shipping cover
24 PTO gasket
14 Shipping cover
15 O-ring, 75.9 mm ID
26 Hose assembly
16 O-ring, 9.1 mm ID
27 90 degree fitting
17 Retaining plate
Nm
3035
7080
B
1 Converter shipping bracket (3)
33 Sealring
34 Piston
Torque
A
10 90 degree fitting
Foldout 12
Nm
5161
lb ft
3845
F OLDOUT 12A,B
B
3
1
4
5
2
13
14
15
16
5
11
8
10
12
120
250
10
0
0
12
31
19
17
29
28
TRANS
OIL
TEMP
20
30
C
300
F
30
8
150
18
32
10
33
13
21
22
34
32
33
11
15
24
16
25
1
17
18
12
14
27
23
26
V07331.01.00
V07030.03.00
F OLDOUT 12,C
1
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
3
11
12
4
13
24
15
14
23
16
21
22
17
18
19
10
20
9
5
Torque
A
B
C
Nm
2429
5161
100120
lb ft
1821
3845
7488
8
6
6
V07034.01.00
F OLDOUT 13
LOCKUP
LUBE
FILTER
COOLER
CONVERTER OUT
LUBE
LUBE
CONVERTER IN
TORQUE
CONVERTER
Orifice
EX
EX
CONVERTER
REGULATOR
CONVERTER
FLOW
EX
LUBE
REGULATOR
REAR
SPLITLINE
TCC *
EX
EX
PCS1
N/O
N/C
EX
PCS2
N/O
EX
PCS4
N/C
EX
PCS3
N/C
EX
EX
EX
EX
Accumulator
Accumulator
Accumulator
EX
EX
CONTROL
MAIN
Accumulator
EX
EX
MAIN
EX
EX
MAIN
FILTER
SS1
N/C
Pressure
Relief
EX
Orifice
***
PS1
DIAGNOSTIC
EX
PCS6
N/C
EX
EX
SS2
N/C
EX
MAIN
REGULATOR
PUMP
EX
6-Speed
Only
EX
EXHAUST
BACKFILL
Accumulator
MAIN
MOD **
N/C
EX
C2
LATCH
EX
EX
C1
LATCH
EX
SUCTION
FILTER
EX
C1
C2
C1
C3
C2
C4
C3
C5
C4
SUMP
C6
C5
C6
NOTES:
LEGEND:
* TCC Solenoid is generally ON from 2nd-range thru 6th-range
MAIN
** Main Mod Solenoid may be ON in Reverse, Neutral, Low (7-speed),
CONTROL MAIN
1st, or 2nd as determined by calibration.
EXHAUST
*** PS1 = Diagnostic Pressure Switch
SUCTION
MAIN MOD
= 7-Speed Transmissions only
COOLER/LUBE
EX. BACKFILL
CONVERTER
C5
V09253.00.00