3K Technician's Guide

TECHNICIANS’ GUIDE
INSPECTION AND ANALYSIS OF THE

ALLISON 3000 / B 300 / B 400
PRODUCT FAMILIES
GN4064EN
(5/05)
ALLISON 3000 / B 300 / B 400 PRODUCT FAMILIES
Glossary of Terms . . . . . . . . . . . 2 P2 Planetary Module . . . . . 43-44

Introduction to P1 Planetary Module . . . . . 45-46
Inspection & Analysis . . . . . . . . 3
Front Support &
General Inspection Oil Pump Module . . . . . . . . 47-49
Guidelines for
Q Cast Parts & Machined Rotating Clutch
Surfaces . . . . . . . . . . . . . . . . . . 4 Module . . . . . . . . . . . . . . . . . 50-54
Q Gears . . . . . . . . . . . . . . . . . . . . 5
C3/C4 Clutch
Q Splines . . . . . . . . . . . . . . . . . . . 6 Module . . . . . . . . . . . . . . . . . 55-57
Q Bearings . . . . . . . . . . . . . . . . 7-8
Main Housing . . . . . . . . . . . 58-59
Q Bushings . . . . . . . . . . . . . . . . . 9
NOTICE: This guide is intended

Direct Mount Oil Cooler . . . . . 60
Q Retaining Rings . . . . . . . . . . 10
for use by technicians skilled Q Thrust Washers . . . . . . . . . . . 11
3070 Main Shaft Module . . . . . 61
in diagnosis and repair of
Q Clutch Plates . . . . . . . . . . 12-13 Transfer Case
automatic transmissions.
Scavenge Pump . . . . . . . . . . . . 62
Contact an authorized Allison Q Springs . . . . . . . . . . . . . . . . . 14
Transmission service outlet for Q Valves & Valve Bores . . . . . . 15 Transfer Case
further information or Adapter Housing . . . . . . . . . 63-64
clarification if required. All Control Module . . . . . . . . . . 16-21 Transfer Case
specifications provided in this Torque Converter Housing Assembly . . . . . . . 65-66
manual are subject to change Module . . . . . . . . . . . . . . . . . 22-27
Transfer Case Cover . . . . . . . . 67
without notice. Torque Converter
Housing Module . . . . . . . . . 28-30 Transfer Case Gears . . . . . . . . 68
Standard Rear Cover & P3 Transfer Case
Planetary Module . . . . . . . . 31-35 C6 Clutch Assembly . . . . . . 69-70
Retarder Module & Transfer Case
P3 Planetary . . . . . . . . . . . . 36-40 C7 Clutch Assembly . . . . . . 71-72
Close Ratio Main Transfer Case Front
Shaft Module . . . . . . . . . . . . . . 41 Output Components . . . . . . . . 73
Wide Ratio Main Transfer Case Rear
Shaft Module . . . . . . . . . . . . . . 42 Output Components . . . . . . 74-75
Wear Limits and
Spring Data . . . . . . . . . . . . . 76-83
ALLISON TRANSMISSION TECHNICIANS’ GUIDE i

 2005 General Motors Corporation.
ALLISON 3000/B 300/B 400 PRODUCT FAMILIES
GLOSSARY OF TERMS
Abrade - Scrape off Metal Transfer - Metal from one

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

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

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

that metal transfer occurs
Grooves - Long narrow
depressions
Inadequate - Not enough
Light Stoning - Using a

medium India oilstone to
remove material
2 ALLISON TRANSMISSION TECHNICIANS’ GUIDE

INTRODUCTION TO INSPECTION & ANALYSIS
The Technicians’ Guide is

intended to provide additional
guidance with the inspection and
analysis of transmission parts.
This guide should be used by
technicians who overhaul Allison
3000/B300/B400 automatic
transmissions in conjunction with
the 3000/B300/B400 Service
Manual (SM2148EN) when
inspecting parts to determine their
serviceability and reuse.
General Rework Guidelines

Replace parts that cannot be
re-worked as outlined in this
manual and Service Manual SM
2148EN. A soft stone or crocus
cloth can be used to attempt
removal of “high spots” from
transmission parts. After the
attempted rework, the part must
meet specification if it is going to
be reused. Some seal surfaces, for
example the output yoke sealing
surface and the converter pump
hub sealing surface, cannot be
reworked. Both of these seal
surfaces have a controlled finish
that can result in a fluid leak if the
part is altered by rework.
ALLISON TRANSMISSION TECHNICIANS’ GUIDE 3

GENERAL INSPECTION GUIDELINES FOR
CAST PARTS & MACHINED SURFACES
A. Housings
D. Splines
B. Machined
Surfaces
C. Fluid
Passages C. Fluid
Passages
A. Cast Parts
A. Replace housings or other cast C. Inspect all fluid passages for Q Torque converter front cover
parts that are cracked or broken. obstructions, porosity, broken flexplate adapter bolt holes and
Inspect clutch housing sealing lands, cracks and land surface lockup clutch backplate bolt
surfaces for imperfections that imperfections. holes (starting with S/N
could damage the piston seals or 6510024410).
interfere with mating parts. D. Replace housings that have
Inspect threaded holes for bad splines worn beyond wear limits. Q Output shafts using a single bolt
threads. Clean damaged threads Refer to the Wear Limits Table for flange or yoke retention
with the correct size tap. (7-1) in Service Manual SM2148EN. (starting with S/N 6510184819).
B. Inspect all machined surfaces NOTE: Some parts have Spiralock® NOTE: Do not use impact guns
for damage that could cause fluid threaded holes . A standard tap will (air wrenches, electric impact
leakage. Inspect mounting faces eliminate the locking feature wrenches, etc.) when working with
and bores for damage. requiring the reworked part to be aluminum threads or when torque
replaced. For repair, use a sequencing bolts.
Spiralock® tap to repair Spiralock®
threaded holes. As of this printing,
the following parts have Spiralock®
threaded holes:

GEARS
A. Gear
Teeth
Check gears for

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

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

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

damage. Remove burrs with a soft otherwise listed in Wear Limits
stone. Spline wear is not considered Table 7-1 in Service Manual
harmful except where it affects the SM2148EN. Do not reuse a splined
fit of the splined parts. Spline wear part that exceeds the published
is determined by comparing feeler maximum spline wear. Backlash
gauge thickness with the thickness cannot be used to establish critical
of the worn area on the spline. spline wear. Accurate backlash
Replace parts having excessive measurement requires the mating
spline wear. The maximum parts to be concentrically located.
movement allowed at the splines is

BEARINGS
B. Bearing
C. Retainer
Race
C. Retainer
A. Rollers
C. Retainer B. Bearing
Race
A. Replace the bearing if any bearing. Replace the bearing if races

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

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

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

BUSHINGS
Bushing wear is strongly

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

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

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

THRUST WASHERS
Thrust
Washers
A. Replace thrust washers if they

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

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

(continued) CLUTCH PLATES
C. Tangs
Note: Current friction plates - two Acceptable

missing splines. Previous versions discoloration -
had one or no missing splines. reuse plates.
Excessive scoring -
B. Thickness replace plates.
& Coning
(see prior
page
graphic)
Broken tangs -
replace plates.
A. Contact
Surfaces
NOTE: The current clutch friction 3060, MD-3560, B300, or 3000MH- cannot be repaired using a soft
plates were implemented April of 2000 Standard with former friction plates stone or crocus cloth.
starting with s/n 6510262117. Current will require a new ECU calibration
production friction plates will have from Allison Transmission to use the B. Measure reaction plate
two missing splines. Former friction current friction plates in C1, C2, C3 thickness and coning. Reference
plates will either have one spline and C4. Any WTEC III ECU equipped the Service Manuals for minimum
missing or none missing. Any 3000/B vehicle with an MD-3060, MD-3560, thickness and maximum coning
300/B 400 model transmission may be B300, or 3000MH-Standard with an specifications. Do not reuse plates
updated from former C5 friction plates ECU calibration installed prior to that do not meet published
to current C5 frictions without October 25th, 1999 will require an
specifications. If reused plates are
recalibrating the transmission ECU. updated ECU calibration to use the
The rest of the clutches in the main current friction plates in C1, C2, C3, slightly coned (within
housing (C1 through C4) must be and C4. Do not intermix both former specification), make sure each plate
updated with current friction plates if and current friction plates in a clutch is stacked with the cone facing the
any other individual clutch besides C5 pack. same direction.
is updated from former to current
friction plates. The MD-3066, A. Inspect reaction plates for C. Inspect reaction plate tangs
3000MH-High, and B400 do not excessive wear, warping, coning for damage. Replace the plate if
require recalibration for updating to and surface damage. Replace any damage cannot be repaired using a
current friction plates. Any WTEC II plate with wear exceeding service soft stone or crocus cloth.
ECU equipped vehicle with an MD- limits or with damage which

SPRINGS
A. Springs
Reference the Service Manual

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

set and wear due to rubbing
adjacent parts. Replace the spring if
any of these defects are identified or
if the spring fails to meet published
service limits. Reference the Spring
Data Charts in Service Manual
SM2148EN for spring identification
and service limit specifications.
Inspect springs for signs of

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

VALVES & VALVE BORES
A. Valves
Valves should move freely in

their bores, when dry, under
their own weight.
A. Valves must be free of nicks,

burrs and scoring and operate
smoothly in their bores without
sticking. Dry valves must move
freely in their bores by their own B. Valve
weight. Replace damaged valves. A Bores
soft stone or crocus cloth can be
used in an attempt to repair slight
irregularities.
B. Valve bores must be free of
nicks, burrs and scoring. No honing
of any kind is allowed. A soft stone
or crocus cloth can be used in an
Valve bores must
attempt to repair slight
be free of nicks,
irregularities.
burrs and scoring.

CONTROL MODULE
A. Channel B. Solenoid C. Separator Plate

Plate Separator Plate
I. Turbine Speed D. Suction Filter

Sensor Assembly
E. Internal
Harness
J. Oil Level
Sensor
H. Stationary Clutch G. Main Valve F. Rotating Clutch

Valve Body Body Valve Body
Assembly Assembly
Supersession Information
A. Inspect the channel plate for B. Inspect the solenoid separator
damage. All passages must be clear plate for dents, nicks, burrs or Converter Regulator Valve
of debris. Inspect all machined distortion. Replace the plate if it Stop Redesign - SIL 12-WT-99
surfaces for burrs, nicks or scoring. has damage which cannot be
Light stoning and crocus cloth may repaired using a soft stone or crocus
be used to eliminate minor high cloth. All passages must be clean
and debris free.
spots. If a channel plate cannot be
repaired so that all machined C. Inspect the separator plate for
surfaces can seal correctly to their dents, nicks, burrs or distortion.
mating parts, or if thread damage Replace the plate if it has damage
cannot be repaired, replace the which cannot be repaired using a
channel plate. soft stone or crocus cloth. All
passages must be clean and debris
NOTE: Do not use impact guns (air free.
wrenches, electric impact
D. Replace the suction filter
wrenches, etc.) when working with
assembly at overhaul.
aluminum threads or when torque
(continued)
sequencing bolts.
Current Former
16 ALLISON TRANSMISSION TECHNICIANS’ GUIDE Stop Stop
Suction Filter Redesign -
SIL 1-WT-00 ALLISON 3000 / B 300 / B 400 PRODUCT FAMILIES
Replace the (continued) CONTROL MODULE
assembly
during
overhaul. Identification
C4 Pressure Detail
Feed C5 Pressure
Through C3 Pressure
Harness Oil Level
Lube Sensor
Pressure Stationary
Valve Body
Turbine Speed
Sensor
Main Valve
Supersession Information Body
Oil Level Sensor Redesign - Main Filter Bore

SIL 19-WT-99
Lockup
Pressure
Suction Main
Filter Pressure
Rotating
Valve Body Converter
Out
Lube Filter
Bore Pump C2 Pressure
Suction “To Cooler” Port
Kit must be used when “From Lube
Cooler” Pressure Coverter In
replacing former sensor
Port
with current sensor. C1 Pressure
E. Replace or repair the control Manual TS2470EN or design sump temperature sensor.
module wiring harness if the Troubleshooting Manual Sensor resistance specifications
wires, terminals or connectors are TS2973EN. differ between the former and
visibly damaged. On transmissions current designs. Be sure to use the
built after S/N 6510096671, inspect NOTE: Transmissions built prior to correct resistance specification
the molded harness channel for S/N 6510141464 used the former chart for the sensor being checked.
cracks or breaks. Replace the (continued)
harness if the
molded channel is 2-Inch Control
damaged. Check Module
sump temperature
sensor resistance
following the
guidelines and
specifications 4”
listed in Service
Manual
SM2148EN, 4-Inch
Troubleshooting Control
Module Main 2”
Pressure Tap

CONTROL MODULE (continued)
“From
“To Cooler” Port Lockup Pressure
Cooler”
Tap
Port
Main Filter
Bore
Main
Lube Pressure
Filter Tap
Bore
C4
C1 Pressure
Pressure Tap
Tap
C3
Pressure
Tap
C5
Pressure
Tap
Main C2
Drain Pressure Pressure
Plug Tap Tap
F, G, H. Valves, valve body bores NOTE: Do not use impact guns (air
and oil passages must be free of wrenches, electric impact wrenches,
debris, nicks, burrs, scoring and etc.) when working with aluminum Internal Wiring Harness Design -
galling. Valves should move freely in threads or when torque sequencing SIL 7-WT-04, Rev. A
their bores, when dry, under their bolts.
own weight. Repair or replace valves
Replace valve springs which are
and/or valve bodies failing to meet
broken, permanently set or worn due
these requirements.
to rubbing adjacent parts. Reference
Valve body machined surfaces must the Spring Data Charts in the Service
be free of debris, nicks, burrs and Manual for spring specifications and
scoring. Light stoning of these identification.
machined surfaces is permitted to
Valve stops and retention pins must
correct minor defects. Replace any
not be damaged or battered. Replace
valve body that cannot be repaired.
valve stops or pins which have
Inspect all threaded holes for damage that cannot be removed
damage and debris. Replace the valve using a soft stone or crocus cloth.
Current standoff base is taller
body if the thread damage cannot be (continued) and made of composite
repaired.
material rather than aluminum.

