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3000
PRODUCT FAMILY
ALLISON 4th GENERATION CONTROLS
SM4013EN
200906
SM4013EN
Service
Manual
2009 JUNE
SM4013EN
Allison Transmission
Allison 4th Generation Controls
VOCATIONAL MODELS
3000 Product Family
3000
3000
3000
3000
3000
3000
EVS
HS
MH
PTS
RDS
TRV
Printed in USA
3200
3200
3200
3200
3500
3500
MH
ORS
SP
TRV
EVS
ORS
3500 RDS
3500 SP
3700 SP
B 300
B 400
T 250
T
T
T
T
T
T
255
260
265
270
280
310
T 325
T 350
T 375
TRADEMARK USAGE
The following trademarks are the property of the companies indicated:
Allison Diagnostic Optimized Connection (Allison DOC) is a trademark of Allison Transmission Inc.
Biobor JF is the registered trademark for a biological inhibitor manufactured by Hammonds Fuel
Additives Company.
DEXRON is a registered trademark of Allison Transmission Inc..
Spiralock is a registered trademark of Spiralock of Michigan.
Teon is a registered trademark of the DuPont Corporation.
TranSyndTM is a trademark of Castrol, Ltd.
VitonTM is a trademark of DuPont Corporation.
ii
CAUTION: A caution is used when an operating procedure, practice, etc., which, if not strictly
observed, could result in damage to or destruction of equipment.
NOTE: A 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.
To help prevent personal injury or property damage caused by sudden and unexpected
vehicle movement, do not check the uid 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 uid or the sump when draining transmission uid. Direct
contact with the hot uid or the hot sump may result in bodily injury.
To help avoid personal injury, such as burns, from hot transmission uid and/or to help
avoid equipment damage, do not stall the torque converter for more than ten seconds
maximum and monitor transmission uid 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 uid temperature. The uid 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 uid.
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.
To help avoid personal injury and/or equipment damage, a driving transmission stall
test must be performed by a trained driver and a qualied technician.
Use appropriate safety equipment such as safety glasses, safety shoes, and gloves.
Do not burn discarded Teon seals toxic gases are produced by burning Teon.
Never dry bearings by spinning them with compressed air. A spinning bearing can
disintegrate, allowing balls or rollers to become lethal ying projectiles. Also, spinning
a bearing without lubrication can damage the bearing.
Avoid contact with the hot uid or the sump when draining transmission uid. Direct
contact with the hot uid or the hot sump may result in bodily injury.
iv
With Retarder
3700 SP
Use proper tools and lifting equipment when installing or removing a transmission
from the repair stand.
To help avoid personal injury, securely support the cooler before removing the bolts
retaining the cooler to the manifold. The cooler weighs 29 kg (64 lb) use care when
handling the cooler.
The transfer case module assembly weighs approximately 270 kg (595 lb).
The control valve module assembly weighs approximately 25 kg (56 lb). Handle
carefully to avoid personal injury or control valve module damage. The control valve
module assembly used in a 3700 SP weighs approximately 29 kg (65 lb).
The retarder module assembly weighs approximately 64 kg (141 lb). Use care to
prevent injury to personnel while handling the retarder module assembly.
Piston springs are highly compressed. Be extremely careful during disassembly.
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.
Piston springs are highly compressed. Be extremely careful during installation.
Personal injury can occur if the spring force is not controlled.
Piston springs are highly compressed. Be extremely careful during removal. Personal
injury can occur if the spring force is not controlled.
Piston springs are highly compressed. Be extremely careful during installation.
Personal injury can occur if the spring force is not controlled.
Springs (108) and (112) are highly compressed. Be extremely careful during
disassembly. Personal injury can occur if the spring force is not controlled.
The retarder module assembly weighs approximately 64 kg (141 lb). Use care to
prevent injury to personnel while handling the retarder module assembly.
The transfer case module assembly weights approximately 270 kg (595 lb).
Transmissions installed in overhaul stands must be positioned vertically before
installing control valve module. Failure to do so could result in personal injury.
The control valve module assembly weighs approximately 25 kg (56 lb). Handle
carefully to avoid personal injury or control valve module damage. The control valve
module assembly used in a 3700 SP weighs approximately 29 kg (65 lb).
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 140
kg (64 lb), use care when handling the cooler.
Transmission dry weights are as follows:
Base transmission243 kg (535 lbs)
With Retarder279 kg (615 lbs)
With PTO provision261 kg (575 lbs)
With Retarder and PTO provision297 kg (655 lbs)
With PTO, Retarder, and Integral Sump Cooler336.5 kg (740 lbs)
3700 SP530 kg (1170 lbs)
Use proper tools and lifting equipment when installing or removing a transmission
from the repair stand.
vi
TABLE OF CONTENTS
TRADEMARK USAGE . . . . . . . . . . . . . . . . . . .i
LIST OF WARNINGS . . . . . . . . . . . . . . . . . . . iv
ELECTROMAGNETIC/RADIO
FREQUENCY INTERFERENCE . . . . . . . 114
i.
j.
vii
a. Preparation . . . . . . . . . . . . . . . . . . . .24
a. Purpose . . . . . . . . . . . . . . . . . . . . . 216
a. Water . . . . . . . . . . . . . . . . . . . . . . .28
c. Metal . . . . . . . . . . . . . . . . . . . . . . . .28
213. FLUID AND FILTER CHANGE
PROCEDURE . . . . . . . . . . . . . . . . . . . .28
b. Assembly . . . . . . . . . . . . . . . . . . . . 221
viii
TABLE OF CONTENTS
c. Mechanics Tools and Shop
Equipment . . . . . . . . . . . . . . . . . . . .33
33. REPLACEMENT PARTS . . . . . . . . . . . . .37
a. Ordering Information . . . . . . . . . . . . . .37
b. Parts Normally Replaced at Overhaul . . .37
34. CAREFUL HANDLING. . . . . . . . . . . . . . .37
Bearings . . . . . . . . . . . . . . . . . . . . 317
i.
j.
l.
i.
ix
TABLE OF CONTENTS
b. Assembly (Foldout 72) . . . . . . . . . . . 520
58. C3/C4 AND MAIN HOUSING MODULE . . . 522
b. Disassembly of C6 Clutch
(Foldout 14) . . . . . . . . . . . . . . . . . . 551
c. Assembly of C6 Clutch (Foldout 14) . . . 551
d. Disassembly of C7 Clutch
(Foldout 13) . . . . . . . . . . . . . . . . . . 552
e. Assembly of C7 Clutch Housing
(Foldout 13) . . . . . . . . . . . . . . . . . . 552
f. Disassembly of Oil Pump
(Foldout 13) . . . . . . . . . . . . . . . . . . 553
g. Assembly of Oil Pump (Foldout 13) . . . 553
h. Disassembly of P4 Carrier
(Foldout 14) . . . . . . . . . . . . . . . . . . 553
i.
xi
j.
l.
l.
c. Illustrations . . . . . . . . . . . . . . . . . . . .61
e. Foldouts . . . . . . . . . . . . . . . . . . . . . .61
xii
i.
TABLE OF CONTENTS
j.
FOLDOUTS
1.
2.
3.
4.
5.
b. Inspection. . . . . . . . . . . . . . . . . . . . .71
xiii
28.
29.
30.
31.
32.
33.
34.
35.
36.
37.
38.
14.
21.
22.
23.
24.
25.
26.
xiv
SCOPE OF MANUAL
Specialty Series:
3200 SP
3500 SP
3700 SP
Bus Urban Series:
B 295
B 300
B 400
T 200 Series:
T 250
T 255
T 260
T 265
T 270
T 280
Highway Series:
T 300 Series:
3000 HS
3000 RDS
T 310
3200 RDS
T 325
3500 RDS
T 350
T 375
3000 EVS
3500 EVS
b. Illustrations.
Motorhome Series:
3000 MH
3200 MH
Truck Recreational Vehicle Series:
3000 TRV
3200 TRV
3500 TRV
Off Road Series:
3200 ORS
3500 ORS
Pupil Transport/Shuttle Series:
3000 PTS
11
12
GENERAL INFORMATION
Figure 11. 3000 Product Family Transmission with PTO ProvisionLeftFront View
Figure 12. 3000 Product Family Transmission with PTO ProvisionRightRear View
Copyright 2009 Allison Transmission, Inc.
13
Figure 14. 3000 Product Family Transmission with Retarder and Remote Sump Cooler Manifold
14
GENERAL INFORMATION
15
SUPPLEMENTARY INFORMATION
13.
ORDERING PARTS
14.
GENERAL DESCRIPTION
16
GENERAL INFORMATION
MY09 Prognostics (excluding 7speed)
15.
MAJOR MODULES
PTO provision
TCM
b. Torque Converter.
1. The torque converter includes a lockup clutch
and torsional damper for direct and smooth
transfer of engine power.
2. The available torque converter models are:
Torque Converter Model
TC 411
TC 413
TC 415
TC 417
TC 418
TC 419
Shift sequences
TC 421
Shift timing
c. Power Takeoff (PTO) Provision. Provision
for a direct, enginedriven PTO is available at two
positions.
d. Main Housing and Gear Module. The main
housing and gear module includes:
Main housing
Throttle position
Engine speed
Turbine speed
Output speed
Sump temperature
Retarder temperature
Engine water temperature
Pressure Switch 1 (PS1) pressure switch
status
Oil level
Any special functions operating
17
16.