(continued) CONTROL MODULE
Feed
Through
Harness
Feed
Through
Stand-Off
C3 Pressure A Solenoid (C1)
Switch
Turbine
Dust Seal Speed Sensor
O-Ring Seal
D Solenoid
(C4)
F Solenoid
(Lockup) C Solenoid
(C3)
B Solenoid
(C2)
Sump
G Solenoid Temperature E Solenoid Oil Level
(C2 Latch) Sensor (TID 2, 3) (C5) Sensor
Replace solenoids if they are visibly I. Replace the Supersession Information

damaged. Proper solenoid resistance turbine speed sensor
is 3 to 4 ohms measured between the if it is visibly damaged. Oil Drain Plug Redesign -
two solenoid terminals. Check SIL 5-WT-98, Rev. A
Turbine speed sensor
resistance between each solenoid resistance must be 300
terminal and the solenoid body. ohms, plus or minus
Replace the solenoid if resistance 30 ohms. Replace the
measures less than 100k ohms. sensor if resistance
Replace the C3 pressure switch if it readings are not
is visibly damaged. Resistance within specification.
between the two switch terminals
should measure 20k ohms or higher J. Replace the
when the switch is open (and no optional oil level
pressure is present). Resistance sensor if it is Current plug
between the two terminals should determined it is not is backward
not exceed 2 ohms when the switch functioning correctly. compatible
is closed (159 kPa-255 kPa or 23-37 with all
(continued)
psi present). control
modules.

Identification Detail: Solenoid

Rotating Clutch Valve Regulator
Body Assembly Solenoid Springs
Regulator
Valves
Rotating
B Solenoid Clutch Valve
(C2) Body
Accumulator
Relay Valve
F Solenoid
(Lockup) C3
Pressure
Switch
A Solenoid
(C1)
Identification Detail: Overdrive Knock

Down Valve Stationary
Stationary Clutch Valve
Valve Body
Body Assembly
D Solenoid
(C4)
C Solenoid
(C3)
Solenoid Solenoid
Regulator Regulator
Valves Springs
E Solenoid (continued)
(C5)

Identification Detail:
Main Valve Body Assembly
Lube Regulator
Valve Spring
Lockup
Lube Regulator Valve Spring
Valve
Converter
Converter Lube Regulator
Regulator Lockup
Regulator Valve Stop
Converter Spring Valve
Valve
Regulator Lockup
Valve Stop Valve Stop
C1 Latch Main
Valve Spring Regulator
Valve Stop
C1 Latch
Valve Stop C1 Latch Valve
Exhaust Main Regulator Valve

Backfill Valve Main Regulator
Valve Spring
Exhaust
Backfill Control Main
Valve Stop Valve Stop
C2 Latch C2 Latch Main Valve Control Main

Valve Stop Valve C2 Latch Body Control Valve Spring
Spring Valve Main Valve G Solenoid

TORQUE CONVERTER MODULE
B. Converter
A. Converter
Pump Hub
Pump Exterior
B. Converter
Pump Hub
Model
Identifiers Inspect the pump hub tangs for cracks,
(see chart) impact damage and broken tangs.
A. Inspect the converter pump NOTE: Do not use crocus cloth on NOTE: Pump hub tang breakage or
exterior for dents and sealing the converter pump hub. Polishing deformity accompanied by charging
surface damage. Replace the the hub with crocus cloth can cause pump bushing failure and ground
converter pump if damage cannot improper input seal performance sleeve wear is often caused by poor
be remove with a soft stone or resulting in fluid leakage. (continued)
crocus cloth. 3000 Product Family Torque Converter Identification Chart
B. Inspect the converter pump Torque Converter TC-421 TC-419 TC-418 TC-417 TC-415 TC-413 TC-411
Model Designation
hub for damage and excessive wear.
Front Cover Sticker Pink Yellow Green Orange Blue Brown White
Minimum pump hub diameter is and Converter Paint
74.999 mm (2.9527 inch). Inspect Dot Color (Exterior
the pump hub tangs for cracks, Marker)
impact damage or broken tangs. Engraved Letter A A B B C D E
Identifiers (Torus Ring
Maximum allowable tang step wear of Converter Pump)
is 0.38 mm (0.015 inch). On PTO- Ink Stamped Letter
equipped models, check the (Exterior of Converter
Pump)
splines inside the hub for wear and
Number of Stator 17 19 17 19 19 19 19
damage. Maximum spline wear is Blades
0.38 mm (0.015 inch). Paint Dot Color on Pink None Yellow None None None None
Stator
22 ALLISON TRANSMISSION
Supersession Information ALLISON 3000 / B 300 / B 400 PRODUCT FAMILIES
Converter Plug and Front TORQUE CONVERTER MODULE
Cover Update - SIL-21-WT-98 (continued)
Current Converter Turbine Shaft

Plug Retaining Bolt Selective Shim
Model
The current front cover has a Identifiers
threaded pilot to accept the D. Pilot
(see chart
current converter plug. previous
Plugs are not interchangeable. page)
F. Flexplate
Adapter
C. Front
Cover
E. Ring Mounting
Gear Face
transmission fluid condition due to correct turbine shaft selective shim NOTE: The flexplate adapter bolt
improper maintenance intervals. is installed following the Service holes use Spiralock® threads
Observation of proper fluid change Manual procedures. starting with S/N 6510024410. A
intervals is key to optimum Spiralock® tap must be used when
transmission life. E. Inspect the engine starter ring repairing damaged threads. Using a
gear for chipped, worn or broken standard tap will destroy the
C. Inspect the torque converter teeth.
front cover mounting faces for locking feature. If this occurs, the
damage. Inspect the flexplate F. Inspect the flexplate adapter torque converter front cover must
adapter bolt holes for stripped or mounting faces for surface damage. be replaced.
(continued)
damaged threads. Replace the adapter if damage
cannot be repaired using a soft
D. Inspect the front cover pilot stone or crocus cloth. Inspect the
for damage and wear. Maximum flexplate adapter bolt holes for
pilot diameter is 50.914 mm (2.004 stripped or damaged threads. Clean
inches). Inspect the torque damaged threads using the
converter end plug and the correct size tap. Replace the
retaining bolt for stripped or adapter if damage cannot be
damaged threads. Verify that the repaired.

TORQUE CONVERTER MODULE (continued)
A. Converter
Pump Interior
Vanes
B. Torus
Ring
C. Sealring
Area
A. Inspect the converter pump

interior. Replace the assembly if
the vanes are damaged, cracked or
loose.
B. Replace the converter pump Replace the assembly if the vanes are damaged, cracked or loose.
assembly if the torus ring is loose
or cracked.
C. Inspect the seal surface Front Cover-to-Converter
between the converter pump Pump Sealring Surface
assembly and the front cover.
Light stoning is permitted to
remove slight irregularities.
(continued)

Turbine hub
sealring groove - ALLISON 3000 / B 300 / B 400 PRODUCT FAMILIES
Sealring installed.
(continued)
D. Turbine Hub
B. Torus
Ring
C. Rivets
E. Splines
Turbine
Assembly
Turbine A. Converter Exterior
Assembly Turbine
Interior Blades
A. Inspect the converter turbine E. Inspect the hub splines for (0.015 inch). Replace the turbine
assembly. Replace the assembly if damage and wear. Spline movment assembly if splines are excessively
the blades are cracked, broken or between the lockup damper and worn.
(continued)
loose. turbine hub cannot exceed 0.38 mm
B. Inspect the torus ring. Replace
the turbine assembly if the torus
ring is loose or cracked.
C. Inspect the rivets. Replace the
turbine assembly if the rivets are
loose or cracked.
D. Inspect the converter turbine
hub. Replace the converter turbine
assembly if the hub is worn beyond
limits. Minimum allowable hub
diameter is 61.34 mm (2.415 inches). Inspect the hub splines and
Inspect the sealring groove for rivets for damage and wear.
damage.

TORQUE CONVERTER MODULE (continued)
C. Lockup
B. Bushing A. Sealring Clutch F. Thrust
Bore Piston Bearing
Front
Cover
D. Backplate
Lockup Damper Update
SIL-8-WT-98, Rev. B
E. Lockup
Inspect sealring bore Damper
and bushing.
A. Inspect the interior of the C. Inspect the lockup clutch distortion is 0.51 mm (0.020 inch).
front cover for damage and wear to piston for damage. Minimum Maximum allowable movement
the lockup damper and thrust allowable piston thickness is 5.71 between the damper and converter
bearing surfaces. Replace the front mm (0.225 inch). turbine splines is 0.38 mm (0.020
cover if damage cannot be repaired D. Inspect the lockup clutch inch). Replace the damper if any of
using a soft stone or crocus cloth. backplate for damage. Minimum these measurements are beyond
allowable plate thickness is 8.58 allowable limits.
Inspect for wear or grooving in the
mm (0.338 inch). Replace the NOTE: The current lockup damper is
turbine sealring bore located in the
backplate if it does not have a not compatible with WTEC II
front cover. Install a new turbine transmissions that had the former
usable wear surface.
sealring in the bore and measure the lockup damper only when the
NOTE: If the backplate is within
sealring inside diameter. Replace calibration date of the ECU is prior to
thickness limits but has surface damage
the cover assembly if diameter September of 1997. Updating those
due to metal transfer between the
exceeds 56.75 mm (2.234 inches). WTEC II ECU calibrations prior to
backplate and lockup damper, the plate
September 1997 will allow the current
B. Inspect the converter cover may be reused by turning it over so that
lockup damper to be used in place of the
the lockup damper has a new contact
bushing for wear that exceeds former lockup damper.
surface.
service limits. Maximum allowable F. Inspect the thrust bearing
E. Replace the lockup clutch
bushing inside diameter is 61.51 mm following the "General Inspection
damper if the friction surfaces are
(2.422 inches). Replace the bushing Guidelines for Bearings" section of
worn beyond service limits.
if it has damage which cannot be this manual. Replace the thrust
Minimum allowable friction surface
removed using a soft stone or bearing if it fails any of these
thickness is 8.05 mm (0.317 inch).
crocus cloth. inspection procedures. (continued)
Maximum allowable damper
(continued) TORQUE CONVERTER MODULE
D. Star E. Thrust
Washer Washer
F. Thrust
Bearing
A. Stator Race
B. Stator
Springs C. Stator
Rollers H. Stator G. Stator
Cam F. Thrust Thrust Plate
I. Roller
Assembly Bearing
Pockets
Springs and rollers are

shown properly oriented.
A. Inspect the stator race for E. Inspect the stator thrust H. Inspect the stator and cam
damage. Replace the race if damage washer for wear beyond service assembly for damage. Replace the
cannot be repaired using a soft limits. Replace the stator thrust stator and cam assembly if
stone or crocus cloth. washer it is worn 0.40 mm (0.010 damaged.
inch) or more. If it is within service
B. Inspect the stator springs for limits, the thrust washer can be NOTE: Use care when cleaning the
correct spring height following per turned over and the un-worn stator and cam assembly. Hot tank
the Service Manual. Replace any surface can be used. temperatures may be high enough
spring which is beyond service to release the cam assembly from
F. Inspect the thrust bearings
limits. following the "General Inspection the stator.
C. Inspect the stator rollers for Guidelines for Thrust Bearings" I. Inspect the stator roller
damage. Rollers should be smooth, section of this manual. Replace any pockets for wear and damage.
round and defect-free. Replace thrust bearings failing these Verify correct spring-to-roller
inspection procedures.
damage or worn rollers. orientation. Inspect the bottom of
G. Inspect the stator thrust plate the cam pocket for wear. Replace
D. Inspect the star washer for for damage and wear. Replace the the stator and cam assembly if it is
excessive wear. Replace the star plate if damage cannot be removed worn 0.40 mm (0.010 inch) or more
washer if damage cannot be using a soft stone or crocus cloth. in the bottom of the pocket.
repaired using a soft stone or Minimum allowable plate thickness (continued)
crocus cloth. is 11.68 mm (0.460 inch).

TORQUE CONVERTER HOUSING MODULE
C. Speed
Sensor &
Bore
D. Bearing
Bore
A. Sealing & E. Retainer

Machined Mounting
Surfaces Surface
B. Breather
A. Inspect for torque converter C. Replace the speed sensor if the E. Inspect the PTO bearing
housing damage. High spots may be sensor body or electrical terminals retainer mounting face surface
removed with crocus cloth or a soft are damaged. Speed sensor and threads for damage. Replace
stone. Inspect threaded holes for resistance is 300 ohms (plus or the housing if surface damage
debris and thread damage. Replace minus 30 ohms). cannot be repaired using a soft
the torque converter housing if it is stone or crocus cloth. Replace the
cracked, if it leaks from a damaged D. On PTO-equipped models, housing if thread damage cannot be
machined surface, or if it has thread inspect the converter housing repaired.
bearing bore for wear. Maximum (continued)
damage which cannot be repaired.
allowable bearing bore inside
B. Inspect the breather for diameter is 140.03 mm (5.513
damage and obstructions. Replace inches).
the breather if it is damaged. Clean Replace the Torque
Converter
the breather if it is blocked with housing if Housing
debris. damage (Non-PTO)
cannot be
repaired
using a soft
stone or
crocus cloth.
Torque Converter
Housing (PTO)
(continued) TORQUE CONVERTER HOUSING MODULE
L. PTO Drive
Gear Bearings
Bearing
Retainer
K. Splines
F. PTO Drive
Assembly
Bearing Retainer
Housing Bore
H. Oil Pump
Drive Hub
I. PTO Gear
Teeth
F. On PTO-equipped models, G. Inspect the retainer housing I. Inspect the PTO drive gear
inspect the PTO drive bearing bushing for damage and wear. teeth for chips, pitting and
retainer housing bore for damage. Replace the bushing if damaged. excessive wear. Replace the gear if
Replace the retainer if damage Maximum allowable bushing inside damage cannot be repaired using a
cannot be repaired using a soft diameter is 75.23 mm (2.962 soft stone or crocus cloth.
stone or crocus cloth. Replace the inches). Replace the bushing if it is
NOTE: Some axial movement fo the
retainer housing if the bushing has worn beyond service limits.
spun in the bushing bore. gear is normal, but movement
should not exceed 3.175 mm (0.125
H. Inspect the oil inch). Replace the PTO bearings if
G. Bushing pump drive hub. axial movement exceeds service
F. Bearing
Bore Replace the drive hub limit.
if damage cannot be
NOTE: Normal operating backlash
repaired using a soft
stone or crocus cloth. after the PTO is installed is 0.1 mm
to 0.66 mm (0.004 to 0.026 inch).
(continued)

TORQUE CONVERTER HOUSING MODULE (continued)
K. Splines
I. PTO
Gear
Teeth
J. Inspect the oil pump drive hub K. Inspect the drive hub splines L. Inspect the PTO drive gear
tangs for step wear, deformation for wear. Replace the drive hub if bearings following the "General
and cracks. Replace the drive hub if spline wear exceeds 0.38 mm Inspection Guidelines for Bearings"
tang step wear exceeds 0.38 mm (0.015 inch). section of this manual. Replace
(0.015 inch) or if either tang is either bearing as needed.
deformed or cracked.
NOTE: Drive hub tang breakage or
deformity accompanied by charging
pump bushing failure and ground
J. Examine
sleeve wear is often caused by poor the oil pump
transmission fluid condition due to drive tangs
improper maintenance intervals. for excessive
Observation of proper fluid change battering.
intervals is key to optimum
transmission life.

STANDARD REAR COVER AND
P3 PLANETARY MODULE
A. Output B. Rear
Speed C. Piston
Cover
Sensor
D. Spring
Pack
E. Retaining
Ring
F. Clutch
3000 Series Close Ratio 3000 Series Wide Ratio
Plates
P3 Carrier Assembly P3 Carrier Assembly
A. Inspect the output speed repaired using a soft stone or crocus Service Manual SM2148EN for
sensor for damage. Replace any cloth. Replace the rear cover if it is spring specifications and
sensor that has body, terminal or cracked. identification.
connector seat damage. Allowable
C. Inspect the C5 clutch piston E. Replace the C5 retaining
output speed sensor resistance is
following the "General Inspection ring if it is bent or distorted.
300 ohms plus or minus 30 ohms.
Guidelines for Cast Parts and
(continued)
B. Inspect the rear cover Machined Surfaces" section of this
following the "General Inspection manual. Replace the piston if it fails Oil Passage
Guidelines for Cast Parts and to meet the inspection guidelines. Detail
Machined Surfaces" section of this Inspect the C5 piston tang for
manual. High spots on machined excessive wear.
surfaces can be removed using a
soft stone or crocus cloth. Inspect D. Inspect the C5 clutch spring
the slot on the back side of the pack for wear due to rubbing
housing where the C5 piston tang adjacent parts and cracked or C5 Pressure
indexes for excessive wear. Replace broken pieces. Check springs for
the rear cover if damage to any wear, breakage and damage.
machined surface cannot be Reference the Spring Data Charts in

P3 PLANETARY MODULE (continued)
C5 Friction Plate Update -
SIL 4-WT-00, Rev. B
F. Clutch
Plates
Current C5 Friction
Plate - missing
two splines.
Former C5 Friction
Plate - one or no
missing splines.
F. Inspect the C5 friction clutch Discard any plates that do not meet C5 is updated from former to current
plates following the “General the guidelines. Minimum allowable friction plates. The MD-3066,
Inspection Guidelines for Friction thickness for reuse is 2.41 mm 3000MH-High, and B400 do not
Plates” section of this manual. (0.095 inch). Maximum cone for require recalibration for updating to
Discard any plates that do not meet reuse is 0.40 mm (0.016 inch). current friction plates. Any WTEC II
ECU equipped vehicle with an MD-
the guidelines. Minimum allowable
NOTE: The current clutch friction 3060, MD-3560, B300, or 3000MH-
thickness for reuse is 2.90 mm Standard with former friction plates
plates were implemented April of
(0.114 inch). Minimum oil groove will require a new ECU calibration
2000 starting with s/n 6510262117.
depth for reuse is 0.20 mm (0.008 Current production friction plates from Allison Transmission to use the
inch). Maximum cone for reuse is will have two missing splines. current friction plates in C1, C2, C3
0.40 mm (0.016 inch). Former friction plates will either and C4. Any WTEC III ECU
have one spline missing or none equipped vehicle with an MD-3060,
NOTE: Battered and worn spline missing. Any 3000/B 300/B 400 MD-3560, B300, or 3000MH-
teeth may be an indicator of model transmission may be updated Standard with an ECU calibration
driveline issues. Replace the clutch from former C5 friction plates to installed prior to October 25th, 1999
plates and check the driveline. current C5 frictions without will require an updated ECU
recalibrating the transmission ECU. calibration to use the current friction
Inspect the C5 reaction clutch The rest of the clutches in the main plates in C1, C2, C3, and C4. Do not
plates following the "General housing (C1 through C4) must be intermix both former and current
Inspection Guidelines for Reaction updated with current friction plates friction plates in a clutch pack.
Plates" section of this manual. if any other individual clutch besides (continued)

Supersession Information ALLISON 3000 / B 300 / B 400 PRODUCT FAMILIES
Planetary Spindle and Indexing STANDARD REAR COVER AND
Ring Update - SIL 15-WT-01. Both
parts are backward compatible. (continued) P3 PLANETARY MODULE
A. P3 Carrier Assembly
Current indexing
(Non-Retarder)
ring has stamped
star identifier.
K. Output Shaft
D. Indexing
Ring
DIMENSION A
DRILLED
IDENTIFICATION
HOLE
B. Output
Q. Output Shaft Speed
Sensor
V06961
Wheel
Current spindle has drilled
identification hole. C. Tapered Roller
G. Pinion H. Pinion Roller Bearing
Gear Bearings
E. Spindle
J. Output Shaft F. Thrust
Bearing races External I. Output Washers
located in rear cover. Retaining Shaft Spacer
Ring
A. Verify a proper press fit spindle has more than 0.051 mm C. Inspect the tapered roller
between the P3 carrier and rear (0.002 inch) clearance in the bore. bearings and races following the
cover or retarder housing by Inspect for thread damage on the "General Inspection Guidelines for
inverting the carrier over a table or carrier hub. Replace the carrier if Bearings" section of this manual.
workbench. If the P3 carrier falls threads are damaged. Replace any bearings failing to meet
the inspection guidelines. Bearing
out of the rear cover or retarder
Replace the output speed signal races are located in the rear cover
housing without using a press or housing and should also be
mallet, the press fit between the wheel roll pin if it is bent, broken,
loose in the housing or damaged in inspected for wear and damage.
tapered bearings and P3 carrier no (continued)
longer exists and the carrier must any way. Replace the carrier if a
be replaced. new roll pin is loose in the bore. Supersession Information
Inspect the P3 carrier for spline B. Inspect the output speed P3 Carrier Update -
wear. Replace the carrier if spline signal wheel following the "General SIL 8-WT-98, Rev B.
wear exceeds 0.38 mm (0.015 inch). Inspection Guidelines for Cast
Inspect the pinion spindle bores in Parts and Machined Surfaces"
the carrier and the pinion thrust section of this manual. Discard and
surfaces for excessive wear and replace the tone wheel if the teeth
damage. Replace the P3 carrier if a are damaged in any way or if the
keyway shows signs of battering.
Current P3 carriers are identified
by machined grooves
IANS’ G onU the
I D E 33
back face of General
 2005 the carrier hub. 3 3
Motors Corporation.
Note: Inspect the output speed signal wheel - discard

and replace the tone wheel if the teeth are damaged in
any way or if the keyway shows signs of battering.
MD Output Speed Signal

Wheel (Non-Retarder).
No damage,
wheel can
be reused. Excessive damage:
this may be an
indication of driveline
issues - replace wheel.
D. Inspect the P3 indexing ring (0.054 inch). Replace damaged or I. Replace the output shaft
for step wear in the area where it worn thrust washers. spacer if it is bent, cracked or if it is
contacts the spindle. Replace the distorted in any way. An attempt
indexing ring if it is broken or if it G. Inspect the pinion gears can be made to repair some minor
has excessive step wear. Indexing following the "General Inspection damage using a soft stone. (continued)
rings with acceptable wear can be Guidelines for Gears" section of this
flipped during reassembly so that a manual. Replace any gears which
fail these inspection procedures or Replace the
new contact surface is used. output speed
if the damage cannot be repaired
signal tone
E. Inspect planetary spindles for using a soft stone.
wheel pin if it
wear and damage. Discoloration is
H. Inspect the pinion roller is bent, broken
only a concern if spindle surface or damaged in
damage exists. bearings following the "General
any way.
Inspection Guidelines for Bearings"
F. Inspect the pinion gear thrust section of this manual. Replace any
washers for damage, distortion and bearings which fail these inspection
excessive wear. Minimum allowable procedures.
thrust washer thickness is 1.39 mm

(continued) P3 PLANETARY MODULE
Supersession Information Supersession Information

Service Kit for Two-Bolt Ouput - Output Configuration Update - SIL 1-WT-99
SIL 15-WT-98
Kit Part Number: 29535910
* Note: Kit contains Belleville washers

and 2 allen-head bolts to replace original
locking tab and hex-head bolts.
J. Inspect the output shaft K. Inspect the output shaft M. Replace the L. Locknut
external retaining ring. Replace following the "General Inspection output bearing Retainer
the retaining ring if it is distorted Guidelines for Cast Parts and locknut if it is
or fits loosely on the shaft. Machined Surfaces" and the cracked,
"General Inspection Guidelines for distorted, has
Splines" sections of this manual. damaged
K. Inspect the Replace the output shaft if it fails threads or has
output shaft these inspection procedures. damage to the
bushing for tangs where the
Inspect the output shaft bushing
damage. removal and M. Output
following the "General Inspection
Guidelines for Bushings" section of installation tool Bearing
this manual. Replace the bushing if indexes. An Locknut
it fails these inspection procedures. attempt can be
Maximum allowable bushing inside made to repair
diameter is 20.19 mm (0.795 inch). slight
L. Replace the output bearing imperfections
locknut retainer whenever the using a soft
locknut is removed. stone.

RETARDER MODULE AND P3 PLANETARY
G. Close Ratio P3 Carrier
Assembly (Retarder)
A. Retarder Housing
F. Retarder
Temperature
Sensor
Inspect for bearing

race wear.
D. Flow Valve
Plug &
Retaining
Ring
B. Retarder
Rotor
E. Retarder
C. Stator Autoflow Valve,
Housing Spring and Plug
A. Inspect the retarder housing area. Replace the housing if sealring C. Inspect the stator housing
following the "General Inspection inside diameter is greater than 95.67 following the "General Inspection
Guidelines for Cast Parts and mm (3.767 inches). Guidelines for Cast Parts and
Machined Surfaces" section of this Machined Surfaces" section of this
manual. High spots on machined B. Inspect the retarder rotor manual. A bearing race fits into the
surfaces can be removed using a following the "General Inspection housing and should be inspected for
soft stone or crocus cloth. Replace Guidelines for Cast Parts and damage. Some light housing
the retarder housing if it is cracked Machined Surfaces" section of this imperfections can be removed using
or if machined surface damage manual. Check for loose, cracked or a soft stone. Discard and replace the
cannot be removed using a soft broken rivets. Replace the rotor if housing if damage is excessive.
stone or crocus cloth. movement exists between the
center hub and the vaned assembly. NOTE: Transmissions built prior to
Install a "known good" rotor Inspect the rotor splines for wear. January 1998 included two small
sealring in the retarder housing and Spline wear cannot exceed 0.38 mm check balls and retainers located in
measure sealring inside diameter. If (0.015 inch). Replace the rotor if it the retarder stator housing.
the retarder housing is slightly exceeds this wear limit. Minimum allowable check ball
grooved or worn, place the sealring movement is 0.50 mm (0.020 inch).
directly in the grooved or worn (continued)

(continued) RETARDER MODULE AND P3 PLANETARY
Oil Passage
Details
C5
Pressure
Exhaust
Exhaust Exhaust
B. From Retarder Main D. From Retarder

(Retarder On) Pressure (Retarder On) From
From Converter A. To Retarder Control Converter (Retarder Off)
(Retarder On) Control
(Retarder Off) Main
To Lube Main
C. To Retarder
(Retarder Off) Pressure
(Retarder On) To
Lube (Retarder Off)
Inspect the slot on the back side of E. Inspect the retarder autoflow
the housing where the C5 piston valve for wear and damage. The
tang indexes for excessive wear. autoflow valve must move freely in
Replace the stator housing if its bore, when dry, under its own
damage to any machined surface weight. Replace or repair the
cannot be repaired using a soft autoflow valve and/or retarder
stone or crocus cloth. Replace the housing as necessary. Crocus cloth
stator housing if it is cracked. can be used to remove slight high
spots.
D. Inspect the valve plugs and
retaining rings. Replace damaged Inspect the autoflow valve spring
valve plugs. Replace damaged or for defects and permanent set.
distorted retaining rings. Reference the Spring Data Charts in
Service Manual SM2148 for spring
specifications and identification.
Replace the spring if it fails any
(continued)

RETARDER MODULE AND P3 PLANETARY (continued)
Oil Passage
Detail
Exhaust
Main
Pressure
Exhaust
Control Main
E. To Retarder
(Retarder On) To
Lube (Retarder Off)
F. From Retarder
(Retarder On) From
Converter (Retarder Off) Supersession Information
Sump Cooling Feature - SIL 13-WT-00
F. Inspect the retarder G. Reference the

temperature sensor exterior for "Inspection and
defects. Replace the temperature Analysis of the
sensor if it is damaged. There are Standard Rear
two temperature sensor types - TID Cover" section of
1 and post-TID 1 (TID 2 and TID 3). this manual for P3
Resistance specifications vary planetary carrier
between the two sensor types. Be assembly details.
sure to use the correct
NOTE: Inspect for
Troubleshooting Manual chart for
the sensor being tested. Replace the step wear on the
temperature sensor if its measured carrier hub splines.
resistance is not within Replace the carrier
Troubleshooting Manual if it is worn.
The sump cooling feature provides additional
specifications. (continued) cooling when the retarder is active through either
an additional auxiliary cooler or the direct mount
cooler for retarder transmissions. The direct
mount cooler for retarder transmissions works as
both the main cooler and auxiliary cooler.