3000 HS
Motorhome Series
Truck Recreational
Vehicle Series
OffRoad Series
Pupil Transport/Shuttle
Series
3000 PTS
Specialty Series
Bus Series
T 200 Series
T 300 Series
18
GENERAL INFORMATION
Vocational
Model
CR/WR/
WCR
Maximum
Forward
Ranges
PTO
Retarder
Deep Sump
Shallow
Sump
OLS
3000 EVS
CR
STD
OPT
STD
OPT
STD
3500 EVS
WR
STD
OPT
STD
OPT
STD
3000 HS
CR
N/A
OPT
STD
N/A
STD
3000 MH
CR
OPT
OPT
STD
N/A
STD
3200 MH
CR
OPT
OPT
STD
N/A
STD
3200 ORS
CR
STD
OPT
STD
N/A
STD
3500 ORS
WR
STD
OPT
STD
N/A
STD
3000 PTS
CR
NA
OPT
STD
N/A
STD
3000 RDS
CR
STD
OPT
STD
N/A
STD
3500 RDS
WR
STD
OPT
STD
N/A
STD
3200 SP
CR
OPT
N/A
STD
OPT
N/A
3500 SP
WR
STD
OPT
STD
OPT
STD
3700 SP
WRC
STD
OPT
STD
N/A
STD
3000 TRV
CR
OPT
OPT
STD
OPT
STD
3200 TRV
CR
OPT
OPT
STD
OPT
STD
B 300
CR
OPT
OPT
STD
OPT
STD
B 400
CR
OPT
OPT
STD
OPT
STD
17.
DIAGNOSTICS
19
GENERAL INFORMATION
NOTE: d1=newest DTC, d5=oldest DTC in memory
d1
DTC type
25
Main DTC
34
Subcode
d1 P 25
34
MONITOR
18.
111
112
19.
RESTORING TRANSMISSION TO
SERVICE
CAUTION: Whenever a transmission is
overhauled, exchanged, or has undergone
repairs, the Transmission Control Valve
Module (TCM) must be RESET TO
UNADAPTED SHIFTS. This will cause the
TCM to erase previous adaptive information
and begin to adapt in Fast Adaptive Mode
from the base calibration. Use the Allison
DOC For PCService Tool (refer to the
Allison DOC Users Guide GN3433EN for
instructions) to RESET TO UNADAPTED
SHIFTS.
GENERAL INFORMATION
110. OPERATING INSTRUCTIONS
Detailed transmission operation information is in
the 3000 and 4000 Product Families Principles of
Operation Manual, PO4016EN, or vocational model
Operators Manuals (see Table 81). Refer to the
latest revision.
111.
3000/3200
3500
3700 SP
First
3.49:1
4.59:1
6.93:1
Second
1.86:1
2.26:1
4.18:1
Third
1.41:1
1.53:1
2.24:1
Fourth
1.00:1
1.00:1
1.69:1
Fifth
0.75:1
0.75:1
1.20:1
Sixth
0.65:1
0.65:1
0.90:1
Seventh
N/A
N/A
0.78:1
Reverse
5.03:1
5.00:1
6.03:1
HYDRAULIC SYSTEM:
Fluid type
Cooler
SIZES:
Base
Transmission
With PTO
Provision
With Retarder
With PTO
Provision and
Retarder
3700 SP
Length (transmission
mounting face to end of
output shaft)
719.4 mm
(28.32 in)
821.9 mm
(32.36 in)
718.6 mm
(28.29 in)
821.6 mm
(32.35 in)
1310.3 mm
(51.58 in)
327.7 mm
(12.90 in)
327.7 mm
(12.90 in)
327.7 mm
(12.90 in)
327.7 mm
(12.90 in)
555.3 mm
(21.87 in)
Dry Weight
530 kg
(1170 lb)
**Gear
113
ELECTROMAGNETIC/RADIO
FREQUENCY INTERFERENCE
114
SCOPE
22.
Prognostics
Operating time
Retarder operation
Display
Meaning
OLXX ##
Oil Level
Shift frequency
OM ##
Oil Life
Monitor
FM ##
Filter Life
Monitor
TM ##
Trans
Health
Monitor
d1 P ## ##
Diagnostic
Trouble
Code
21
23.
24.
25.
22
PREVENTIVE MAINTENANCE
Sump uid temperature at 60104C
(140220F)
Display
(Former)
Display (MY08,
Cal/Sfw or
newer)
Interpretation
of Display
oL95
oL FL
Sensor failure
Interpretation of Display
oL, oK
oL Lo 01
oL HI 01
oL, , (N)
DDR Message
OL
SETTLING TIME X
OL
OL
OL
SELECT N (Neutral)
OL
SUMP TEMP LO
OL
OL
OL
CHECK CODES
Display
(Former)
Display (MY08,
Cal/Sfw or
newer)
Interpretation
of Display
oL 0X
oL 0X
Settling time
too short*
oL EL
Engine rpm
too low
oL EH
Engine rpm
too high
oL SN
N (Neutral) must
be selected
oL TL
Sump uid
temperature
too low
oL TH
Sump uid
temperature
too high
oL SH
Output shaft
rotation
oL50
oL59
oL65
oL70
oL79
oL89
23
27.
28.
24
PREVENTIVE MAINTENANCE
5. If the uid level is not within the HOT RUN
band, add or drain as necessary to bring the
uid level to within the band. Safe operating
level is within the HOT RUN band on the
dipstick (refer to Figure 21).
29.
25
Degrees (F)
MILPRF46167
32
26
SAE 0W30
(Arctic)
30
22
TranSyndTM/
TES 389
35
31
DEXRONVI/
TES 389
25
13
SAE 10W
25
13
SAE 15W40
20
SAE 30W
32
SAE 40W
10
50
211.
26
General
Severe
General
Severe
General
Severe
25,000 miles
(40,000 km)
12 months
12,000 miles
(20,000 km)
6 months
25,000 miles
(40,000 km)
12 months
12,000 miles
(20,000 km)
6 months
150,000 miles
(240,000 km)
48 months
75,000 miles
(120,000 km)
36 months
HIGH CAPACITY FILTERS a, AND WHEN PROGNOSTICS IS TURNED OFF OR NOT CALIBRATED IN TCM
12,000 miles
(20,000 km)
6 months
25,000 miles
(40,000 km)
12 months
12,000 miles
(20,000 km)
6 months
PROGNOSTICS
300,000 miles
(480,000 km)
48 months
150,000 miles
(240,000 km)
48 months
NOTE: If prognostics is turned off or not calibrated in the TCM,use of high capacity lter and uid change intervals must be followed.
N.A.
N.A.
N.A.
N.A.
NOTE: Change uid/lters at or before recommended mileage, months, or hours have elapsed, whichever occurs rst.
NOTE: Local conditions, severity of operation or duty cycle may require more or less frequent uid change intervals that differ from the published recommended
uid change intervals. In the absence of a uid analysis program, the uid change intervals listed in the charts above should be used.
NOTE: General Vocation: Intercity Coach with duty cycle less than or equal to one stop per mile and all other vocations not listed in severe vocation.
NOTE: Severe Vocation: All Retarders, On/Off Highway, Refuse, Transit, Shuttle Transit, 2000 MH, and Intercity Coach with duty cycle greater than one stop
per mile.
a
b
High capacity lters released in models starting with S/N 6510670912, 65200667342
Prognostics released on models starting with S/N 6510822005, 6520099957
PREVENTIVE MAINTENANCE
25,000 miles
(40,000 km)
12 months
27
Limit
Viscosity
Water
*mg
c. Metal.
PREVENTIVE MAINTENANCE
a. Drain Fluid.
WARNING: Avoid contact with the hot uid
or the sump when draining transmission
uid. Direct contact with the hot uid or the
hot sump may result in bodily injury.
29
Initial Fill*
3000 Product
Family
3700 SP
Directmount
Retarder
Remote
*Does
Accumulator
Nonretarder
PREVENTIVE MAINTENANCE
214. BREATHER
a. Location and Purpose. The breather is located
on top of the transmission converter housing. It
serves 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
determines 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.
211
212
PREVENTIVE MAINTENANCE
Table 29. Clutch Pressure Test Conditions
Transmission
Model/ Test Type
Engine rpm
Range
Clutches
Pressurized
3000 Product
FamilyIdle Check
580620
7193C (160200F)
N (Neutral)
R (Reverse)
Low C
1C
C5
C3 C5
C3 C6
C1 C5
3000 Product
FamilyHigh Speed
20802120
7193C (160200F)
R (Reverse)
N (Neutral)
1C
2C
C3 C5
C5
C1 C5
C1 C4
3000 Product
FamilyHigh Speed
20802120
2L
3L
4L
5L
6L
3700 SPHigh
Speed
20802120
R (Reverse)
N (Neutral)
C5 LoC
1C
2C
2L
3L
4L
5L
6L
C1
C1
C1
C2
C2
C4
C3
C2
C3
C4
LU
LU
LU
LU
LU
C3 C5
C5
C3 C6
C1 C5
C1 C4
C1 C4 LU
C1 C3 LU
C1 C2 LU
C2 C3 LU
C2 C4 LU
213
214
Table 210. Main Pressure and Clutch Pressure Specications (Sump Fluid Temperature Same as in Table 25)
Engine rpm
Range
Main Press.
Spec
kPa (psi)
Clutches
Applied
Range Clutch
Press. Spec
*kPa (psi)
Lube Press.
Spec*
kPa (psi)
Lockup
Clutch Press.
Spec
kPa (psi)
Dropbox Main
Press. Spec*
kPa (psi)
3000 Product
FamilyIdle
580620
Neutral Main
Mod OFF
15152035
(220295)
C5
14402035
(210295)
1035 (15)
NA
14402035
(210295)
Neutral Main
Mod ON
13101725
(190250)
C5
12351725
(180250)
1035 (15)
NA
12351725
(180250)
Reverse Main
Mod OFF
14502035
(210295)
C3, C5
13752035
(200295)
1035 (15)
NA
13752035
(200295)
Reverse Main
Mod ON
11701585
(170230)
C3, C5
10951585
(160230)
1035 (15)
NA
10951585
(160230)
Low C (3000
7Speed) Main
Mod OFF
12401725
(180250)
C3, C6
11651725
(170250)
1035 (15)
NA
11651725
(170250)
Low C (3000
7Speed) Main
Mod ON
8701340
(125195)
C3, C6
7951340
(115195)
1035 (15)
NA
7951340
(115195)
1C Main Mod
OFF
12401725
(180250)
C1, C5
11651725
(170250)
1035 (15)
NA
11651725
(170250)
1C Main Mod
ON
8701340
(125195)
C1, C5
7951340
(115195)
1035 (15)
NA
7951340
(115195)
2C Main Mod
OFF
12401725
(180250)
C1, C4
11651725
(170250)
1035 (15)
NA
11651725
(170250)
2C Main Mod
ON
8701340
(125195)
C1, C4
7951340
(115195)
1035 (15)
NA
7951340
(115195)
Transmission
Model/Test Type
Table 210. Main Pressure and Clutch Pressure Specications (Sump Fluid Temperature Same as in Table 25) (contd)
215
Engine rpm
Range
Main Press.
Spec
kPa (psi)
Clutches
Applied
Range Clutch
Press. Spec
*kPa (psi)
Lube Press.
Spec*
kPa (psi)
Lockup
Clutch Press.
Spec
kPa (psi)
Dropbox Main
Press. Spec*
kPa (psi)
3000 Product
FamilyHigh
Speed
20802120
Neutral Main
Mod OFF
18052205
(260320)
C5, LU
17302205
(250320)
160240
(2335)
050 (07.3)
17302205
(250320)
Neutral Main
Mod ON
14151725
(205250)
C5, LU
13351725
(195250)
160240
(2335)
050 (07.3)
13351725
(195250)
Reverse
18052205
(260320)
C3, C5, LU
17302205
(250320)
160240
(2335)
050 (07.3)
17302205
(250320)
Low C (3000
7Speed)
15501965
(225285)
C3, C6
14751965
(215285)
160240
(2335)
NA
14751965
(215285)
1C
15501965
(225285)
C1, C5, LU
14751965
(215285)
160240
(2335)
050 (07.3)
14751965
(215285)
2C
15501965
(225285)
C1, C4, LU
14751965
(215285)
160240
(2335)
050 (07.3)
14751965
(215285)
2L
10801365
(155200)
C1, C4, LU
10051365
(145200)
160240
(2335)
10051365
(145200)
10051365
(145200)
3C
15501965
(225285)
C1, C3
14751965
(215285)
160240
(2335)
NA
14751965
(215285)
3L
10801365
(155200)
C1, C3, LU
10051365
(145200)
160240
(2335)
10051365
(145200)
10051365
(145200)
4C
15501965
(225285)
C1, C2
14751965
(215285)
125200
(1830)
NA
14751965
(215285)
4L
10801365
(155200)
C1, C2, LU
10051365
(145200)
125200
(1830)
10051365
(145200)
10051365
(145200)
5C
15501965
(225285)
C2, C3
14751965
(215285)
125200
(1830)
NA
14751965
(215285)
5L
10801365
(155200)
C2, C3, LU
10051365
(145200)
125200
(1830)
10051365
(145200)
10051365
(145200)
6C
13451590
(220290)
C2, C4
12701590
(185230)
125200
(1830)
NA
12701590
(185230)
6L
10351415
(150205)
C2, C4, LU
9601415
(140205)
125200
(1830)
9601415
(140205)
9601415
(140205)
*To pass this specication, 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 specication.
PREVENTIVE MAINTENANCE
Transmission
Model/Test Type
216
PREVENTIVE MAINTENANCE
Converter out temperature: 82104C
(180220F)
2. Perform a hot check of the transmission uid
level and adjust as necessary
3. Turn all engine accessories off.
4. Place Allison DOC For PCService Tool
in clutch test mode. Use the shift selector
to select D (Drive). Next, select 4 (Fourth
Range) on the Range Panel thats displayed
on the computer screen during Clutch Test
mode. Do not try to use the shift selector
to try to attain 4 (Fourth Range). Using 4
(Fourth Range) reduces the torque imposed
on the transmission driveline. Do not perform
a transmission stall test in R (Reverse).
CAUTION: To help avoid transmission or
driveline damage, full throttle stall tests
must not be performed in R (Reverse)
range, all models, or low ranges, 7speed
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 uid 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 the internal (sump)
temperature. Never use sump uid
temperature to determine the length of the
stall condition. If the stall test is repeated,
do not let the engine overheat.
217
PREVENTIVE MAINTENANCE
217. FLUID LEAK DIAGNOSIS
Most uid leaks can be located and repaired by
visually nding the leak and replacing or repairing
the necessary parts. On some occasions, a uid
leak may be difcult to locate or repair. The following
procedure may help in locating and repairing most
leaks.
a. Finding the Leak.
1. Identify the uid. Determine whether it is
engine oil, automatic transmission uid, or
hydraulic uid from a specic vehicle system.
b. Powder Method.
219
220
PREVENTIVE MAINTENANCE
Figure 25. Output Flange and Oil Seal3000 Product Family (Except 3700 SP)
b. Assembly .
1. For all models, except those with parking
brake, install the output seal (1) using installer
J39928 and J359211 Drive Sleeve. If
equipped with a parking brake, install the
rear seal using installer J359214 and
J359211 Drive Sleeve. Place the seal on
the installer tool so the seal P/N faces outward
after the seal is installed. Drive the seal
into its bore until the installer tool bottoms
out squarely against its locating surface.
Lubricate the seal.
2. If used, install parking brake assembly (5)
and retain with four bolts (6). Tighten bolts to
228266 Nm (168196 lb ft).
221
PTO(s)
Scavenge Pump
222
Paragraph
Paragraph
218. OUTPUT
FLANGE/YOKE AND OIL
SEAL MAINTENANCE
(All, Except 3700 SP) or
Figure 26
42g. Removal of
Transfer Case Module
3700SP(1)
42h. Removal of Control
Valve Module (Figure 46)
SCOPE
32.
31
33
34
**
Description
Reference Paragraph
J3940
512c, e, l, n, t, v 513a, c
516l, n, o
J8092
Drive Handle
J24171A
16
J26417A
215a
8E
J2846734
Handle
57a
J29109
Repair Stand
62a
J33163
517a
J35921
6A
J359211
Output Bearing
Installer/Drive Sleeve
6B
J359213
55e 56c
6C
J359214B
218b 513f
J35922
Bearing/Bushing Installers
7A
J359221
Turbine Shaft/Output
Shaft/P2 Planetary Bushing
Installer
7B
J359222
7C
J359223
512f, o, q, w, y 513f
J35923
8A
J359231
57a, b
8B
J359232
57a, b 512e, f, n, o, v
513c, d 514a, b
8C
J359233
57a, b
8D
J359234
Compressor Base
57a, b 514a, b
J35924
517f, i
10A
J359252
512c, h, l, q, t, y 513a, f
11
J35926
42a, f 62a
35
**
Description
Reference Paragraph
27
J38547
219b 516m, o
12
J 38548
53b 62q
13
J38564A,B,C
42h 62q
14
J38565
PTO Bearing/Sleeve
Installer
55d 56b
15
J38566
53b
23
J38568
23A
J385681
516a
23B
J385682
516a
23C
J385683
516m
22
J38569
P3 Carrier/C6/C7 Housing
Bushing Installer
514b 516c, e
24
J38572
26
J38573
C6 Spring Compressor
516b, c
25
J38579
Bearing Installers
25A
J385791
Drive/Driven Bearing
Installer
516k
25B
J385792
516k, m, o
19
J39354
Rivet Installer
58b
28
J39623
516s
21
J39928A
20
J41462
56a 56c
17
J42048
512c, h, l, q, t, y
29
J47028
515b
10B
J47347
512b, g 513a, f
30
J47942
517e, h
*We
believe this source and its tools to be reliable. These tools may be available from other manufacturers. Allison
Transmission, Inc. does not endorse, indicate any preference for, or assume any responsibility for the products or tools
from these rms, or for any such items that may be available from other sources.
**SPX (KentMoore Service Solutions) 28635 Mound Road, Warren, Michigan 48092
36
REPLACEMENT PARTS
35.
34.
CAREFUL HANDLING
37
38
i.
Inspecting Gears.
1. Inspect gears for scuffed, nicked, burred, or
broken teeth. If a defect cannot be removed
with a soft stone, replace the gear.
2. Inspect gear teeth for wear that has changed
the original tooth shape. If this condition is
found, replace the gear.
3. Inspect the thrust face of gears for scores,
scratches, and burrs. Remove such defects
with a soft stone. If scratches and scores
cannot be removed with a soft stone, replace
the gear.
4. Inspect gears for load pattern and signs of
distress. Any sign of distress indicates that
a gear failure during operation is possible.
Reusing distressed gears is an individual
customer decision based on experience.
Backlash cannot be used to establish critical
gear wear. Backlash tolerances are of such
nature that a gear usually pits, scuffs, scores,
39
311
Former Resistance
(Ohms) Before January,
2006
Temp F
Temp C
250
200
40
40
340
300
68
20
450
400
230
110
312
Figure 38. Main Mod, TCC, and PCS1 through PCS6Solenoid Resistance vs. Temperature
Table 33. Sump Solenoid Resistance
Sump Temperature
Resistance
(Ohms)
(C)
(F)
32
4.65
20
68
5.05
40
104
5.45
313
Figure 39. ON/OFF SolenoidsSS1 and SS2 (C6 Enable) in 7Speed Models
5. Measure the resistance of retarder air solenoid
SS2 (if equipped) If the resistance does not
meet specications in Figure 310, replace
solenoid.
314
315
36.
ASSEMBLY PROCEDURES
316
g. LipType Seals.
1. When replacing liptype seals, make sure
the springloaded lip is toward the uid to be
sealed (toward the inside of the unit). Coat
the inside of the seal with high temperature
grease (MILG3545A 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 identication. Precoated
seals do not require any additional sealant
before installation.
h. ButtJoint Sealrings.
1. Buttjoint sealrings require special handling
during assembly. The sealrings contain
materials that absorb moisture from the
atmosphere causing the sealring to expand.
The sealrings are shipped in airtight packages.
Do not open the sealed package until the
buttjoint sealring is ready to be installed into
the transmission.
37.
317
318
319
WEAR LIMITS
39.
SPRING SPECIFICATIONS
311.
ENGINE, TRANSMISSION
ADAPTATION REQUIREMENTS
320
321
322
freedom of movement
damaged or wornout
correctly lubricated
correctly indexed
323
324
SCOPE
42.