(continued) RETARDER MODULE AND P3 PLANETARY
K. Separator B. Retarder C. Solenoid Assembly

Plate Solenoid Wiring Harness
A. Retarder
Control
Body
D. Plug
E. Relay
Valve
Spring
F. Relay
Valve
H. Retarder
Control
I. Charge Valve
G. Charge Pressure
Pressure
Port Plug
J. Plug Spring
A. Inspect the retarder control resistance between each solenoid rubbing adjacent parts. Reference
valve body following the “General terminal and the solenoid body. the Spring Data Charts in Service
Inspection Guidelines for Cast Replace the solenoid if either Manual SM2148EN for spring
Parts and Machined Surfaces” reading is less than 100k ohms specifications and identification.
section of this manual. All passages resistance.
must be clean and debris free. Valve F, H. Inspect the retarder
bores must be free of nicks, burrs C. Replace the retarder valve control valve and relay valve for
and scoring. Crocus cloth or a light body wiring harness if the wires, nicks, burrs, scoring and other
stone can be used to attempt terminals or connectors are visibly damage. A soft stone or crocus cloth
removal of slight irregularities, damaged. Check the installed can be used to attempt removal of
however no honing of any kind is harness for tight bends or crimps slight irregularities. Valves must
permitted. which might damage harness wires. move freely in their bores, when
dry, under their own weight.
B. Replace the retarder solenoid D, G, J. Replace any valve plug
if the body, connector or terminals which is cracked or has stripped or K. Inspect the separator plate for
show visible signs of damage. damaged threads. nicks, burrs, scoring and distortion
Solenoid resistance should be 3 to 4 (flatness). Replace the plate if
E, I. Replace any valve springs damage cannot be repaired using a
ohms measured between the two which are broken, cracked,
solenoid terminals. Check light stone or crocus cloth.
permanently set or worn due to (continued)

RETARDER MODULE AND P3 PLANETARY (continued)
Retarder
Pressure
Control
Main
Main
Pressure
Exhaust
Main
Pressure
NOTE: Retarders built prior to S/N NOTE: Reference SILs 1-WT-98, NOTE:Transmissions built prior to
6510021203 included a retarder Rev A. and 13-WT-00 for retarder S/N 6510141464 used the former
signal valve located under the flow update details. design retarder temperature sensor.
valve plug. Inspect the signal valve Pre and post-serial number sensor
NOTE: Retarders built prior to
for nicks, burrs and scoring. resistance specifications differ. Be
Replace valves if damage cannot be January 1998 included a retarder sure to use the appropriate
repaired using a soft stone or crocus valve body channel plate. Inspect the specification chart for the sensor
cloth. The valve must operate in the channel plate following the “General being checked.
bore smoothly without sticking or Inspection Guidelines for Cast and
hanging. Machined Parts” section of this
manual. Replace the valve body if it
fails any of these inspection
procedures. All channel plate
passages must be clean and debris
free.

CLOSE RATIO MAIN SHAFT MODULE
Close Ratio Main

Shaft Assembly
H. P3 Sun
Gear
D. Thrust
Bearings
G. Selective
F. Bearing Shim
Spacer
E. P2 Sun B. Main
Gear Shaft
Pilots
D. Thrust
Bearing
I. Spiral
Retaining
Ring
A. Main
B. Main Shaft
Shaft
C. Journal
Pilots
A. Inspect the main shaft journal diameter is less than 42.97 and Machined Surfaces" and
following the "General Inspection mm (1.692 inch). “General Inspection Guidelines for
Guidelines for Gears" and "General D. Inspect the thrust bearings
Splines” sections of this manual.
Inspection Guidelines for Splines" following the "General Inspection Replace the spacer if it fails any of
sections of this manual. Replace the Guidelines for Bearings" section of these inspection procedures.
main shaft if it fails any of these this manual. Replace any bearing G. Inspect the selective shim for
inspection procedures. that fails any of these inspection damage and distortion. Replace the
B. Inspect the front and rear procedures. shim if it is distorted or if damage
main shaft pilots for damage. The E. Inspect the P2 sun gear
cannot be removed by light stoning.
front main shaft pilot fits inside the following the "General Inspection H. Inspect the P3 sun gear
turbine shaft. The rear main shaft Guidelines for Gears" and "General following the "General Inspection
pilot fits inside the output shaft. Inspection Guidelines for Splines" Guidelines for Gears" and "General
Replace the main shaft if pilot sections of this manual. Replace the Inspection Guidelines for Splines"
outside diameter is less than 19.98 gear if it fails any of these inspection sections of this manual. Replace the
mm (0.787 inch). procedures. gear if it fails any of these
C. Inspect the P2 bushing journal inspection procedures.
F. Inspect the main shaft bearing
area for damage. Replace the main spacer following the "General I. Replace the spiral retaining
shaft if the P2 planetary bushing Inspection Guidelines for Cast Parts ring if it is removed.

WIDE RATIO MAIN SHAFT MODULE
B. Main Shaft Pilots
C. Journal
B. Main Shaft
Pilots
A. Main Shaft
E. Thrust
G. Selective Bearing
Shim
F. Bearing
Spacer
E. Thrust
D. P2 Sun Bearing
H. Spiral Gear
Retaining
Ring
Wide Ratio Main

Shaft Assembly
A. Inspect the main shaft C. Inspect the P2 bushing journal F. Inspect the main shaft bearing
following the "General Inspection area for damage. Replace the main spacer following the "General
Guidelines for Gears" and "General shaft if P2 planetary bushing Inspection Guidelines for Cast
Inspection Guidelines for Splines" journal diameter is less than 42.97 Parts and Machined Surfaces"
sections of this manual. Replace the mm (1.692 inch). “General Inspection Guidelines for
main shaft if it fails any of these Splines” sections of this manual.
D. Inspect the P2 sun gear
inspection procedures. Replace the spacer if it fails any of
these inspection procedures.
B. Inspect the front and rear Guidelines for Gears" and "General
main shaft pilots for damage. The Inspection Guidelines for Splines" G. Inspect the selective shim for
front main shaft pilot fits inside the sections of this manual. Replace the damage and distortion. Replace the
turbine shaft. The rear main shaft gear if it fails any of these shim if it is distorted or if damage
pilot fits inside the output shaft. inspection procedures. cannot be removed by light stoning.
Replace the main shaft if the pilot
E. Inspect the thrust bearings H. Replace the spiral retaining
outside diameter is less than 19.98
following the "General Inspection ring if it is removed.
mm (0.787 inch).
Guidelines for Bearings" section of this
manual. Replace any bearing that fails
any of these inspection procedures.

P2 PLANETARY MODULE
D. P3 Ring A. P2 Planetary
Gear Carrier
B. Carrier
E. Index Bushing
Ring I. Pinion
Gear
C. Carrier
Hub
J. Retaining
Rings G. Pinion
Spindle
H. Pinion
Roller
Bearings
F. Pinion Thrust
Washers
A. Inspect the P2 carrier D. Inspect the P3 ring gear

following the "General Inspection following the "General Inspection
Guidelines for Cast Parts and Guidelines for Gears" and "General P1 and P2 Carrier Assembly
Machined Surfaces" and the Inspection Guidelines for Splines" Updates - SIL 8-WT-98, Rev B
"General Inspection Guidelines for sections of this manual. Replace the No Sealrings -
Splines" sections of this manual.
ring gear if it fails any of these Current P2 Carrier
Replace the carrier if any spindle
has more than 0.051 mm (0.002 inspection procedures.
inch) clearance in its bore. E. Inspect the P2 indexing ring
B. Inspect the P2 carrier bushing
for step wear in the area where it
for damage. Replace the bushing if contacts the spindle. Replace the
damaged. Replace the bushing if indexing ring if it is broken or if it
has excessive step wear or damage C. Carrier
inside diameter exceeds 43.20 mm
which cannot be repaired using a Hub
(1.701 inches).
soft stone or crocus cloth. Indexing
C. Inspect the carrier hub for Former P2 carriers used two hub
rings with acceptable wear can be
damage. Replace the carrier if sealrings. They are only compatible
damage cannot be repaired using a flipped during reassembly so that a with former P1 carriers. Current P2
soft stone or crocus cloth. new contact surface is used. carriers are only compatible with
(continued) current P1 carriers.

Planetary Spindle and
Indexing Ring Update -
SIL 15-WT-01. Both parts
are backward compatible.
Current indexing
ring has stamped
star identifier.
Q. Output Shaft
3000 Series Wide Ratio 3000 Series Close Ratio

E. Index
P2 Carrier Assembly P2 Carrier Assembly
Ring
F. Replace the pinion gear thrust I. Inspect the P2 pinion gears

washers if they are damaged, following the "General Inspection
distorted, galled or showing signs of Guidelines for Gears" section of this DIMENSION A
excessive wear. Minimum allowable manual. Replace any gear that fails DRILLED
IDENTIFICATION
thrust washer thickness is 1.39 mm these inspection procedures or if HOLE
(0.054 inch). damage cannot be removed using a

soft stone.
G. Replace planetary spindles if V06961
Current spindle has
they are worn or damaged. J. Inspect the P2 carrier drilled identification hole.
Discoloration is only a concern if retaining rings for damage or
spindle surface damage exists. distortion. Replace any retaining
rings with damage that cannot be
H. Inspect the pinion roller
removed using a soft stone.
bearings following the "General
Inspection Guidelines for Bearings" G. Pinion Spindle
section of this manual. Replace any
bearing failing these inspection
procedures.

P1 PLANETARY MODULE
A. P1 Planetary
B. P2 Ring Carrier
Gear
C. Index Ring
E. Pinion
Spindle
F. Pinion
Gear
D. Pinion
Thrust
H. Retaining Washers
Rings G. Pinion Roller
Bearings
A. Inspect the P1 carrier following Thrust bearings fit on both sides of

the "General Inspection Guidelines the carrier. Inspect the thrust
for Cast Parts and Machined bearings following the "General P1 and P2 Carrier Assembly
Surfaces" and the "General Inspection Guidelines for Bearings" Updates - SIL 8-WT-98, Rev B
Inspection Guidelines for Splines" section of this manual. Replace any
sections of this manual. Replace the bearing that fails any of these No Sealrings -
carrier if any spindle has more than inspection procedures. Current P2 Carrier
0.051 mm (0.002 inch) clearance in

NOTE: On units built prior to S/N
its bore.
6510142342, install two new
sealrings in the P1 carrier and
measure sealring end gap. If the P1 C. Carrier
carrier hub is slightly grooved or Hub
Thrust
Bearing
worn, place the sealring directly in
Inspection the grooved or worn area. Replace
the P1 carrier if sealring end gap is
greater than 1.20 mm (0.047 Current P1 carriers are only
inches). Reference SIL 20-WT-98, compatible with current P2
Rev. A for details. carriers.
(continued)
Oil groove identifies
current P1 carrier. ALLISON TRANSMISSION TECHNICIANS’ GUIDE 45
Planetary Spindle and

Indexing Ring Update -
SIL 15-WT-01. Both parts are
backward compatible.
E. Pinion Spindle
DIMENSION A
DRILLED
IDENTIFICATION
HOLE
Current indexing
ring has stamped
star identifier. V06961
Current spindle has drilled
identification hole.
Q. Output Shaft
E. Index
Ring
B. Inspect the P1 ring gear D. Replace the pinion gear thrust G. Inspect the pinion roller
following the "General Inspection washers if they are damaged, bearings following the "General
Guidelines for Gears" and the distorted, galled or showing signs of Inspection Guidelines for Bearings"
"General Inspection Guidelines for excessive wear. Minimum allowable section of this manual. Replace any
Splines" sections of this manual. thrust washer thickness is 1.39 mm bearing failing these inspection
Replace the ring gear if it fails any (0.054 inch). procedures.
of these inspection procedures.
E. Replace planetary spindles if H. Inspect the P1 carrier retaining
C. Inspect the P1 indexing ring they are worn or damaged. rings for damage or distortion.
for step wear in the area where it Discoloration is only a concern if Replace any retaining rings with
contacts the spindle. Replace the spindle surface damage exists. damage that cannot be removed
indexing ring if it is broken or if it using a soft stone.
has excessive step wear or damage F. Inspect the P1 pinion gears
which cannot be repaired using a following the "General Inspection
soft stone or crocus cloth. Indexing Guidelines for Gears" section of this
rings with acceptable wear can be manual. Replace any gear that fails
flipped during reassembly so that a these inspection procedures or if
new contact surface is used. damage cannot be removed using a
soft stone.

FRONT SUPPORT & OIL PUMP MODULE
D. Non-PTO D. PTO-Model A. Front

Model Ground Ground Sleeve Support
Sleeve Assembly
E. Bushing
Journal
I. Roller
Bearing
B. Front
K. Charging Pump Support
Gear Set Sleeve
F. Charging
Pump
Housing I. Thrust
Bearing
C. Sealring
H. Main Grooves
Pressure
Relief Ball
& Spring
M. Wear Plate
L. Stiffening Plate
A. Inspect the front support procedures. If the ground sleeve has D. Inspect the ground sleeve
assembly following the "General rotated in the front support, replace following the "General Inspection
Inspection Guidelines for Cast Parts both components (the ground sleeve Guidelines for Splines" section of this
and Machined Parts" section of this and the front support assembly). If manual. Replace the shaft if it fails
manual. Replace the assembly if it the ground sleeve is replaced, check any of these inspection procedures.
fails any of these inspection the front support for flatness after
E. Inspect the journal area where
ground sleeve installation. Replace
the charging pump driven gear
G. Bushing the front support if it is more than
bushing rides. Replace the shaft if
0.051 mm (0.002 inch) from flat.
the journal is damaged or galled.
B. Replace the front support if the Minimum allowable journal diameter
sleeve has nicks, burrs or other is 57.04 mm (2.246 inch).
damage which cannot be repaired
NOTE: Ground sleeve galling is
using a soft stone or crocus cloth.
typically an indicator of poor
Minimum allowable front support
transmission fluid condition due to
sleeve diameter is 98.83 mm (3.891
improper maintenance intervals.
inches).
Observation of proper fluid change
C. Inspect the three sealring intervals is key to optimum
grooves on the front support transmission life.
Non-PTO Charging Housing assembly hub for nicks, burrs, cracks (continued)
and other damage.
FRONT SUPPORT & OIL PUMP MODULE (continued)
Front support oil Front support oil