Title
33. REPLACEMENT
PARTS
Replacement Parts
34. CAREFUL
HANDLING
Careful Handling
37. REMOVING
(OR INSTALLING)
TRANSMISSION
(Figure 312,
Figure 313)
Removing Transmission
Spring Data
DISASSEMBLY OF TRANSMISSION
With Retarder
3700 SP
41
42
TRANSMISSION DISASSEMBLY
43
44
TRANSMISSION DISASSEMBLY
3. Support cooler (7) to prevent it from falling
from manifold (16).
4. Remove sixteen M10 x 1.5 x 60 bolts (1).
5. Remove six M8 x 1.25 x 25 bolts (5).
WARNING: To help avoid personal
injury, securely support the cooler before
removing the bolts retaining the cooler to
the manifold. The cooler weighs 29 kg (64
lb) use care when handling the cooler.
45
TRANSMISSION DISASSEMBLY
explate adapter bolt holes. Then place
a screwdriver at an angle to prevent
converter rotation (Figure 47, View C).
5. Remove M16 x 2 x 30 bolt (1) using
J 38564 converter bolt tool .
6. Remove shim (2) located under bolt (1)
(Figure 47, View A).
7. Attach a sling to the explate adapter by
positioning the adapter connections an equal
distance from each other. Using a chain hoist,
carefully lift torque converter module (3) out of
the converter housing (Figure 47, View A).
8. Place two wooden blocks on the workbench,
spaced to support the torque converter
module and high enough for the converter hub
to clear the workbench. Lower the converter
module, converter hub down, onto the blocks.
47
48
TRANSMISSION DISASSEMBLY
secure retarder module (2) (Figure 49) to
main housing (3).
WARNING: The retarder module assembly
weighs approximately 64 kg (141 lb). Use
care to prevent injury to personnel while
handling the retarder module assembly.
2. Thread an M10 eye bolt into the retarder
output shaft (7) (Foldout 11A) and lift the
retarder module (2) (Figure 49) from main
housing (3).
3. Remove retarder gasket (1) (Figure 49) from
main housing (3) or retarder housing (2).
49
TRANSMISSION DISASSEMBLY
2. Lift front support and charging pump module
(3) away from the turbine shaft.
3. Using a hoist and a M16 eye bolt, lift
turbine shaft and rotating clutch module (1)
(Figure 416) from the main housing module.
411
412
SCOPE
53.
52.
Title
33. REPLACEMENT
PARTS
Replacement Parts
34. CAREFUL
HANDLING
Careful Handling
37. REMOVING
(OR INSTALLING)
TRANSMISSION
(Figure 312, Figure 313)
Removing Transmission
Spring Data
51
52
MODULE REBUILD
53
54
MODULE REBUILD
(Figure 58, Figure 59). See Figure 34 for
reference.
55
Use P/N
Shim Thickness
29502277
29502276
29502275
56
MODULE REBUILD
54.
57
55.
NOTE: Beginning with S/N 6510717281,
S/N 6520083093, S/N 6610220990,
S/N 6620005821, S/N 9370007661,
S/N 9320006231, S/N 9470006080, and
S/N 9420007560, material of specic
seals has been modied to be compatible
with DEXRONVI uids. Transmissions
prior to the above serial numbers are not
compatible with DEXRONVI uids. Seal
compatibility can be identied by a "D6C" or
8 color marks on the face of the seal. See
SIL 6WT07 for more information.
1. If removed, install bushing (6)75.5 mm (2.972
inches) using a press or soft mallet and
J359222 Oil Pump Body Bushing/Ground
Sleeve Bearing/P1 Sun Gear Bushing Installer
and J8092 Drive Handle. Press bushing
(6) ush to 0.25 mm (0.010 inch) below the
surface.
2. Install sealring (8) (178.8 mm). Install oil seal
(4) ush to 0.25 mm (0.010 inch) below the
surface using a press and J359213 Oil Pump
(Input) Seal Installer and J359211 Output
Bearing Installer/Drive Sleeve. Press sealring
(8) ush, to 0.25 mm (0.010 inch) below the
surface.
f.
Module Assembly.
1. With a mallet, lightly tap PTO gear assembly
(9) into converter housing (22) until the gear
assembly is seated.
2. Use guide bolts to install bearing retainer
assembly (3), rocking the retainer while
installing.
MODULE REBUILD
56.
59
510
MODULE REBUILD
11. Measure the OD of the driven (outer) pump
gear. Minimum allowable OD is 126.95 mm
(4.998 inch).
12. Measure the width of the driven pump gear.
Minimum allowable width for reuse is 17.81
mm (0.701 inch ).
13. Inspect the bushing inside the drive (inner)
gear for wear or damage. Measure the ID of
the drive gear bushing. Maximum allowable
ID for reuse is 57.30 mm (2.256 inch). If worn
or damaged, remove the bushing (11) from
the drive gear.
14. Measure the width of the drive and driven
pump gears. Minimum allowable width for
reuse is 17.81 mm (0.701 inch).
15. Examine the tang slots in the drive pump gear.
Replace the gear if the slots have step wear.
16. Install gear set (10) into pump housing
(9). Measure pump gear side clearance
(Figure 519). Maximum allowable clearance
for reuse is 0.13 mm (0.005 inch).
511
512
MODULE REBUILD
c. Assembly of the Pump Housing (Foldout 71).
NOTE:
For models without PTO, proceed
with Step 1.
For models with PTO, skip to Step 4.
1. If old bushing was removed, install new
bushing (8) 75.15 mm ID (Foldout 71) into
pump housing (9) using a press and tools
J359222 Oil Pump Body Bushing/Ground
Sleeve Bearing/P1 Sun Gear Bushing Installer
and J8092 Drive Handle.
2. Install oil seal (5) using a press and
J359213 Oil Pump (Input) Seal Installer
and J359211 Output Bearing Installer/Drive
Sleeve.
3. Install a 4.4 inch ID Oring (4).
4. Install pressure relief ball (27) and pressure
relief spring (26) into pump housing
(Figure 522). Using tool J41462 Main
Pressure Relief Spring Compressor, compress
spring (26). Install pin (25) to retain spring and
ball (Figure 523).
513
514
MODULE REBUILD
3. Inspect and measure the ID of sun gear
bushing (43). Maximum allowable ID for
reuse is 68.22 mm (2.685 inch). Remove the
bushing with a hammer and chisel if visually
damaged or worn beyond service limits.
4. Remove 298 mm ID retaining ring (44).
5. Remove C2 clutch pressure plate (39).
6. Measure the thickness of C2 clutch pressure
plate (39). Minimum allowable thickness for
reuse is 6.25 mm (0.246 inch). Check atness
of the C2 clutch pressure plate (39). Maximum
allowable distortion for reuse is 0.45 mm
(0.018 inch).
7. Remove six C2 clutch pack friction plates (38)
and six steel reaction plates (37).
Figure 525. Thrust Bearing Installed
on Front Support
8. Insert three 88 mm ID buttjoint sealrings (23)
into the sealing bore of the rotating clutch hub
and measure the end gap with feeler gauges.
Maximum allowable sealring end gap for
reuse is 0.57 mm (0.022 inch).
9. Remove three buttjoint sealrings (23) from
the rotating clutch hub and install them onto
the hub of front support (21). If any do not
meet specications, replace all three buttjoint
sealrings.
57.
515
516
MODULE REBUILD
C1 return spring assembly (25). Remove
retaining ring (28). Remove J 359231 Piston
Spring Compressor (C1).
NOTE: Beginning with S/N 6510717281,
S/N 6520083093, S/N S/N 6610220990,
S/N 6620005821, S/N 9370007661,
S/N 9320006231, S/N 9470006080, and
S/N 9420007560, material of specic
seals has been modied to be compatible
with Dexron VI uids. Transmissions
prior to the above serial numbers are not
compatible with DexronVI uids. Seal
compatibility can be identied by a "D6C" or
8 color marks on the face of the seal. See
SIL 6WT07 for more information.
Figure 528. Proper Placement of
Micrometer B
17. Remove 74 mm ID thrust bearing (15) from
rotating clutch hub assembly (12). Inspect
thrust bearing (15) using guidelines from
35e. Inspecting Bearings.
18. Remove 48 mm ID retaining ring (16) from
turbine shaft assembly (5) or (8).
19. Inspect turbine shaft bushing (7) inside the
end of turbine shaft (5) or (8). Measure the
ID of the turbine shaft bushing. Maximum
allowable ID for reuse is 20.19 mm (0.795
inch). Remove with hammer and chisel if
visually damaged or worn beyond service
limits.
20. Remove three 51 mm OD buttjoint sealrings
(10) from turbine shaft assembly (5) or (8).
21. Remove Oring (4) from turbine shaft
assembly (5) or (8).
WARNING: Piston springs are highly
compressed. Be extremely careful during
disassembly. Personal injury can occur if
the spring force is not controlled.
22. Place rotating clutch on J 359234 Compressor
Base so rotating drum is supported by tool
tangs (Figure 532, View C). Install
J 359231 Piston Spring Compressor (C1)
(Figure 532, View A), bearing, washer, and
J 2846734 Handle. Tighten tool, compressing
C1 balance piston (26) (Foldout 72) and
517
518
MODULE REBUILD
519
520
MODULE REBUILD
12. Install C2 spring assembly (21) with the inner
locating ring down in the rotating clutch drum
(11) (Figure 533). Make sure the spring
assembly properly aligns with the rotating
clutch drum (11) and C2 piston splines.
521
58.
MODULE REBUILD
523
MODULE REBUILD
59.
525
526
MODULE REBUILD
Figure 34 shown in 35e. Inspecting
Bearings.
2. Install P3 sun gear (7).
527
528
MODULE REBUILD
P2 or P3 pinions, review Section 3. GENERAL
OVERHAUL INFORMATION for inspection
criteria of pinion gears, thrust washers, and
carriers. Replace any parts that do not meet
inspection guidelines or service specications
in this section or Table 71. Measure end play
of all four pinion gears.
4. Remove retaining ring (13) (159.2 mm OD).
Remove indexing ring (12). Remove four
pinion spindles (11) from P2 carrier (3).
Inspect indexing ring (12) for step wear.
Indexing rings may be ipped over and reused
if corners are not abnormally worn (see
Figure 537).
511.
P2 PLANETARY MODULE
529
530
MODULE REBUILD
531
MODULE REBUILD
output shaft bushing. Maximum allowable ID
for reuse is 20.19 mm (0.795 inch).
2. If replacement is necessary, remove tapered
bearing (13) (75 mm ID) from P3 carrier (12)
with bearing puller.
3. Measure pinion end play of all four pinions.
Pinion end play should not exceed 0.94 mm
(0.037 inch).
NOTE: The spindles and pinions do not
need to be removed before removing the
output shaft assembly (7).
4. Remove retaining ring (10) (159 mm OD).
Remove indexing ring (11). Remove four
pinion spindles (15).
5. Slide pinion gear (17), thrust washers (16)
and (19), and two bearings (18) (28 mm ID,
38.025 mm OD) from the side of P3 planetary
carrier (12). Repeat the procedure with the
three remaining pinion gears.
6. Inspect indexing ring (11) for minor wear.
They may be ipped over and reused if corner
is not abnormally worn (see Figure 537).
7. Measure the thickness of all thrust washers
(16) and (19). Minimum allowable thickness
for reuse is 1.39 mm (0.054 inch). Measure
the step wear of each thrust washer. Maximum
allowable step wear for reuse is 0.12 mm
(0.005 inch).
d. Disassembly of Retarder Stator Assembly
(Foldout 11A).
1. Remove Oring (28) (297.1 mm ID) from stator
assembly (20).
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. Compress retainer and spring assembly (22)
using J359232 Piston Spring Compressor.
Remove retaining ring (21) (128 mm ID) from
stator (27) and slowly release the spring
tension. Remove C5 clutch piston (23) from
retarder stator (27).
533
MODULE REBUILD
g. Assembly of Retarder Housing Assembly
(Foldout 11A).
NOTE: Beginning with S/N 6510717281,
S/N 6520083093, S/N 6610220990,
S/N 6620005821, S/N 9370007661,
S/N 9320006231, S/N 9470006080, and
S/N 9420007560, the material of specic
seals has been modied to be compatible
with DEXRON VI uids. Transmissions
prior to the above serial numbers are not
compatible with DEXRON VI uids. Seal
compatibility can be identied by a "D6C" or
8 color marks on the face of the seal. See
SIL 6WT07 for more information.
535
MODULE REBUILD
8. Support retarder housing (49) so that turning
torque of P3 carrier assembly (6) can be
checked after installation of bearing retainer
nut (60) (Figure 552). Maximum allowable
drag is 3 Nm (26 lb in).
537
538
MODULE REBUILD
yoke/ange side using J3940 Bearing Race
Remover.
8. Replace any parts that do not meet the
general inspection guidelines listed in Section
3. GENERAL OVERHAUL INFORMATION of
this manual.
b. Disassembly of the P3 Planetary Carrier
Assembly (Foldout 11B).
1. Remove pin (11) if damaged or if removing the
bearing assembly (13) or replacing the output
speed signal wheel (33).
2. If replacement is necessary, remove bearing
assembly (13) with bearing puller.
3. Measure the pinion end play of all four pinion
gears. If pinion end play exceeds 0.94
mm (0.037 inch) for P1, P2 or P3 pinions,
review Section 3. GENERAL OVERHAUL
INFORMATION for inspection criteria of
pinion gears, thrust washers, and carriers.
Replace any parts that do not meet inspection
guidelines or service specications in this
section or Table 71.
539
MODULE REBUILD
Planetary Bushing Installer and J8092 Drive
Handle until J359211 Output Bearing
Installer/Drive Sleeve seats against output
shaft (8).
4. Install output shaft assembly (6) into P3
planetary carrier 12.
5. Install retaining ring (15) (50.8 mm ID,
Figure 555).
541
542
MODULE REBUILD
543
MODULE REBUILD
(29). Hold bracket (31) in place and install M8
x 1.25 x 20 retaining bolt (32). Tighten the bolt
to 2429 Nm (1821 lb ft).
9. When rear cover (41) is used, be sure to
install plug (39) and washer (40). Torque plug
(39)to 6067 Nm (4450 lb ft).
545
MODULE REBUILD
14. Release spring force and remove
J359232 Piston Spring Compressor
(C5) and J359234 Compressor Base.
547
548
MODULE REBUILD
b. Assembly (Foldout 191).
1. If removed, install new bearings (9) and
(10) into driven gear (11) using a press and
J47028 Scavenge Pump Bearing Installer
and J8092 Drive Handle. Install bearing with
driver against numbered bearing cage.
2. Install bearings (9) and (10) to a depth of 3
mm (0.118 inch).
3. Install new Orings (5) (12.4 mm ID) and (6)
(12.4 mm ID) onto shaft (4).
4. Install thrust washer (16) into pump body (17).
5. Lubricate gear set (15) and install the gear set
into pump body (17).
6. Position pump cover (14) on pump body (17)
and install four M8 x 1.25 x 20 bolts (19).
Tighten bolts (19) to 2429 Nm (1821 lb ft).
7. Align the ats on the driven gear hub with the
ats on the inner gear set. Slide driven gear
assembly (8) into pump assembly (13).
8. Install a new gasket (18), pump assembly
(13), and driven gear assembly (8) into pump
housing (3).
9. Secure the pump assembly (13) to the pump
housing (3) with three M8 x 1.25 x 30 bolts
(7). Tighten the bolts (7) to 2429 Nm (1821
lb ft).
10. Install thrust washer (12) into pump housing
(3).
11. Insert shaft (4) into pump housing (3) with the
hole in the shaft (4) aligned with the hole in
the pump housing (3).
12. Install retaining pin (2) into pump housing (3)
through the hole in shaft (4).
549
MODULE REBUILD
b. Disassembly of C6 Clutch (Foldout 14).
1. Remove retaining ring (6) (244.5 mm OD)
holding C6 clutch plates (10) and (11) and C6
clutch hub (7) in the C6 clutch housing.
2. Remove C6 clutch hub (7) by lifting it out along
with ve C6 clutch friction plates (10), four C6
clutch steel reaction plates (11), and backplate
(9). One steel reaction plate (11) will remain
in the C6 clutch housing (19). Inspect clutch
hub splines for wear and damage. Replace
hub (7) if it is damaged.
3. Remove the remaining steel reaction plate
(11) from the C6 clutch housing (19).
4. Separate backplate (9), ve friction plates
(10), and ve reaction plates (11).
5. Visually inspect the friction plates (10) for
damage or excessive wear. If a plate has
perceivable wear or distortion, measure for
step wear of friction plate (10), maximum
allowable step wear for reuse is 0.13 mm
(0.005 inch). Measure the cone of friction
plates (10). Maximum allowable cone of
friction plate for reuse is 0.4 mm (0.016 inch).
If replacement is necessary, remove the
friction plates by gently prying them from the
backplate.
6. Inspect steel reaction plates (11) for wear,
damage, and the following specications:
minimum thickness allowed: 2.36 mm (0.093
inch), maximum allowable cone 0.40 mm
(0.016 inch) if any of the above specications
are not met, replace the part.
7. Inspect backplate (9) for burrs, wear, damage,
atness, and the following specications:
minimum thickness 7.9 mm (0.311 inch), and
maximum cone 0.40 mm (0.016 inch).
8. Remove retaining ring (12) after using
J38573 C6 Spring Compressor to compress
the C6 piston spring retainer assembly (13).
9. Release the piston spring force, remove
the special tool and check sealring bores
in housing (19) for wear, nicks, and other
damage. Remove spring retainer assembly
(13).
10. Remove piston (14) by rmly striking the
housing against a at surface. Remove
sealrings (15) and (16) from piston (14).
551
552
MODULE REBUILD
9. Install pressure relief valve (6), and spring (7)
into bore in the pump housing.
553
MODULE REBUILD
J385792 Fwd/Rear Output and Idler Bearing
Installer on the press table, and then carefully
press the output shaft (57) into the bearing
until it is fully seated.
8. Place front yoke assembly (44) on a press
table.
9. Position output housing (49) on the yoke.
10. Place bearing spacer (54) and shims (51),
(52), or (53) on output shaft (57) the number
of shims could be one or more.
11. Install output shaft (57) into front output
housing (49) through bearing (47), output
seal (46), and into yoke (44). Once all the
components are properly aligned, press front
output shaft (57). Rotate output housing (49)
during this procedure to help the shaft and its
related components seat properly.
12. Install at washer (43) and front output shaft
nut (42).
13. Perform the bearing preload procedure as
explained in 516p. Output Housing Bearing
Preload Procedure (Foldout 14) which uses
the rear output housing as an example.
n. Disassembly of the Rear Output Housing
(Foldout 14).
1. Remove retaining ring (64) to remove P4 ring
gear (65).
555
556
MODULE REBUILD
s. Assembly of Transfer Case Module
(Foldout 122, Foldout 13, Foldout 14).
557
558
MODULE REBUILD
65. Position the wiring harness connector through
the transfer case and the connector plate.
66. Install four M8 x 1.25 x 25 bolts (32) and
tighten them to 58 Nm (46 lb ft).
67. Lube and Install a new Oring (5) on suction
hose tting (2). (Figure 571).
559
560
MODULE REBUILD
561
MODULE REBUILD
Spring Remover/Installer after turning handle
counterclockwise to release spring force.
563
564
MODULE REBUILD
3. If present, install two bolts (136) and OLS
assembly (137). Tighten bolts to 1013 Nm
(710 lb ft).
4. Install the turbine speed sensor (94), and the
bolt (93). Tighten bolt to 1013 Nm (710
lb ft).
n. Installation of Filters (Foldout 151,
Foldout 152).
1. Install suction lter (5), gasket (7) and face
seal (6). Install three bolts (3). Tighten bolts to
1013 Nm (710 lb ft).
2. Install two lters (162), two Orings (161), two
Orings (160), two gaskets (159), and two lter
covers (158).
3. If present and not previously installed, install
OLS assembly (161) and two bolts (160).
Tighten bolts to 1013 Nm (710 lb ft).