passage detail - passage detail -
back. front.
C1 Pressure
C2 Pressure
Lube
Pressure
Main
Pressure
Pump Main
Suction Pressure
Lockup
Pressure Converter In Lockup
Converter Converter
C2 C1 C1 C2 Pressure
Out Out
Pressure Pressure Pressure Pressure
Inspect the area in the ground sleeve F. Inspect the charging pump H. Replace the main pressure relief
where the turbine shaft sealrings ride housing following the "General check ball if it is chipped, nicked,
for grooves, scoring and other wear Inspection Guidelines for Cast Parts battered or damaged in any way.
or damage. Install new sealrings in and Machined Parts" section of this Inspect the main pressure relief
the ground sleeve and measure the manual. Replace the housing if it fails spring following the "General
end gap. If the ground sleeve is worn any of these inspection procedures. Inspection Guidelines for Springs"
or grooved, place the sealrings Replace the charging pump housing section of this manual. Replace the
directly in the grooves or worn area. if gear cavity depth exceeds 17.93 mm spring if it fails any of these
Maximum allowable sealring end gap (0.706 inch). Replace the charging
is 0.94 mm (0.037 inch). Replace the inspection procedures. Refer to the
pump housing if gear cavity diameter Spring Data Charts in Service
ground sleeve if any of the seal ring exceeds 127.30 mm (5.012 inch).
end gaps exceeds this specification. Manual SM2148EN for spring
G. Non-PTO models include a specifications and identification.
NOTE: When replacing the ground
bushing that fits in the front of the
sleeve, total shaft runout cannot I. The front support thrust
housing. Replace the bushing if it has
exceed 0.30 mm (0.012 inch) once it bearing fits on the back of the front
nicks, burrs, scoring or other damage
is pressed into the front support.On support assembly. Inspect this thrust
transmissions built prior to S/N which cannot be removed using
crocus cloth. Maximum allowable bearing following the "General
6510024410 the turbine shaft must Inspection Guidelines for Bearings"
also be replaced when replacing the bushing diameter is 75.23 mm (2.962
inches). (continued)
ground sleeve.
(continued) FRONT SUPPORT & OIL PUMP MODULE
Redesigned Charging Pump
Gear Set - SIL 13-WT-04 Ground
sleeve oil
passage
detail.
Former Current
Orange bushing identifies current gear set.
Arrow on front
support lines
up with flat on
ground sleeve.
C2
Lockup Pressure
Pressure
C1
Flat Lube Pressure
Pressure
Ground sleeve intallation detail.
section of this manual. Replace the bushing has spun in the gear. inch). The maximum allowable
bearing if it fails any of these Maximum allowable bushing inside clearance between the outer gear and
inspection procedures. diameter is 57.30 mm (2.256 inches). the pump housing is 0.36 mm (0.014
Minimum allowable outside inch).
J. The roller bearing fits inside the diameter of the outer gear is 126.95
back of the front support hub. L. The stiffening plate is used on
mm (4.998 inches).
Inspect this bearing following the 3066 and B400 models only. Replace
"General Guidelines for Bearings" NOTE: Install the pump gear set in the stiffening plate if it is bent, shows
section of this manual. Replace the the oil pump housing to perform the signs of overheating or if it has
bearing if it fails any of these following inspections and scoring, cracks or other damage
inspection procedures. measurements. which cannot be repaired using a soft
stone or crocus cloth.
K. Replace the charging pump gear Maximum allowable clearance
set if the sides, faces or gear teeth are between the installed gear set and M. Replace the wear plate if it is
damaged. Replace the gear set if the mounting face of the pump housing galled or moderately scored. Pay
inside gear shows damage or is 0.13 mm (0.005 inch). This is often particular attention to the area
battering where the converter pump referred to as pump gear side where the charging pump gear set
or PTO drive tangs index into the clearance. Maximum allowable gear rides. Minimum allowable wear plate
gear. Replace the gearset if the tooth tip clearance (the gap between thickness is 4.70 mm (0.185 inch).
a tooth on the outer gear and a tooth
on the inner gear) is 0.20 mm (0.008

ROTATING CLUTCH MODULE
L. C1 Clutch
H. Rotating Drum M. C2 Return Spring
E. Retaining Bolt Piston
Assembly
F. Shim I. Rotating
Clutch Hub
Non-PTO Model
A. Turbine PTO Model Z. Retaining

Shaft G. Retaining V. Thrust Rings
Ring Bearing
T. C1 Drive
Hub
N. C2 Clutch O. C1 Return P. C1 R. C1
Q. C1 Clutch S. C1 Backing
Piston Spring Balance Pressure
Pack Plate
Assembly Piston Plate
V. Thrust
Bearing
U. C2 Drive V. Thrust
W. C2 Clutch Pack Y. P1 Sun Gear Bearing
Hub X. C2 Backing Plate
Assembly
A. Inspect the turbine shaft C. Inspect the bearing journal

following the "General Inspection area for damage. Replace the Turbine shaft oil
passage detail.
Guidelines for Cast Parts and turbine shaft if damage cannot be
Machined Surfaces" section of this repaired with a light stone or
manual. Replace the turbine shaft if crocus cloth.
it fails any of these inspection
procedures. Maximum allowable D. Inspect the three seal ring
spline wear is 0.38 mm (0.015 inch). grooves for damage. Replace the
turbine shaft if damage cannot be D. Sealring
B. Inspect the turbine shaft repaired with a light stone or Grooves
bushing following the "General crocus cloth. (continued) B. Bushing
C. Journal
Inspection Guidelines for Bushings"
section of this manual. Replace the
bushing if it fails any of these
inspection procedures. Maximum
allowable bushing inside diameter J. Sealring
is 20.19 mm (0.795 inch). Bore
K. Bushing
(continued) ROTATING CLUTCH MODULE
C1 and C2 Friction Plate Turbine Shaft Update -
Update - SIL 4-WT-00, Rev. B. SIL 8-WT-98, Rev. B.
Groove
identifies
current
Current C2 friction plate - two turbine
missing splines. Previous shaft.
versions had one or no
missing splines.
Rotating Clutch Hub Update - Former Current
SIL 8-WT-99, Rev. A (No Weld) (Weld)
Current C1 friction plate - two

missing splines. Previous
versions had one or no
missing splines.
E. Replace the torque converter drum if it fails any of these K. Inspect the rotating hub
retaining bolt if the threads are inspection procedures. Maximum bushing following the "General
distorted or damaged. allowable spline wear is 0.38 mm Inspection Guidelines for Bushings"
(0.015 inch). section of this manual. Replace the
F. Replace the selective turbine
I. Inspect the rotating clutch bushing if it fails any of these
shaft shim if it is damaged.
hub following the "General inspection procedures or if it has
G. Inspect the turbine shaft Inspection Guidelines for Cast damage which cannot be repaired
retaining ring following the Parts and Machined Surfaces" and using a soft stone or crocus cloth.
"General Inspection Guidelines for “General Inspection Guidelines for Maximum allowable bushing inside
Snap Rings" section of this manual. Splines” sections of this manual. diameter is 99.25 mm (3.907 inch).
Replace the retaining ring if it fails Replace the hub if it fails any of
any of these inspection procedures NOTE: The rotating clutch hub was
or if the ring is bent, distorted or updated beginning with S/N
J. Inspect the area inside the hub 6510184386 (3060 and 3560 models)
shows other signs of damage.
where the front support sealrings and S/N 6510130438 (3066 and
H. Inspect the rotating drum ride for grooves and damage. B300/B400 models). The former
following the "General Inspection Install three new sealrings in the hub has no weld in the area shown.
Guidelines for Cast Parts and wear area of the bore and check The current hub is welded and
Machined Surfaces" and “General each seal's end gap. Replace the machined in the area shown.
Inspection Guidelines for Splines” rotating clutch hub if end gap
(continued)
sections of this manual. Replace the exceeds 1.44 mm (0.057 inch).
ROTATING CLUTCH MODULE (continued)
Rotating clutch
hub oil passage
detail.
C2 Pressure
C1 Pressure Supersession Information
C1 Piston Update - SIL 4-WT-00, Rev. B.
Housing in good condition - reuse.
Current piston
is completely
interchangeable
with former.
Etched housing - do NOT use. FORMER CURRENT
L, N, P. Inspect the C1 clutch M, O. Replace the C1 and C2 NOTE: Battered and worn spline
piston, C2 clutch piston and C1 return spring assemblies if they teeth may be an indicator of
balance piston following the have a permanent spring set, wear driveline issues. Replace the clutch
"General Inspection Guidelines for due to rubbing adjacent parts or if plates and check the driveline.
Cast Parts and Machined Surfaces" they are cracked or broken.
section of this manual. Replace any NOTE: The current clutch friction
Reference the Spring Data Charts in
component if it fails any of these plates were implemented April of
Service Manual SM2148EN for 2000 starting with s/n 6510262117.
inspection procedures. spring specifications and Current production friction plates
NOTE: Aluminum castings (like identification. will have two missing splines.
clutch housings) can be etched by Former friction plates will either
Q, W. Inspect the C1 and C2
caustic parts cleaners and solvents. have one spline missing or none
clutch friction plates following the missing. Any 3000/B 300/B 400
Etched components are identified
"General Inspection Guidelines for model transmission may be updated
by a dull to dark gray color - not the
Friction Plates" section of this from former C5 friction plates to
bright finish of a normal machined
manual. Replace any plates failing current C5 frictions without
aluminum part. Etched components
are also identified by roughness in these inspection procedures. recalibrating the transmission ECU.
the piston seal surface which can Minimum allowable friction plate The rest of the clutches in the main
cause piston seals to abrade and thickness is 2.21 mm (0.087 inch). housing (C1 through C4) must be
result in low clutch apply pressure Minimum allowable oil groove updated with current friction plates
and transmission damage. Replace depth is 0.20 mm (0.008 inch). if any other individual clutch
Maximum allowable plate coning is besides C5 is updated from former
etched or damaged components.
0.40 mm (0.016 inch). (continued)

(continued) ROTATING CLUTCH MODULE
C1 Backing Plate and Apply Plate Updates -
SIL 22-WT-98, Rev. A
Current apply plate is 2 mm thinner than former. Current

backing plate is 2 mm thicker than former.
to current friction plates. The MD- Inspect the C1 clutch reaction Current C1 backing plate minimum
3066, 3000MH-High, and B400 do plates following the "General allowable thickness is 8.25 mm
not require recalibration for Inspection Guidelines for Reaction (0.325 inch). Maximum allowable
updating to current friction plates. Plates" section of this manual. distortion of all plates is 0.15 mm
Any WTEC II ECU equipped Replace any plates failing these (0.006 inch).
vehicle with an MD-3060, MD-
inspection procedures. Minimum
3560, B300, or 3000MH-Standard NOTE: Transmissions built prior to
with former friction plates will allowable reaction plate thickness
is 2.41 mm (0.095 inch). Maximum S/N 6510164169 used two identical
require a new ECU calibration from C1 pressure plates. Transmissions
Allison Transmission to use the allowable reaction plate coning is
0.40 mm (0.016 inch). built after that used different plates.
current friction plates in C1, C2, C3
and C4. Any WTEC III ECU The current C1 apply pressure plate
equipped vehicle with an MD-3060, R, S. Inspect the C1 pressure (next to the C1 piston) is
MD-3560, B300, or 3000MH- plate and C1 backplate for flatness, approximately 2 mm thinner and has
Standard with an ECU calibration galling and other damage. Replace a different shape than the current C1
installed prior to October 25th, any plate with damage that cannot backplate (opposite end of the C1
1999 will require an updated ECU be removed using a soft stone or clutch pack). When replacing the
calibration to use the current crocus cloth. Former C1 pressure former pressure plates in a
friction plates in C1, C2, C3, and plate minimum allowable thickness transmission having the current
C4. Do not intermix both former is 6.25 mm (0.246 inch). Current C1 plates, both current plates must be
and current friction plates in a
apply plate minimum allowable used. Mixing former and current
clutch pack.
thickness is 4.25 mm (0.167 inch). plates will result in C1 clutch failure.
(continued)
ROTATING CLUTCH MODULE (continued)

C1 Drive Hub - SIL 8-WT-98, Rev. B C2 Drive Hub - SIL 8-WT-98, Rev. B
Newest hub is identified Newest hub is identified

by a machined groove. by a machined groove.
T. Inspect the C1 drive hub Maximum allowable spline wear is for Splines” sections of this manual.
following the "General Inspection 0.38 mm (0.015 inch). Replace the assembly if it fails any
Guidelines for Cast Parts and of these inspection procedures or if
V. Inspect the thrust bearings
Machined Surfaces" and the it has damage which cannot be
"General Inspection Guidelines for repaired using a soft stone or crocus
Guidelines for Bearings" section of
Splines" sections of this manual. cloth. Inspect the P1 sun gear
this manual. Replace any bearings
Replace the hub if it fails any of bushing following the "General
which fail any of these inspection
these inspection procedures. Inspection Guidelines for Bushings"
procedures.
Maximum allowable spline wear is section of this manual. Replace the
0.38 mm (0.015 inch). X. Inspect the C2 backing plate bushing if it fails any of these
for damage. Replace any plate with inspection procedures. Maximum
NOTE: Only the newest C1 drive
damage that cannot be removed allowable bushing inside diameter
hub is available for service. It is
using a soft stone or crocus cloth. is 68.22 mm (2.685 inches).
backwards compatible for units
without the newest C1 hub. Minimum allowable backing plate
Z. Inspect the retaining rings
thickness is 6.25 mm (0.246 inch).
U. Inspect the C2 drive hub Check the plate for flatness.
Guidelines for Retaining Rings"
following the "General Inspection Maximum allowable distortion is
section of this manual. Replace any
Guidelines for Cast Parts and 0.45mm (0.018 inch).
retaining rings failing any of these
Machined Surfaces" and the
Y. Inspect the P1 sun gear inspection guidelines or if the rings
"General Inspection Guidelines for
assembly following the "General are distorted or have damage which
Splines" sections of this manual.
Inspection Guidelines for Gears" cannot be repaired using a soft
Replace the hub if it fails any of
and “General Inspection Guidelines stone or crocus cloth.
ALLISON 3000/ B 300/ B 400 PRODUCT FAMILIES
C3 / C4 CLUTCH MODULE
Housing in good condition - reuse.
A. C3 Backplate B. P1 Ring
Assembly Gear
Etched housing - do NOT use.
G. C3 and C4 F. C3 and C4 Clutch E. C3 and C4 Spring

Clutch Packs Piston Return C. C3 Clutch Housing
Retainer
Plate Assemblies Assemblies
D. C4
Clutch
Housing
A. Inspect the C3 backplate allowable spline wear is 0.38 mm identifier) is compatible with the
assembly following the "General (0.015 inch). black wear plates. Do not change the
Inspection Guidelines for Cast Parts former P1 ring gear just because a unit
and Machined Surfaces" section of NOTE: The P1 ring gear end face grind has the black wear plates installed.
this manual. Replace the assembly if operation was eliminated starting Reference SIL 18-WT-04.
it fails any of these inspection with S/N 6610136125. The former P1
ring gear identifier was a groove C. Inspect the C3 clutch housing
procedures. Check the backplate
and wear plates for flatness. machined on the outside diameter of following the "General Inspection
Maximum allowable distortion is the gear. The current P1 ring gear does Guidelines for Cast Parts and
0.15 mm (0.006 inch). Minimum not have a groove on the O.D. The Machined Surfaces" section of this
current P1 ring gear is not compatible manual. Replace the housing if it
allowable wear plate thickness is
with aluminum wear plates riveted to fails any of these inspection
2.81 mm (0.111 inch).
the C3 housing and the clutch procedures. Check the housing for
B. Inspect the P1 ring gear backplate. If the former P1 ring gear is flatness. Maximum allowable
following the "General Inspection replaced with the current P1 ring gear distortion is 0.15 mm (0.006 inch).
Guidelines for Gears" and General and the unit has aluminum wear Check the wear plates for flatness.
Inspection Guidelines for Splines" plates, then the wear plates must be Maximum allowable distortion is
sections of this manual. Replace the updated to the current wear plates 0.15 mm (0.006 inch). Minimum
ring gear if it fails any of these that are black in color. The former P1 allowable wear plate thickness is
inspection procedures. Maximum ring gear (with the O.D. groove 2.81 mm (0.111 inch).
(continued)