565
566
SCOPE
Title
33. REPLACEMENT
PARTS
Replacement Parts
34. CAREFUL
HANDLING
Careful Handling
37. REMOVING
(OR INSTALLING)
TRANSMISSION
(Figure 312,
Figure 313)
Removing Transmission
Spring Data
62.
ASSEMBLY OF TRANSMISSION
61
62
TRANSMISSION ASSEMBLY
h. Main Shaft Selective Shim Measurement For
Close Ratio Models (Figure 67).
1. Place a straightedge across the retarder
or rear cover mounting surface of the main
housing.
2. Measure dimension A, from the top of the
straightedge to the selective shim thrust
surface on the main shaft bearing spacer.
3. Measure dimension B, thickness of
straightedge. Subtract dimension B from
dimension A the 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
mounting surface and place a straightedge
across the P3 planetary carrier.
Figure 65. P2 Planetary Module and C5
Clutch Pack Installation
NOTE: Friction plates should be soaked
in clean transmission uid as discussed
in 36d. Clutches and Pistons prior to
assembly.
g. Installation of the Main Shaft (Figure 66).
Install main shaft (1) as assembled in Section 5.
MODULE REBUILD, without selective shim (2)
and thrust bearing (3) (does not apply to 3700 SP
models).
63
Figure 67. Main Shaft Selective Shim Measurement (Close Ratio Models)
3000 Product Family Except 3700 SP
i. Main Shaft Selective Shim Measurement
(Wide Ratio Models) (Figure 68).
1. Place a straightedge across the retarder
or rear cover mounting surface of the main
housing.
64
TRANSMISSION ASSEMBLY
dimensions E from dimension D the
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
thrust bearing.
Figure 68. Main Shaft Selective Shim Measurement (Wide Ratio)3500 Model
j. Main Shaft Selective Shim Measurement For
3700 SP (Figure 69).
65
66
TRANSMISSION ASSEMBLY
67
68
TRANSMISSION ASSEMBLY
69
610
TRANSMISSION ASSEMBLY
Figure 615. Torque Converter Module Installation and Selective Shim Measurement
Table 61. Torque Converter Selective Shims
Dimension C
Use P/N
29505688
29505681
29505682
29505683
29505684
29505685
29505686
611
612
TRANSMISSION ASSEMBLY
NOTE:
For units without retarder, go to
Step 1.
For units with retarder, skip Steps
15 and go to Step 6.
1. Install the two M10 guide studs at rear of main
housing where the cooler housing attaches.
Install the gasket (5) and the cooler housing
(7) onto the guide bolts. Be sure the housing
and gasket are properly aligned.
2. Install the ve M10 x 1.5 x 205 bolts (12) with
new washers (11).
3. Remove the two M10 guide studs and install
the remaining two or four M10 x 1.5 x 205
bolts (12) with new washers (11).
4. Install the three M12 x 1.75 x 230 bolts (13)
with new washers (14). Tighten the M10 x
1.5 x 205 bolts (12) to 5161 Nm (3845 lb
613
614
TRANSMISSION ASSEMBLY
NOTE:
For models without PTO, go to Step 3.
For models with PTO, skip Step 3 and
go to Step 4.
3. Install input speed sensor assembly (3)
(Foldout 61), Oring (4), retainer (5), and M8
x 1.25 x 20 bolt (6) into the converter housing
module. Tighten M8 x 1.25 x 20 bolt (6) to
2429 Nm (1821 lb ft).
4. Install input speed sensor assembly (18)
(Foldout 62), Oring (19), retainer (20), and
M8 x 1.25 x 20 bolt (21) into the converter
housing module. Tighten M8 x 1.25 x 20 bolt
(21) to 2429 Nm (1821 lb ft).
v. Installation of Common ExternallyMounted
Parts (Figure 618).
1. Install transmission breather (26), if not
previously installed. Tighten breather to 1216
Nm (912 lb ft).
615
616
TRANSMISSION ASSEMBLY
617
618
72.
SPRING DATA
Description
Wear Limit
mm (inches)
Foldout 5
Bushing, Maximum ID
61.51 (2.422)
10
5.71 (0.225)
12
0.51 (0.020)
12
0.625 (0.025)
0.38 (0.015)
13
0.15 (0.006)
14
8.58 (0.338)
12, 17
71
Description
Wear Limit
mm (inches)
15
56.75 (2.234)
17
61.34 (2.415)
22
11.68 (0.460)
23
33
Foldout 62
74.99 (2.952)
75.23 (2.962)
140.06 (5.514)
10, 16
0.57 (0.022)
10, 16
1.15 (0.045)
13
0.38 (0.015)
22
Foldout 71
140.03 (5.513)
75.23 (2.962)
17.93 (0.706)
127.30 (5.012)
9, 10
0.36 (0.014)
10
0.20 (0.008)
10
126.95 (4.998)
10
17.81 (0.701)
10, 14
0.13 (0.005)
11
57.30 (2.256)
14
4.70 (0.185)
57.04 (2.246)
20
98.83 (3.891)
23
0.57 (0.022)
23
1.44 (0.057)
16, 17
Foldout 72
72
0.25 (.010)
20.19 (0.795)
10
0.46 (0.018)
10
0.94 (0.037)
11
0.38 (0.015)
Description
Wear Limit
mm (inches)
13
99.25 (3.907)
29
0.15 (0.006)
29
4.20 (0.165)
32
8.20 (0.323)
30, 38
0.40 (0.016)
30, 38
2.21 (0.087)
30, 38
0.20 (0.008)
31, 37
0.40 (0.016)
31, 37
2.36 (0.093)
34, 36
0.38 (0.015)
39
0.45 (0.018)
39
6.25 (0.246)
43
68.22 (2.685)
Foldout 81
0.15 (0.006)
0.13 (0.005)
5, 16
68.22 (0.006)
5, 16
2.81 (0.111)
0.38 (0.015)
0.40 (0.016)
7, 15
2.21 (0.087)
7, 15
4.00 (0.157)
7, 15
0.20 (0.008)
0.40 (0.016)
3.20 (0.126)
2.36 (0.093)
9, 16
0.40 (0.016)
9, 16
3.41 (0.135)
13, 18
0.15 (0.006)
22
1.15 (0.045)
28
2.90 (0.114)
28
0.20 (0.008)
7
7, 15, 29
8, 14, 28
8, 14
28
Foldout 82,
Foldout 91
NA
0.38 (0.015)
9, 8
19.98 (0.787)
73
Description
Wear Limit
mm (inches)
9, 8
42.97 (1.692)
Foldout 92
NA
0.38 (0.015)
19.98 (0.787)
42.97 (1.692)
35.92 (1.414)
52.98 (2.086)
Foldout 101
P1 PLANETARY MODULE
9, 12
1.39 (0.054)
9, 12
0.12 (0.005)
10
0.94 (0.037)
14
0.38 (0.015)
Foldout 102
6
P2 PLANETARY MODULE
P2 Carrier Bushing, Maximum ID
43.20 (1.701)
7, 10
1.39 (0.054)
7, 10
0.12 (0.005)
0.94 (0.037)
14
0.38 (0.015)
Foldout 11A
20.19 (0.795)
0.38 (0.015)
16, 19
1.39 (0.054)
16, 19
0.12 (0.005)
0.94 (0.037)
95.67 (3.767)
0.38 (0.015)
17
29, 32
31
Foldout 11B
20.19 (0.795)
0.38 (0.015)
17, 20
1.39 (0.054)
17, 20
0.12 (0.005)
0.94 (0.037)
18
Foldout 13
74
C7 CLUTCH HOUSING
44
76.20 (3.000)
61
8.67 (0.341)
62
2.21 (0.087)
Description
Wear Limit
mm (inches)
62
0.20 (0.008)
62
0.25 (0.010)
63
2.06 (0.081)
63
0.25 (0.010)
68
Bushing, Maximum ID
47.26 (1.861)
69
1.00 (0.040)
Foldout 14
C6 CLUTCH HOUSING
7.90 (0.311)
0.40 (0.016)
10
3.68 (0.145)
10
0.20 (0.008)
11
2.36 (0.093)
11
0.40 (0.016)
19
2.29 (0.090)
21
C6 Housing Bushing
36.18 (1.424)
Foldout 172
6
53.22 (2.095)
8, 11
1.39 (0.054)
8, 11
0.12 (0.005)
0.94 (0.037)
9
Foldout 191
16
SCAVENGE PUMP
Scavenge Pump Thrust Washer, Minimum Thickness
2.47 (0.097)
75
76
Ref.
Spring
Part No.
Color
Code
No. Coils
Wire Dia.
mm (in.)
Spring OD
mm (in.)
Approx.
Free Length
mm (in.)