C3 / C4 CLUTCH MODULE (continued)
Supersession Information Supersession Information Supersession Information

C3/C4 Apply Springs Update - C3/C4 Friction Plate Update - C3/C4 Friction Plate Slot Wear
SIL 4-WT-00, Rev. B. SIL 4-WT-00, Rev. B. and Discoloration -
SIL 27-WT-04
Slight friction material

Current C3 & C4 friction discoloration is
Former and current assemblies plates - two missing acceptable. Slight lube
are completely interchangeable. splines. slot wear is acceptable.
NOTE: Aluminum castings (like procedures. Check the housing for F. Inspect the C3 and C4 clutch
clutch housings) can be etched by flatness. Maximum allowable piston return plate assemblies
caustic parts cleaners and solvents. distortion is 0.15 mm (0.006 inch). following the "General Inspection
Etched components are identified by Guidelines for Reaction Plates"
a dull to dark gray color - not the E. Inspect the C3 and C4 spring section of this manual. Minimum
bright finish of a normal machined retainer assemblies following the allowable plate thickness is 3.41 mm
aluminum part. Etched components "General Inspection Guidelines for (0.135 inch). Maximum allowable
are also identified by roughness in Cast Parts and Machined Surfaces" plate coning is 0.40 mm (0.016 inch).
the piston seal surface which can section of this manual. Inspect the Replace springs which are cracked,
cause piston seals to abrade and assemblies for wear due to rubbing broken or permanently set.
result in low clutch apply pressure adjacent parts and cracked, broken Reference the Spring Data Charts in
and transmission damage. Replace or permanently set springs. Service Manual SM2148EN for
etched or damaged components. Reference the Spring Data Charts in spring specifications and
Service Manual SM2148EN for identification.
D. Inspect the C4 clutch housing (continued)
spring specifications and
identification.
Machined Surfaces" section of this
manual. Replace the housing if it
fails any of these inspection

(continued) C3 / C4 CLUTCH MODULE
C3 Clutch Housing & C3 Back plate Update -
SIL 17-WT-04, Rev. B.
Former and current assemblies are

completely interchangeable.
G. Inspect the C3 and C4 clutch friction plates will either have one and C4. Any WTEC III ECU equipped
friction plates following the spline missing or none missing. Any vehicle with an MD-3060, MD-3560,
"General Inspection Guidelines for 3000/B 300/B 400 model transmission B300, or 3000MH-Standard with an
Friction Plates" section of this may be updated from former C5 ECU calibration installed prior to
manual. Replace any plates failing friction plates to current C5 frictions October 25th, 1999 will require an
these inspection procedures. without recalibrating the transmission updated ECU calibration to use the
Minimum allowable plate thickness ECU. The rest of the clutches in the current friction plates in C1, C2, C3,
is 2.21 mm (0.087 inch). Maximum main housing (C1 through C4) must and C4. Do not intermix both former
allowable plate coning is 0.40 mm be updated with current friction and current friction plates in a clutch
(0.016 inch). plates if any other individual clutch pack.
besides C5 is updated from former to
NOTE: Battered and worn spline
Inspect the C3 and C4 clutch
current friction plates. The MD-3066,
teeth may be an indicator of 3000MH-High, and B400 do not reaction plates following the
driveline issues. Replace the clutch require recalibration for updating to "General Inspection Guidelines for
plates and check the driveline. current friction plates. Any WTEC II Reaction Plates" section of this
ECU equipped vehicle with an MD- manual. Replace any plates failing
NOTE: The current clutch friction 3060, MD-3560, B300, or 3000MH- these inspection procedures.
plates were implemented April of Standard with former friction plates Minimum allowable reaction plate
2000 starting with s/n 6510262117. will require a new ECU calibration thickness is 2.41 mm (0.095 inch).
Current production friction plates will from Allison Transmission to use the Maximum allowable reaction plate
have two missing splines. Former current friction plates in C1, C2, C3 coning is 0.40 mm (0.016 inch).

MAIN HOUSING
A. Main Housing
(rear view)
Main Housing (front view)
B. Splines
C. Fluid Main Housing (bottom view)

Passages
A. Inspect the main housing C. Inspect all

assembly following the "General fluid passages for
Inspection Guidelines for Cast obstructions,
Parts and Machined Surfaces" and porosity and cracks.
“General Inspection Guidelines for Inspect bolt holes
Splines” sections of this manual. for stripped or
Replace the housing if it fails any of damaged thread.
Replace the housing
these inspection procedures or if
if damage cannot be
the damage cannot be repaired
repaired.
(continued)
B. Maximum main case C5 clutch
spline wear is 1.15mm (0.045 inch).
Replace the main case if spline wear
exceeds the service limit. Examine clutch spline wear
carefully for proper tolerance.

Main Housing Update -
SIL 13-WT-00 ALLISON 3000 / B 300 / B 400 PRODUCT FAMILIES
(continued) MAIN HOUSING
From Converter To Converter Main Pressure

(to Cooler) (from Cooler) Oil Passage
Control Main Detail - Main
Sump
C3 Pressure Housing
Bottom View.
Wiring
Harness
Feedthrough
C6 Pressure
C5 Pressure Lube
Pressure
C4 Pressure
Lube Filter
Cavity
Main Filter
Cavity
Pump Suction
Lock-up C2 C1
Pressure Converter Converter In
Out Pressure Pressure
Oil Passage Detail - Oil Passage Detail - * All 3000

Main Housing Main Housing Product Family
Rear View. models except
Front View. 3070PT
C5 Pressure
Main
Pressure
To Cooler
Main
Lube Pressure
Pressure
Lock-up
Pressure
Pump
Suction Converter Out Control Main
C6 Pressure Sump
Converter In C2 Pressure From Cooler
C1 Pressure

DIRECT MOUNT OIL COOLER
Non-Retarder
D. Hose
Connector
A. Cooler
Housing
B. Cooler
Housing
Cover
C. Cooler
Plate
F. Copper Assembly
Washers
E. O-Ring
E. O-Ring
A. Inspect the cooler housing B. Inspect the cooler housing D. Inspect the hose connector on
following the “General Inspection cover following the “General each side of the cooler housing for
Guidelines for Cast Parts and Inspection Guidelines for Cast cracks, obstructions and burrs.
Machined Surfaces” section of this Parts and Machined Surfaces” Replace either hose connector id
manual. Inspect the copper washer section of this manual. Inspect the damage cannot be repaired.
seats for pitting and galling. Inspect cooler inlet and outlet bores for
the cooler inlet and outlet bores for cracks, burrs and obstructions. E. Always replace the O-rings
cracks, burrs and obstructions. Replace the housing if damage whenever the cooler is
Replace the housing if damage cannot be repaired using a soft disassembled.
cannot be repaired using a soft stone or crocus cloth. F. Replace any copper washers if
stone or crocus cloth. Inspect bolt they show signs of corrosion or
holes for stripped or damaged C. Inspect the cooler plate
assembly for cracks, obstructions distortion.
threads. Replace the housing if
damage cannot be repaired. and debris. Inspect the O-ring
grooves for chips, burrs and damage
which many prevent proper sealing.
Replace the assembly if damage
cannot be repaired.

3070PT Components

Oil
Pump 3070 MAIN SHAFT MODULE
C7
Clutch C6
Clutch
C. Journal
C. Journal
(P3)
(P2)
B. Main
P4 Planetary A. Main Shaft Shaft
Pilot
C. Journal D. Thrust
(C6) Bearing
D. Thrust H. Spiral
Bearing Retaining
Ring
E. P2 Sun
F. Bearing
G. P3 Sun Gear
Spacer
Gear
3070PT Main
Shaft Assembly
A. Inspect the main shaft journal diameter is 35.92 mm (1.414 F. Inspect the main shaft bearing
following the "General Inspection inches). Minimum allowable P2 spacer following the "General
Guidelines for Gears" and "General journal diameter is 42.97 mm (1.692 Inspection Guidelines for Cast
Inspection Guidelines for Splines" inches). Minimum allowable P3 Parts and Machined Surfaces" and
sections of this manual. Replace the journal diameter is 52.98 mm (2.086 "General Inspection Guidelines for
main shaft if it fails any of these inches). Splines" sections of this manual.
inspection procedures. Replace the Replace the spacer if it fails any of
main shaft if spline wear exceeds D. Inspect the thrust bearings these inspection procedures.
0.38 mm (0.015 inch). following the "General Inspection Replace the bearing spacer if spline
Guidelines for Bearings" section of wear exceeds 0.38 mm (0.015 inch).
B. Inspect the front main shaft
this manual. Replace any bearing
pilot for damage. The front main G. Inspect the P3 sun gear
that fails any of these inspection
shaft pilot fits inside the turbine following the "General Inspection
procedures.
shaft. Minimum allowable front Guidelines for Gears" and "General
pilot diameter is 19.98 mm (0.787 E. Inspect the P2 sun gear Inspection Guidelines for Splines"
inch). Replace the main shaft if following the "General Inspection sections of this manual. Replace the
worn beyond service limits. Guidelines for Gears" and "General gear if it fails any of these
Inspection Guidelines for Splines" inspection procedures. Replace the
C. Inspect the bushing journal
sections of this manual. Replace the sun gear if spline wear exceeds 0.38
areas for damage. Replace the main
gear if it fails any of these mm (0.015 inch).
shaft if any of the three journals is
inspection procedures. Replace the
galled or worn beyond service H. Replace the spiral retaining
sun gear if spline wear exceeds 0.38
limits. Minimum allowable C6 ring if it is removed.
mm (0.015 inch).

TRANSFER CASE SCAVENGE PUMP
C. Scavenge
Pump Body
B. Scavenge
Pump Gear
Set Scavenge
Pump Cover
F. Thrust
Washers
G. Roller
A. Scavenge Bearing
Pump
Housing
D. Scavenge
Pump Driven E. Scavenge
Gear Assembly Pump Scavenge Pump
Shaft Assembly
A. Inspect the scavenge pump the depth of the scavenge pump body E. Inspect the scavenge pump
housing assembly following the where the gears fit. Subtract the shaft for damage. Replace the shaft if
"General Inspection Guidelines for thickness of each gear from the depth damage cannot be removed using a
Cast Parts and Machined Surfaces" of the pump body. Maximum soft stone or crocus cloth.
section of this manual. Replace the allowable clearance is 0.125 mm
F. Inspect the scavenge pump
housing if it fails any of these (0.0005 inch). Replace components if
inspection procedures or if the they are beyond service limits. thrust washers following the
damage cannot be repaired using a "General Inspection Guidelines for
C. Inspect the scavenge pump body Thrust Washers" section of this
soft stone or crocus cloth.
and scavenge pump cover for galling. manual. Replace the thrust washer if
B. Inspect the scavenge pump gear Replace the pump body if it is galled it fails any of these inspection
set following the "General Inspection or damaged. procedures or if it has damage that
Guidelines for Gears" section of this cannot be repaired using a soft stone
manual. Replace the gear set if it D. Inspect the scavenge pump
or crocus cloth.
fails any of these inspection driven gear assembly following the
procedures. Replace the gear set if "General Inspection Guidelines for G. Inspect the driven gear roller
damage cannot be repaired with a Gears" section of this manual. bearing following the “General
light stone or crocus cloth. Measure Replace the gear if it fails any of Inspection Guidelines for Bearings”
the thickness of each gear. Measure these inspection procedures. section of this manual. Replace the
bearing if it fails any of these

TRANSFER CASE ADAPTER HOUSING
B. 3070 7-inch
Control Module.
C6 Clutch
Valve Body
7”
A. Adapter
Housing
Note: Component detail is the same as other
models with the addition of C6 valve body.
NOTE: Reference the "Inspection B. Refer to the "Control Module" Inspect all threaded holes for
and Analysis of the Rear Cover and section of this manual for details damage and debris. Replace the
P3 Planetary Module" section of this (except for the C6 clutch valve valve body if the thread damage
manual for P3 planetary, output body). cannot be repaired.
shaft and C5 clutch assembly
C, D. Valves, valve body bores NOTE: Do not use impact guns (air
inspection.
and oil passages must be free of wrenches, electric impact
A. Inspect the adapter housing debris, nicks, burrs, scoring and wrenches, etc.) when working with
following the "General Inspection galling. Valves should move freely aluminum threads or when torque
Guidelines for Cast Parts and in their bores, when dry, under sequencing bolts.
Machined Surfaces" section of this their own weight. Repair or replace
manual. Replace the housing if it valves and/or valve bodies failing to Replace valve springs which are
fails any of these inspection meet these requirements. broken, permanently set or worn
procedures. due to rubbing adjacent parts.
Valve body machined surfaces
Reference the Spring Data Charts in
must be free of debris, nicks, burrs
the Service Manual for spring
and scoring. Light stoning of these
specifications and identification.
machined surfaces is permitted to
correct minor defects. Replace any (continued)
valve body that cannot be repaired.

TRANSFER CASE ADAPTER HOUSING (continued)
Identification Detail: Regulator Solenoid

Valve Spring Regulator
C6 Clutch Valve Body Valve
C6 Clutch
Body
C6
Interlock Regulator
Valve Valve Solenoid
Assembly
C6 Interlock
Valve Spring
Regulator
C6 Clutch Body
Valve Solenoid
Cover Plate
Assembly
Valve stops and retention pins Inspect the C6 clutch body cover
must not be damaged or battered. plate for damage. Replace the plate
Replace valve stops or pins which if damage cannot be repaired using
have damage that cannot be a soft stone or crocus cloth.
removed using a soft stone or
crocus cloth. D. C7 Clutch
Valve Body
Replace solenoids if they are visibly Spring
damaged. Proper solenoid
Signal Valve
resistance is 3 to 4 ohms measured
between the two solenoid
terminals. Check resistance C7
between each solenoid terminal and Solenoid
the solenoid body. Replace the
solenoid if resistance measures less
Pin
than 100k ohms. Control
Valve Spring
Stop

TRANSFER CASE HOUSING ASSEMBLY
F. Shims
D. Oil Pump
Assembly
F. Shims
E. Transfer
Case
Wiring
Harness
Idle
Cover
B. Transfer
Case
Adapter
A. Transfer Shaft
Case
Housing
C. Manifold
Assembly
F. Transfer Case Shims
A. Inspect the transfer case B. Inspect the transfer case C. Inspect the manifold assembly
housing following the "General adapter shaft following the "General following the "General Inspection
Inspection Guidelines for Cast Parts Inspection Guidelines for Cast Parts Guidelines for Cast Parts and
and Machined Surfaces" section of and Machined Surfaces" and Machined Surfaces" section of this
this manual. Replace the housing if it "General Inspection Guidelines for manual. Replace the manifold if it
fails any of these inspection Splines" sections of this manual. fails any of these inspection
procedures. Inspect cover and Replace the shaft if it fails any of procedures. Inspect the manifold
manifold mounting surfaces for these inspection procedures. inside diameter where the C7 clutch
nicks, burrs and flatness. Replace housing seal rings ride for grooving,
Spline wear cannot exceed 0.35 mm
both housings if damage cannot be scoring and other damage. Replace
(0.015 inch). Replace the adapter
repaired using a soft stone or crocus the manifold if it is excessively worn.
shaft if spline wear exceeds this limit.
cloth. (continued)
NOTE: Transfer case housing halves
are matched sets and must be
replaced in pairs.

TRANSFER CASE HOUSING ASSEMBLY (continued)
Identification Detail:
Oil Pump Assembly
Driven Gear
Front Cover
Drive
Gear
Pressure Rear
Reversing
Relief Valve Cover
Spring Ring
Plug
D. Inspect the oil pump assembly Reference the Spring Data Charts in
following the "General Inspection Service Manual SM2148EN for
Guidelines for Cast Parts and spring specifications and
Machined Surfaces" section of this identification.
manual. Replace the assembly if it E. Inspect the transfer case
fails any of these inspection controls wiring harness for
procedures. damaged connectors, wires and
Inspect the oil pump pressure relief terminals. Repair or replace the
valve and pin for scoring, nicks and harness components as necessary.
signs of battering. Replace the valve F. Replace the transfer case
and pin if damage cannot be repaired shims if they are damaged in any
using a light stone or crocus cloth. way.
(continued)
Replace the pressure relief valve plug
if its threads are damaged. Replace
the pressure relief valve spring if it is
bent, broken or permanently set.

TRANSFER CASE COVER
B. Transfer Case
Controls Cover
C. Idler
Cover
D. Output Speed
A. Transfer
Sensor
Case
Housing
A. Inspect the transfer case B. Inspect the transfer case D. Inspect the output speed
housing following the "General controls cover following the sensor for damage. Replace the
Inspection Guidelines for Cast "General Inspection Guidelines for sensor if it has body, terminal or
Parts and Machined Surfaces" Cast Parts and Machined Surfaces" connector seat damage. Allowable
section of this manual. Replace the section of this manual. Replace the output speed sensor resistance is
cover if it fails any of these cover if it fails any of these 300 ohms plus or minus 30 ohms.
inspection procedures. Inspect inspection procedures. Replace the sensor if it is outside
cover and bearing retainer service specifications.
mounting surfaces for nicks, burrs C. Inspect the idler cover
and flatness. Replace both covers if following the "General Inspection
damage cannot be repaired using a Guidelines for Cast Parts and
soft stone or crocus cloth. Machined Surfaces" section of this
manual. Replace the cover if it fails
NOTE: Transfer case housing halves any of these inspection procedures.
are matched sets and must be
replaced in pairs.

TRANSFER CASE GEARS
B. Tapered Roller
Bearings
A. Transfer Case A. Transfer Case A. Transfer Case

Driven Gear Drive Gear Idler Gear
(30 Teeth) (37 Teeth)
A. Inspect the transfer case drive, B. Inspect the transfer case gear
driven and idler gears following tapered roller bearings following
the "General Inspection Guidelines the "General Inspection Guidelines
for Gears" and "General Inspection for Bearings" section of this manual.
Guidelines for Splines" sections of Replace any bearings failing any of
this manual. Replace any gears these inspection procedures.
which fail these inspection Replace the corresponding transfer
procedures or if the gears have case housing bearing cup when a
damage which cannot be repaired bearing is replaced.

TRANSFER CASE C6 CLUTCH ASSEMBLY
C. C6 Clutch
Hub A. C6 Clutch
Housing
E. C6 Clutch
Friction Plates
D. C6 Clutch
Piston
C6
Backplate
B. C6
Bushing
G. C6 Clutch
Hub Thrust
F. C6 Spring Bearing
H. Retaining Retainer
Rings Assembly
A. Inspect the C6 clutch housing B. Inspect the C6 clutch sleeve D. Inspect the C6 clutch piston
following the "General Inspection and C6 clutch bushing for damage. following the "General Inspection
Guidelines for Cast Parts and Replace the sleeve or bushing if Guidelines for Cast Parts and
Machined Surfaces" and “General excessively worn or if damage Machined Surfaces" section of this
Inspection Guidelines for Splines” cannot be removed using a light manual. Replace the piston if it fails
sections of this manual. Replace the stone or crocus cloth. Maximum any of these inspection procedures.
housing if it fails any of these allowable C6 bushing inside
NOTE: Aluminum castings (like
inspection procedures. Maximum diameter is 36.18 mm (1.424 inches).
allowable spline wear is 2.29 mm clutch pistons) can be etched by
C. Inspect the C6 clutch hub caustic parts cleaners and solvents.
(0.090 inch).
following the "General Inspection Etched components are identified
Guidelines for Cast Parts and by a dull to dark gray color - not the
Machined Surfaces" and the bright finish of a normal machined
"General Inspection Guidelines for aluminum part. Etched components
Splines" sections of this manual. are also identified by roughness in
Replace the hub if it fails any of the piston seal surface which can
these inspection procedures. cause piston seals to abrade and
result in low clutch apply pressure
and transmission damage. Replace
etched components.
(continued)
TRANSFER CASE C6 CLUTCH ASSEMBLY (continued)
E. Inspect the C6 clutch friction Replace any plates failing any of broken in any way. Reference the
plates following the "General these inspection procedures. Spring Data Charts in Service
Inspection Guidelines for Friction Minimum allowable plate thickness Manual SM2148EN for spring
Plates" section of this manual. is 2.41 mm (0.095 inch). Maximum specifications and identification.
Replace any plates failing these allowable coning is 0.40 mm (0.016
G. Inspect the C6 clutch hub
inspection procedures. Minimum inch).
thrust bearing following the
allowable plate thickness is 3.68 mm
Inspect the C6 clutch backplate "General Inspection Guidelines for
(0.145 inch). Minimum allowable oil
for damage. Replace the backplate if Bearings" section of this manual.
groove depth is 0.20 mm (0.008
damage cannot be repaired using a Replace the bearing if it fails any of
inch). Maximum allowable coning is
soft stone or crocus cloth. these inspection procedures.
0.40 mm (0.016 inch).
Minimum allowable backplate
H. Inspect the C6 clutch pack
NOTE: Battered and worn spline thickness is 7.90 mm (0.311 inch).
retaining rings for damage and
teeth may be an indicator of Check the backplate for flatness.
distortion following the "General
driveline issues. Replace the clutch Maximum allowable distortion is
Inspection Guidelines for Retaining
plates and check the driveline. 0.40 mm (0.016 inch).
Rings" section of this manual.
Inspect the C6 steel reaction F. Replace the C6 spring retainer Replace any retaining ring with
plates following the "General assembly if it has a permanent damage that cannot be repaired
Inspection Guidelines for Reaction spring set, wear due to rubbing using a light stone or crocus cloth.
Plates" section of this manual. adjacent parts or if it is cracked or

TRANSFER CASE C7 CLUTCH ASSEMBLY
A. C7 Clutch
B. C7 Clutch
Housing
Hub
D. C7 Clutch
C7
Pack
Bushing
C7 Backplate
C. C7 Clutch
Piston
E. C7 Clutch Pack
Retaining Ring
Inspect the pressure relief

check ball for free movement.
A. Inspect the C7 clutch housing Inspect the C7 clutch hub bushing B. Inspect the C7 clutch hub
following the "General Inspection following the "General Inspection following the "General Inspection
Guidelines for Cast Parts and Guidelines for Bushings" section of Guidelines for Cast Parts and
Machined Surfaces" and "General this manual. Replace the bushing if Machined Surfaces" and the
Inspection Guidelines for Splines" it fails any of these inspection "General Inspection Guidelines for
sections of this manual. Replace the procedures or if it has damage Splines" sections of this manual.
housing if it fails any of these which cannot be repaired using a Replace the hub if it fails any of
inspection procedures. soft stone or crocus cloth. these inspection procedures or if it
Maximum allowable bushing inside has damage which cannot be
Inspect the pressure relief check diameter is 47.26 mm (1.861 inch). repaired using a soft stone or crocus
ball for free movement. Minimum cloth.
allowable check ball movement is
1.00 mm (0.040 inch). Replace the C. Inspect the C7 clutch piston
check ball if it is stuck in the bore. following the "General Inspection
The ball is staked in the housing. Guidelines for Cast Parts and
Machined Surfaces" section of this
manual. Replace the piston if it fails
any of these inspection procedures.
(continued)

TRANSFER CASE C7 MODULE (continued)
D. Inspect the C7 clutch friction Inspect the C7 steel reaction Check the backplate for flatness.
plates following the "General plates following the "General Maximum allowable distortion is
Inspection Guidelines for Friction Inspection Guidelines for Reaction 0.40 mm (0.016 inch).
Plates" section of this manual. Plates" section of this manual.
Replace any plates failing these Replace any plates failing any of E. Inspect the C7 clutch pack
inspection procedures. Minimum these inspection procedures. retaining ring for damage and
allowable plate thickness is 2.21 Minimum allowable plate thickness distortion following the "General
mm (0.087 inch). Minimum is 2.11 mm (0.083 inch). Maximum Inspection Guidelines for Retaining
allowable oil groove depth is 0.20 allowable coning is 0.25 mm Rings" section of this manual.
mm (0.008 inch). Maximum (0.010 inch). Replace the retaining ring if damage
allowable coning is 0.25 mm cannot be repaired using a light
(0.010 inch). Inspect the C7 clutch backplate for stone or crocus cloth.
damage. Replace the backplate if
NOTE: Battered and worn spline damage cannot be repaired using a
teeth may be an indicator of soft stone or crocus cloth.
driveline issues. Replace the clutch Minimum allowable backplate
plates and check the driveline. thickness is 8.67 mm (0.341 inch).

TRANSFER CASE FRONT OUTPUT COMPONENTS
Seal
F. Front Output
Yoke, Nut &
Washer
C. Tapered
Roller
Bearings
B. Front
Output
Shaft
E. Bearing A. Front Output

Shim Housing
D. Bearing
Spacer
A. Inspect the transfer case front C. Inspect the front output shaft F. Inspect the front output yoke
output housing following the tapered roller bearings following following the "General Inspection
"General Inspection Guidelines for the "General Inspection Guidelines Guidelines for Cast Parts and
Cast Parts and Machined Surfaces" for Bearings" section of this manual. Machined Surfaces" and the "General
section of this manual. Replace the Replace any bearings failing any of Inspection Guidelines for Splines"
housing if it fails any of these these inspection procedures. sections of this manual. Replace the
inspection procedures. Replace the Replace the corresponding bearing yoke if it fails any of these inspection
roller bearing races or "cups" if they cup when a bearing is replaced. procedures. Minimum allowable seal
are damaged. journal outside diameter is 76.20 mm
D. Inspect the front output shaft (3.00 inches). Inspect the output
B. Inspect the front output shaft bearing spacer for damage. Replace yoke nut for damaged threads.
following the "General Inspection the spacer if damage cannot be Replace the nut if damaged. Replace
removed using a soft stone or the output nut washer if it has
Machined Surfaces" and the "General
crocus cloth. damage which cannot be repaired
Inspection Guidelines for Splines"
sections of this manual. Replace the E. Replace the output bearing
Replace the output nut if it does not
shaft if it fails any of these inspection shims if they damaged in any way. have at least 25 pound feet of
procedures. Inspect the shaft bearing
turning torque while being threaded
journal areas for galling and other
onto the shaft.
damage. Replace the shaft if
damaged.

TRANSFER CASE REAR OUTPUT COMPONENTS
A. Rear Output
Housing
G. P4 Ring Gear
F. Output Yoke,
Nut & Washer
C. Tapered
Roller
Bearings
E. Bearing
Shims
B. Rear
Output I. P4 Sun
Shaft D. Bearing Gear
Spacer H. P4 Carrier
(25 Teeth)
Assembly
A. Inspect the transfer case rear C. Inspect the rear output shaft F. Inspect the rear output yoke
output housing following the tapered roller bearings following following the "General Inspection
"General Inspection Guidelines for the "General Inspection Guidelines Guidelines for Cast Parts and
Cast Parts and Machined Surfaces" for Bearings" section of this manual. Machined Surfaces" and the "General
section of this manual. Replace the Replace any bearings failing any of Inspection Guidelines for Splines"
housing if it fails any of these these inspection procedures. Replace sections of this manual. Replace the
inspection procedures. Replace the the corresponding bearing cup when yoke if it fails any of these inspection
roller bearing races or "cups" if they a bearing is replaced. procedures. Minimum allowable seal
are damaged. journal outside diameter is 76.20 mm
D. Inspect the rear output shaft
(3.00 inches). Inspect the output
B. Inspect the rear output shaft bearing spacer for damage. Replace
yoke nut for damaged threads.
following the "General Inspection the spacer if damage cannot be
Replace the nut if damage cannot be
Guidelines for Cast Parts and removed using a soft stone or crocus
repaired using a soft stone or crocus
Machined Surfaces" and the "General cloth.
cloth. Replace the output nut
Inspection Guidelines for Splines"
E. Replace the output bearing washer if it is damaged. Replace the
sections of this manual. Replace the
shims if they are damaged in any output nut if it does not have at least
shaft if it fails any of these inspection
way. 25 pound feet of turning torque
procedures. Inspect the shaft bearing
while being threaded onto the shaft.
journal areas for excessive wear or
galling. Replace the shaft if damaged. (continued)

(continued) TRANSFER CASE REAR OUTPUT COMPONENTS
M. P4
Pinion
K. Thrust
Washers
L. Roller
Bearing
J. Spindle
G. Inspect the P4 ring gear I. Inspect the P4 sun gear L. Inspect the pinion needle
following the "General Inspection following the "General Inspection roller bearings following the
Guidelines for Cast Parts and Guidelines for Gears" and the "General Inspection Guidelines for
Machined Surfaces" and the "General "General Inspection Guidelines for Bearings" section of this manual.
Inspection Guidelines for Splines" Splines" sections of this manual. Replace any bearings failing these
sections of this manual. Replace the Replace the gear if it fails any of inspection procedures.
ring gear if it fails any of these
inspection procedures. M. Inspect the P4 pinion gears
H. Inspect the P4 planetary J. Replace the pinion spindles if following the "General Inspection
carrier following the "General they are damaged. Replace the Guidelines for Gears" section of this
Inspection Guidelines for Cast pinion spindle set screws if manual. Replace any gear that fails
Parts and Machined Surfaces" and threads are damaged. these inspection procedures or if
the "General Inspection Guidelines damage cannot be removed using a
K. Replace the pinion gear thrust soft stone.
for Splines" sections of this manual.
washers if they are galled or
Replace the housing if it fails any of
excessively worn.