3.3 (0.13)
0.71.6
(0.160.36)
Foldout 5
25
Stator
29500064
No Code
N/A
Convoluted
N/A
N/A
17.8 (0.70)
Foldout 72
21
C2 Return
Spring
Assembly
29503215
No Code
12*
2.04 (0.080)*
13.00
(0.512)*
45.3 (1.78)*
37.0
(1.46)
48235379
(10841209)**
Foldout 72
25
C1 Return
Spring
Assembly
23045586
No Code
10*
2.19 (0.086)*
16.00
(0.630)*
45.2 (1.78)**
27.5
(1.08)
57636369
(12961432)**
Foldout 81
10
C3 Return
29505570
No Code
11*
1.70 (0.067)*
12.00
(0.472)*
38.9** (1.53)
24.5
(0.96)
232256**
(52.257.6)
Foldout 81
20
C4 Return
29505570
No Code
11*
1.70 (0.067)*
12.00
(0.472)*
38.9 (1.53)**
24.5
(0.96)
232256
(52.257.6)**
Foldout 11A
Foldout 11B
23/23
C5 Retainer
29507780
No Code
9.5*
1.83 (0.072)*
14.35
(0.565)*
39.2 (1.54)*
25.0
(0.98)
30443364
(684756)**
Foldout 11A
Foldout 11B
46/55
Retarder
29515692
None
11.4
4.12 (0.162)
36.17 (1.42)
114.3 (4.50)
91.1
(3.59)
200.0226.6
(44.9650.94)
Foldout 11B
Foldout 172
23/16
C5 Retainer
29500867
No Code
11.5*
2.16 (0.085)*
16.00
(0.630)*
52.1 (2.05)**
33.0
(1.30)
30343498
(682.1786.4)**
Foldout 14
13
C6 Spring
Retainer
Assembly
29501191
No Code
10
1.84 (0.072)
12.70
(0.500)
35.10 (1.382)
26.20
(1.032)
212331
(474524)**
Foldout 151
71
A Trim
23049338
No Code
0.67 (0.026)
11.05
(0.435)
6.5 (0.26)
3.45
(0.14)
3.24.2
(0.720.94)
Foldout 151
66
Lock Up
29542938
No Code
0.67 (0.026)
11.05
(0.435)
6.5 (0.26)
3.45
(0.14)
0.720.94
(0.720.94)
Foldout 151
89
D Trim
29542936
No Code
0.67 (0.026)
11.05
(0.435)
6.5 (0.26)
3.45
(0.14)
3.24.2
(0.720.94)
Foldout 151
76
B Trim
29542936
No Code
0.67 (0.026)
11.05
(0.435)
6.5 (0.26)
3.45
(0.14)
3.24.2
(0.720.94)
Foldout 151
Foldout 151
79 83
Diagnostic
Trim C
29542941
No Code
No Code
1.30 (0.039)
10.50
(0.433)
27.03 (1.06)
15.49
(1.02)
2.45 (0.78)
29542936
mm (in.)
Ref.
Spring
Part No.
Color
Code
No. Coils
Wire Dia.
mm (in.)
Spring OD
mm (in.)
Approx.
Free Length
mm (in.)
N (lb) min
100
Lockup
Relay
23049326
No Code
10
1.37 (0.054)
14.10
(0.555)
42.1 (1.66)
17.0
(0.67)
49.260.2
(11.0613.53)
Foldout 151
104
Lube
Regulator
23049327
Red
13
1.22 (0.048)
11.10
(0.437)
46.3 (1.82)
23.5
(0.93)
46.551.3
(10.511.5)
Foldout 151
108
Main
Regulator
29500963
Lt. Blue
15
2.87 (0.113)
22.0 (0.866)
98.5 (3.88)
54.6
(2.15)
305337
(68.675.8)
Foldout 151
112
Control Main
29542926
Orange
10
1.83 (0.072)
14.8 (0.583)
44.6 (1.76)
24.2
(0.95)
131145
(29.532.6)
Foldout 151
123
C2 Latch
29542929
Lt. Green
11
1.32 (0.052)
11.43
(0.450)
41.3 (1.63)
19.0
(0.75)
64.178.3
(14.417.6)
Foldout 151
127
Exhaust
Back
23049391
No Code
17
0.61 (0.024)
7.80 (0.307)
29.2 (1.15)
18.2
(0.72)
2.402.94
(0.540.66)
Foldout 151
130
C1 Latch
29542929
Blue
12
1.37 (0.054)
16.26
(0.640)
46.2 (1.82)
29.2
(1.15)
16.718.9
(3.754.25)
Foldout 151
134
Converter
Regulator
29507456
Pink
10.2
1.57 (0.060)
11.00
(0.433)
30.3 (1.19)
22.8
(0.90)
53.759.3
(12.013.3)
Foldout 11A
67/74
Retarder
Valve Body
29529310
Lt Green/
Lt Gray
10.45
0.97 (0.038)
12.19 (0.50)
38.15 (1.50)
17.70
(0.70)
14.70 (10.84)
Foldout 71
26
Main
Pressure
Relief Valve
29507709
No Code
10.0
3.25 (0.128)
17.96 (0.71)
52.38 (2.06)
40.66
(1.61)
509.30 (375.59)
Foldout 151
161
Filter Life
29546549
Lt Blue
10.77
1.09 (0.043)
10.80 (0.43)
27.30 (1.07)
16.67
(0.66)
18.69 (13.78)
Individual Springs
the Complete Spring Assembly
OD at Larger End
**For
Foldout 151
77
78
OWNER ASSISTANCE
81
SERVICE LITERATURE
Publication Name
Troubleshooting Manual
TS3989EN
*Worldwide
SA2229EN
Directory
*
SGI, Inc.
Attn: Allison Literature Fulllment Desk
8350 Allison Avenue
Indianapolis, IN 46268
TOLL FREE: 8886665799
INTERNATIONAL: 3174714995
Table 81. Service Literature
3000 Product
Family
Publication Name
Allison DOC For PC Service Tool
User Guide
GN3433EN
*Mechanics
Tips
MT4015EN
MT4108EN
*Mechanics
MT3657EN
MT3655EN
*Mechanics
MT4085EN
Series)
*Mechanics
*Operators
Tips (T Series)
OM3749EN
Manual (Emergency
Vehicle Series)
OM3656EN
*Operators
OM3750EN
*Operators
Manual (Motorhome
OM3349EN
*Operators
Series)
*Operators
Manual (Pupil
Transport/Shuttle Series)
OM3751EN
*Operators
OM3752EN
*Operators
OM3753EN
*Operators
Manual (T Series)
OM3529EN
Series)
Parts Catalog
PC2150EN
CD2150EN
Principles of Operation
PO4016EN
*Service
SM4013EN
82
Manual
3000 Product
Family
Foldout 1
Foldout 1
FOLDOUT 1
Foldout 2
Foldout 2
FOLDOUT 2
Foldout 2. 3000 Product Family Transmission (Except 3700 SP) with PTO Provision and RetarderCross Section
Foldout 3
Foldout 3
FOLDOUT 3
Foldout 4
Foldout 4
FOLDOUT 4
Foldout 5
(28)
(28)
(29)
(30)
(31)
(32)
(33)
(34)
Torque
Nm
lb ft
3035
2226
Foldout 5
FOLDOUT 5
Foldout 6
62
Torque
Nm
lb ft
2429
1821
5161
3845
1216
912
1013
710
Foldout 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)
Torque
Nm
lb ft
5161
3845
2429
1821
1216
912
FOLDOUT 6
Foldout 7
Torque
Nm
lb ft
5161
3845
72
(1)
(2)
(2)
(2)
(2)
(2)
(2)
(2)
Foldout 7
(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)
Torque
Nm
lb ft
100120
7489
FOLDOUT 7
Foldout 8
82
(1)
(1)
(1)
(1)
(1)
(1)
(1)
(2)
(3)
(4)
(5)
(6)
(7)
(8)
(9)
Torque
Nm
lb ft
5161
3845
Foldout 8
FOLDOUT 8
Foldout 82. 3000 Product Family Main Shaft Module (Except 3500 and 3700 SP)Disassembled View
Foldout 9
A 3500
Selective shim
Thrust bearing assembly
Main shaft module
Spiral retaining ring
P2 sun gear
Thrust bearing assembly
Bearing spacer
Main shaft
92
(1)
(2)
(3)
(4)
(5)
(6)
(7)
(8)
B 3700SP
Thrust bearing assembly
Main shaft module
Spiral retaining ring
Thrust bearing
P2 sun gear
Bearing spacer
P3 sun gear
Main shaft
Foldout 9
FOLDOUT 9
Foldout 10
P1 planetary module
Internal retaining ring
Thrust bearing assembly
P1 planetary carrier assembly
Retaining ring
P1 indexing ring
P1 planetary spindle (6)
P1 planetary carrier
P1 thrust washer (6)
P1 pinion gear (6)
Roller bearing assembly (12)
P1 thrust washer (6)
Thrust bearing assembly
P2 planetary ring gear
102
(1)
(2)
(3)
(4)
(5)
(6)
(7)
(8)
(9)
(10)
(11)
(12)
(13)
(14)
P2 planetary module
Internal retaining ring
P2 planetary carrier assembly
Carrier and bushing assembly
P2 planetary carrier
Bushing
Thrust washer (4)
Roller bearing (8)
P2 pinion gear (4)
Thrust washer (4)
P2 planetary spindle (4)
P2 indexing ring
Internal retaining ring
P3 planetary ring gear
Foldout 10
FOLDOUT 10
Foldout 11A
Foldout 11A
(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)
Retarder housing
Gasket
Cover
Bolt, M8 x 1.25 x 25 (9), C
Spring pin, 5 x 45
Retarder valve
Retarder valve spring
Oring
Valve plug
Internal retaining ring
Oil seal assembly
Nut, bearing retainer
Belleville spring washer
Roller bearing
Separator plate
Retarder control body assembly
Retarder valve body
Valve
Spring
Plug assembly
Oring, 16.4 mm ID
Plug
Plug assembly
Plug
Oring, 16.4 mm ID
Spring
Regulator valve
Retainer pin
Solenoid and connector assembly
Solenoid, variable bleed
Oring, square cut
Oring
Bolt, M8 x 1.25 x 65, C
Plug assembly
Plug, C
Oring
Shipping cover
Gasket
Jumper manifold
Remote manifold
Bolt, M10 x 1.5 x 30 (4), B
Torque
Nm
lb ft
90110
6681
5161
3845
2429
1821
Nm
lb ft
6067
4450
7488
5565
1013
710
Foldout 11A
Foldout 11A
FOLDOUT 11A
Foldout 11B
Torque
Nm
lb ft
90110
6681
2429
1821
7488
5565
Foldout 11B
FOLDOUT 11B
Foldout 12
(6)
(7)
(8)
(9)
(10)
(11)
(12)
(13)
A KentMoore Tools
J 38547 Forward/rear output seal installer
J 38568 Bearing cup installers
J 385681 Drive/driven bearing cup installer
J 385682 Idler bearing cup installer
J 385683 Forward/rear output bearing cup
installer
J 38569 P3 carrier/C6/C7 housing bushing
installer
J 38572 Transfer case holding xture
J 38573 C6 spring compressor
J 38579 Bearing installers
J 385791 Drive/driven bearing installler
J 385792 Forward/rear output and idler bearing
installer
J 38547 Front and rear output seal installer
J 39623 Bearing end play checker
122
(1)
(2)
(3)
(4)
(5)
(6)
(7)
(8)
(9)
(10)
(11)
(12)
(13)
(14)
(15)
(16)
(17)
(18)
(19)
(20)
(21)
(22)
Foldout 12
Nm
lb ft
5161
3845
FOLDOUT 12
Foldout 13
(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)
Foldout 13
(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)
Nm
lb ft
5161
3845
58
46
2429
1821
1214
910
610815
450600
2.734.09
2436 lb in.
Foldout 13
Foldout 13
FOLDOUT 13
Foldout 14
Foldout 14
(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)
Idler cover
Bolt, M10 x 1.5 x 40 (5), A
Orice plug, 5 mm (0.197 inch)
Drain plug assembly, D
Oring
Bearing retainer
Bolt, M10 x 1.5 x 35 (8), A
P4 carrier assembly
P4 carrier
Planetary pinion shaft setscrew (3), D
P4 spindle
Roller bearings
Pinion gear (17T)
Thrust washer
Sun gear
External retaining ring
Ring gear (59T)
Rear output shaft
Tapered roller bearing cone
Tapered roller bearing cup
Output bearings spacer
Output bearing retainer shim 0.254 mm (0.010
inch)
Output bearing retainer shim 0.127 mm (0.005
inch)
Output bearing retainer shim 0.076 mm (0.003
inch)
Output housing gasket
Output housing
Bolt, M10 x 1.5 x 40 (6), A
Tapered roller bearing cup
Tapered roller bearing cone
Output oil seal
Rear yoke assembly (16 TYS)
Flat washer
Rear output shaft nut, E
Bolt, M10 x 1.5 x 100 (9), A
Torque
Nm
lb ft
5161
3845
2429
1821
1214
910
2535
1826
610815
450600
FOLDOUT 14
Foldout 15
Foldout 15
(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)
(91)
(92)
(93)
Bracket
Bolt, M6 x 1.0 x 45 (2), A
Face seal
Accumulator spring
Accumulator plug (2)
Accumulator plug (2)
Accumulator spring (2)
Switch assembly
Switch
Bracket
Bolt, M6 x 1.0 x 95 (12), A
Solenoid body assembly
Body Assembly valve and pin
Body
Pin (3)
Variable bleed solenoid (TCC)
Oring
Oring
TCC valve
Spring
Variable bleed solenoid (PCS1)
Oring
Oring
PCS1 valve
Spring
Variable bleed solenoid (PCS2)
Oring
Oring
PCS2 valve
Spring
Clip
Diagnostic valve
Spring
Variable bleed solenoid (PCS3)
Oring
Oring
PCS3 valve
Spring
Variable bleed solenoid (PCS4)
Oring
Oring
PCS4 valve
Spring
Variable bleed solenoid (Main Mod)
Oring
Oring
Bolt, M6 x 1.0 x 20 (2), A
Speed sensor
Bolt, M6 x 1.0 x 60 (2), A
Separator plate
Main valve body assembly
Retention pin 5 OD x 43
Lockup valve
Spring
Valve stop
Retention pin 3 OD x 45
Lube regulator valve
Spring
Valve stop
Retention pin 5 OD x 43
Main regulator valve
Spring
Valve stop
Retention pin, 5 OD x 43
Control main valve
Spring
Clip
Retention pin, 2.5 OD x 40
Solenoid assembly
Oring
Oring
Control valve body
Retention pin 5 OD x 43
Retention pin 5 OD x 43
Retention pin 5 OD x 43
C2 latch valve
Spring
Valve stop
Retention pin, 5 OD x 43
Exhaust backll valve
Spring
Valve stop
C1 latch valve
Spring
Valve stop
Retention pin, 5 OD x 43
Converter regulator valve
Spring
Valve stop
Bolt, M6 x 1.0 x 45 (2), B
Oil level sensor assembly
Ferrule Viton (2)
Separator plate
Channel plate gasket
Oil transfer plate assembly
Drain plug
Dowel pin (2)
(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)
(175)
(176)
(177)
(178)
(179)
(180)
(181)
(182)
(183)
(184)
(185)
(186)
Torque
Nm
lb ft
1013
710
58
46
2.53.5
2231 lb inch
Foldout 15
Nm
lb ft
2532
1824
5161
3845
Foldout 15
FOLDOUT 15
Foldout 16
(34)
(35)
(36)
(37)
(38)
(39)
(40)
(41)
(42)
(43)
(44)
Foldout 16
(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)
Connector
Connector Assembly, 2Way (TCC)
Connector Assembly, 2Way (PCS1)
Connector Assembly, 2Way (PCS2)
Bolt, M6 x 1.0 x 45 (3)
Bracket
Bolt, M6 x 1.0 x 45 (2)
Seal, Face (3)
Spring, Accumulator (2)
Plug, Accumulator (2)
Plug, Accumulator (2)
Spring, Accumulator (2)
Switch Assembly
Switch
Bracket
Bolt, M6 x 1.0 x 95 (12)
Body Assembly, Solenoid
Body Assembly, Solenoid Valve And Pin
Body
Pin (3)
Solenoid, TCC, Variable Bleed, CENL. Connector
Body
Oring, 13.0 mm ID
Oring, 10.5 mm ID
Valve, Lockup Trim
Spring
Solenoid, PCS1, Variable Bleed, CENH.
Connector Body
Oring, 13.0 mm ID
Oring, 10.5 mm ID
Valve, Clutch Trim
Spring, Trim
Solenoid, PCS2, Variable Bleed, CENH.
Connector Body
Oring, 13.0 mm ID
Oring, 10.5 mm ID
Valve, Clutch Trim
Spring, Trim
Clip
Valve, Diagnostic (3)
Spring, Diagnostic (3)
Solenoid, PCS3, Variable Bleed, CENL.
Connector Body
Oring, 13.0 mm ID
Oring, 10.5 mm ID
Valve, Clutch Trim
Spring, Trim
(127)
(128)
(129)
(130)
(131)
(132)
(133)
(134)
(135)
(136)
(137)
(138)
(139)
(140)
(141)
(142)
(143)
(144)
(145)
(146)
(147)
(148)
(149)
(150)
(151)
(152)
(153)
(154)
(155)
(156)
(157)
(158)
(159)
(160)
(161)
(162)
(163)
(164)
(165)
(166)
Foldout 16
Foldout 16
FOLDOUT 16
Foldout 17
172
Output ange
Blank ange
Oring
Oring
Oring
Retainer plug
Bolt, M10 x 1.5 x 30 (2), A
Output shipping cover
Output yoke
Output yoke
Bolt
Slinger
Torque
Nm
lb ft
3035
2226
7080
5160
Foldout 17
(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)
P3 carrier assembly
Internal retaining ring
P3 indexing ring
Carrier and bushing assembly
P3 planetary carrier
Bushing
P3 planetary spindle (4)
P3 thrust washer (4)
P3 pinion gear set (contains 4 pinions)
Roller bearing assembly (8)
P3 thrust washer (4)
Selective shim
Adapter housing gasket
Adapter housing assembly
External retaining ring
Spring retainer assembly
C5 clutch piston
C5 outer piston sealring
C5 inner piston sealring
Adapter housing
Plug assembly
Plug, A
Oring
Filter screen
Bolt, M10 x 1.5 x 70 (4), B
Transfer case housing gasket
Bolt, M10 x 1.5 x 205, (stepped and knurled
shank) B
Bolt, M10 x 1.5 x 205, (bulged shank) B
Bolt, M12 x 1.75 x 60 (3), C
Bolt, M10 x 1.5 x 100 (3), B
Bolt, M10 x 1.5 x 40 (2), B
Bolt, M12 x 1.7 x 45 (15), C
Bolt, M10 x 1.5 x 40 (19), B
Torque
Nm
lb ft
3447
2535
5161
3845
90110
6681
FOLDOUT 17
Foldout 18
182
Gasket
Cover
Cooler port manifold
Bolt, M10 x 1.5 x 28 (6), A
Gasket (without retarder)
Gasket (retarder)
Cooler housing
Gasket (2)
Connector (2)
Bolt, M10 x 1.5 x 35 (8), A
Washer
Bolt, M10 x 1.5 x 205 (used with retarder), A
Bolt, M12 x 1.75 x 230 (3, with retarder), B
Washer (3)
Bolt, M10 x 1.5 x 70 (9, without retarder), A
Bolt, M10 x 1.5 x 225 (6, with retarder), A
Washer (9, or 6)
Pressure tap plug assembly (2), C
Pressure tap plug
Oring
Plug, 1/214, D
Elbow (2)
Gasket
Cover
Bolt, M12 x 1.75 x 25 (2), E
Bolt, M10 x 1.5 x 35 (17), A
Oring (2)
Plate assembly
Oring
Oring
Torque
Nm
lb ft
5161
3845
100120
7488
1013
710
2227
1620
90110
6681
Foldout 18
(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)
Torque
Nm
lb ft
33
24
63
47
113
79
FOLDOUT 18
Foldout 19
Torque
Nm
lb ft
3035
2325
192
(1)
(2)
(3)
(4)
(5)
(6)
(7)
(8)
(9)
(10)
(11)
(12)
Parking brake, 12 x 4
Bolt, M16 x 2.0 x 40 (4), A
Brake drum
Bolt, 3824 x 34 (2), B
Stud (2)
PTO gasket
Bolt, M10 x 1.5 x 35 (8), C
PTO assembly
Stud (2)
PTO gasket
Bolt, M10 x 1.5 x 35 (8), C
PTO assembly
Torque
Nm
lb ft
228266
168196
5666
4149
5161
3845
Foldout 19
FOLDOUT 19
FOLDOUT 20
FOLDOUT 21
FOLDOUT 22
FOLDOUT 23
FOLDOUT 24
FOLDOUT 25
FOLDOUT 26
FOLDOUT 27
FOLDOUT 28
FOLDOUT 29
FOLDOUT 30
FOLDOUT 31
FOLDOUT 32
FOLDOUT 33
FOLDOUT 34
FOLDOUT 35
FOLDOUT 36
FOLDOUT 37
FOLDOUT 38
SM4013EN 200906