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

A. Maximum Variations. Wear limits information adjacent parts, or permanent set. Discard springs
in this Section shows the maximum wear at which which do not meet the load height specications ac-
components are expected to function satisfactorily. Ta- cording to Table 7–2, Spring Data.
ble 7–1 lists the Wear Limits Data and is referenced to
B. Inspection. Inspection criteria (load vs. height)
the exploded views (Foldouts 7 through 19) in the
and identication characteristics of the springs are pre-
back of this manual.
sented in Table 7–2. The Spring Data are keyed to the
B. Cleaning and Inspection. Parts must be clean to exploded views (Foldouts 7 through 19) in the back of
permit effective inspection for wear or damage. Refer this manual.
to Section 3.
NOTE:
7–2. SPRING DATA When more than one spring part number is listed
A. Spring Replacement. Springs should be replaced for the same location, refer to the latest edition of
if there are signs of overheating, wear due to rubbing Parts Catalog PC2150EN to determine which
spring is used in your specific assembly number.
Table 7–1. Wear Limits Data Wear Limit

Illustration Description mm (inches)
Foldout 7 TORQUE CONVERTER MODULE
9 Cover Bushing, Maximum ID 61.51 2.422
11 Piston, Minimum Thickness 5.71 0.225
13 Lockup Clutch Friction Plate Flatness, Maximum Distortion 0.51 0.020
13 Lockup Clutch Friction Plate, Minimum Thickness 8.05 0.317
13, 18 Turbine-To-Damper Spline Wear, Maximum Movement 0.38 0.015
14 Backing Plate Wear Surface, Minimum Thickness 8.58 0.338
16 Turbine Hub Hook-Type Sealring, Maximum ID When Installed In 56.75 2.234
Cover 7 Bore
18 Turbine Hub, Minimum OD 61.34 2.415
23 Stator Thrust Plate, Minimum Thickness 11.68 0.460
34 Converter Pump Hub, Minimum OD 74.999 2.9527
Foldout 8,B TORQUE CONVERTER HOUSING MODULE — WITH PTO
6 Bearing Retainer Bushing, Maximum ID 75.23 2.962
7 Bearing Retainer Bearing Bore, Maximum ID 140.06 5.514
10, 17 Oil Pump Drive Hub Seals, When Installed in Sealing Bore, 1.15 0.045
Maximum End Gap
14 Oil Pump Drive Hub, Maximum Tang Wear 0.38 0.015
23 Converter Housing Bearing Bore, Maximum ID 140.03 5.513

(continued) WEAR LIMITS AND SPRING DATA
Table 7–1. Wear Limits Data (cont’d) Wear Limit
Foldout 9,A FRONT SUPPORT AND CHARGING PUMP MODULE
8 Pump Housing Bushing, Maximum ID 75.23 2.962
9 Pump Housing Gear Cavity, Maximum Depth 17.93 0.706
9 Pump Housing Gear Cavity, Maximum ID 127.30 5.012
9, 10 Driven Gear-To-Pump Housing, Maximum Diametrical Clearance 0.36 0.014
10 Drive/Driven Gear, Maximum Gear Tooth Tip Clearance 0.20 0.008
10 Driven Gear, Minimum OD 126.95 4.998
10 Drive/Driven Gear, Minimum Width 17.81 0.701
10, 14 Gear-To-Plate Maximum Side Clearance 0.13 0.005
11 Pump Drive Gear Bushing, Maximum ID 57.30 2.256
14 Wear Plate, Minimum Thickness 4.70 0.185
16, 17 Ground Sleeve Oil Pump Bushing Journal, Minimum OD 57.04 2.246
20 Front Support Sleeve, Minimum Dimension 98.83 3.891
23 Front Support Seal, Maximum End Gap 1.44 0.057
Foldout 9,B ROTATING CLUTCH MODULE

7 Turbine Shaft Bushing ID, Maximum 20.19 0.795
10 Turbine Shaft Seal, Maximum End Gap 0.94 0.037
11 Drum, Maximum Spline Wear 0.38 0.015
13 Rotating Clutch Hub Bushing, Maximum ID 99.25 3.907
29 C1 Clutch Pressure Plate Flatness, Maximum Distortion 0.15 0.006
29 C1 Clutch Pressure Plate, Minimum Wear Surface Thickness 6.25 0.246
30, 37 C1, C2 Friction Plate, Maximum Cone 0.40 0.016
30, 37 C1, C2 Friction Plate, Minimum Thickness 2.21 0.087
30, 37 C1, C2 Friction Plate, Minimum Oil Groove Depth 0.20 0.008
31, 36 C1, C2 Steel Reaction Plate, Maximum Cone 0.40 0.016
31, 36 C1, C2 Steel Reaction Plate, Minimum Thickness 2.41 0.095 *
33, 35 C1, C2 Drive Hub, Maximum Spline Wear 0.38 0.015
38 C2 Clutch Pressure Plate, Maximum Cone 0.45 0.018
38 C2 Clutch Pressure Plate, Minimum Thickness 6.25 0.246
42 P1 Sun Gear Drive Hub Bushing, Maximum ID 68.22 2.685
* 0.0965 For MD 3070PT Model

WEAR LIMITS AND SPRING DATA (continued)

Foldout 10,A MAIN HOUSING MODULE
4 Backing Plate Flatness, Maximum Distortion 0.15 0.006
5, 16 C3, C4 Wear Plate Flatness, Maximum Distortion 0.15 0.006
5, 16 C3, C4 Wear Plate, Minimum Thickness At Wear Point 2.81 0.111
7 P1 Ring Gear, Maximum Spline Wear 0.38 0.015
8, 19, 38 C3, C4, C5 Friction Plate Cone, Maximum Distortion 0.40 0.016
8, 19 C3, C4 Friction Plate, Minimum Thickness 2.21 0.087
C3, C4 Friction Plate, Maximum Friction Material Erosion Around
8, 19 4.00 0.157
Lubrication Slots
8, 19 C3, C4 Friction Plate, Minimum Oil Groove Depth 0.20 0.008
9, 18, 37 C3, C4, C5 Reaction Steel Plate Cone, Maximum Distortion 0.40 0.016
9, 18, 37 C3, C4, C5 Reaction Steel Plate, Minimum Thickness 2.41 0.095
11, 21 C3, C4 Piston Return Plate Cone, Maximum Distortion 0.40 0.016
11, 21 C3, C4 Piston Return Plate, Minimum Thickness 3.41 0.135
17, 24 C3, C4 Clutch Housing Flatness, Maximum Distortion 0.15 0.006
27 Main Housing Clutch Plate Splines, Maximum Wear 1.15 0.045
38 C5 Friction Plate, Minimum Thickness 2.90 0.114
38 C5 Friction Plate, Minimum Oil Groove Depth 0.20 0.008
Foldout 10,B
MAIN SHAFT MODULE (3000, 3500, MD 3060, and MD 3560)
and 11,A
9, 8 Main Shaft Pilot, Minimum OD 19.98 0.787
9, 8 Main Shaft P2 Bushing Journal, Minimum OD 42.97 1.692
9, 8 Main Shaft Splines, Maximum Wear 0.38 0.015
Foldout 11, B MAIN SHAFT MODULE (3700 SP and MD 3070PT)
8 Main Shaft Pilot (Front), Minimum OD 19.98 0.787
8 Main Shaft P2 Bushing Journal, Minimum OD 42.97 1.692
8 Main Shaft C6 Bushing Journal, Minimum OD 35.92 1.414
8 Main Shaft P3 Bushing Journal, Minimum OD 52.98 2.086
9 Main Shaft Splines, Maximum Wear 0.38 0.015

(continued) WEAR LIMITS AND SPRING DATA
Foldout 12,A P1 PLANETARY MODULE
9, 12 P1 Pinion Thrust Washer, Minimum Thickness 1.39 0.054
10 Pinion, Maximum End Play 0.94 0.037
Foldout 12,B P2 PLANETARY MODULE
2 P2 Carrier Seal, Maximum End Gap 1.20 0.047
7 P2 Carrier Bushing, Maximum ID 43.20 1.701
Foldout 13,A;
RETARDER AND P3 PLANETARYMODULE
13,B; 13,C
8 Output Shaft Bushing, Maximum ID 20.19 0.795
29 Retainer Ball, Minimum Movement (N/A To Foldout 13,B and 13,C) 0.50 0.020
30, 33 Retarder Rotor Sealring, Maximum ID 56.75 2.234
Foldout 13,D REAR COVER AND P3 PLANETARY MODULE
7 Output Shaft Bushing, Maximum ID 20.19 0.795
Foldout 15 C7 CLUTCH HOUSING
44 Yoke Journal Seal Wear, Minimum Diameter 76.20 3.000
61 C7 Backplate, Minimum Thickness 8.67 0.341
62 C7 Friction Plate, Maximum Cone 0.25 0.010
63 C7 Reaction Plate, Minimum Thickness 2.11 0.083
63 C7 Reaction Plate, Maximum Cone 0.25 0.010
68 Bushing, Maximum ID 47.26 1.861
69 Ball, Free Movement 1.00 0.040

WEAR LIMITS AND SPRING DATA (continued)

Foldout 16 C6 CLUTCH HOUSING
9 Backplate, Minimum Thickness 7.90 0.311
9 Backplate, Maximum Cone 0.40 0.016
11 C6 Reaction Plate, Minimum Thickness 2.41 0.095
11 C6 Reaction Plate, Maximum Cone 0.40 0.016
19 C6 Housing, Maximum Groove Wear 2.29 0.090
21 C6 Housing Bushing 36.18 1.424
Foldout 18,A OUTPUT FLANGE AND YOKE
1, 7 Journal Seal Wear, Minimum Diameter 89.78 3.535
Foldout 18,B TRANSFER CASE ADAPTER HOUSING AND P3 MODULE
6 P3 Carrier Bushing, Maximum ID 53.22 2.095
Foldout 19,C Scavenge Pump Thrust Washer, Minimum Thickness 2.47 0.097

Table 7–2. Spring Data
Spring Approx. Free
Length Under Load
Color No. Wire Dia. OD Length
Foldout Ref. Spring Part No. Code Coils mm (in.) mm (in.) mm (in.) mm (in.) N (lb) min.
7 25 Stator 29500064 No Code N/A N/A N/A 17.8 3.3 0.7–1.6
Convoluted (0.70) (0.13) (0.16–0.36)
9,B 21 C2 Return 29503215 No Code 12* 2. 04* 13.00* 45.3** 37.0 4823–5379**
(0.080) (0.512) (1.78) (1.46) (1084–1209)
9,B 25 C1 Return 23045586 No Code 10* 2.19* 16.00* 45.2** 27.5 5763–6369**
(0.086) (0.630) (1.78) (1.08) (1296–1432)
(continued) WEAR
10,A 10 C3 Return 29505570 No Code 11* 1.70* 12.00* 38.9** 24.5 232–256**
(0.067) (0.472) (1.53) (0.96) (52.2–57.6)
10,A 12 C3 Retainer 29505861 No Code 4* 2.59* 13.26* 12.8** 11.0 11310–14610**
ALLISON
(0.102) (0.522) (0.50) (0.43) (2543–3284)
10,A 20 C4 Return 29505570 No Code 11* 1.70* 12.00* 38.9** 24.5 232–256**
(0.067) (0.472) (1.53) (0.96) (52.2–57.6)
10,A 22 C4 Retainer 29505861 No Code 4* 2.59* 13.26* 12.8** 11.0 11310–14610**
(0.102) (0.522) (0.50) (0.43) (2543–3284)
13,A/13,B 23/23 C5 Retainer 29507780 No Code 9.5* 1.83* 14.35* 39.2** 25.0 3044–3364**
TRANSMISSION
(0.072) (0.565) (1.54) (0.98) (684–756)
13,A 46 Retarder 6880775 Yellow/ 12 1.93 16.61 53.85 35.31 73–89
Red Stripe (0.076) (0.654) (2.12) (1.39) (16.5–20.1)
13,A 46 Retarder 29512751 Silver (End) 10.5 2.16 19.05 61.5 25.9 177.5–196.3
(0.085) (0.75) (2.42) (1.02) (39.9–44.1)
13,A 46 Retarder 29515101 Green 16.0 3.78 36.6 106.7 73.66 120.1–146.7
TECHNICIANS’
(0.149) (1.44) (4.20) (2.90) (27.0–33.0)
13,A/13,B 46/55 Retarder 29515692 None 11.4 4.12 36.17 114.3 91.1 200.0–226.6
(0.162) (1.42) (4.50) (3.59) (44.96–50.94)
GUIDE
13,A 92 Retarder Control 29510494 Solid Orange 7 1.60 15.50 27.8 18.0 44–50.9
Low, 27 psi (0.063) (0.610) (1.09) (0.71) (9.9–11.4)
LIMITS AND SPRING DATA
81
* Individual Springs
** For the complete Spring Assembly
Table 7–2. Spring Data (cont’d)
82
Spring Approx. Free
Length Under Load
13,A 92 Retarder Control 29510495 Solid Silver 7.5 1.40 15.09 30.8 18.0 32.5±35.9
Medium, 36 psi (0.055) (0.594) (1.21) (0.71) (7.3±8.05)
ALLISON
13,A 92 Retarder Control 29510496 Solid Blue 8 1.14 14.59 36.0 18.0 19.8±21.9
High, 45 psi (0.045) (0.574) (1.42) (0.71) (4.5±4.9)
13,B 78 Retarder Control 29529300 White/ 8.52 1.27 13.46 33.02 16.51 34.22±37.86

Low, 54 psi Black Stripe (0.050) (0.530) (1.30) (0.650) (7.69±8.51)
13,B 78 Retarder Control 29529299 Yellow/ 9.25 1.04 12.19 37.8 16.51 23.44±25.94
Medium, 64 psi Red Stripe (0.041) (0.480) (1.49) (0.650) (5.27±5.83)
TRANSMISSION
13,B 78 Retarder Control 29529298 Pink/ 8.23 0.94 12.19 31.47 16.51 9.39±10.37
High, 76 psi White Ends (0.037) (0.480) (1.24) (0.650) (2.11±2.33)
13,D/18,B 23/16 C5 Retainer 29500867 No Code 11.5* 2.16* 16.00* 52.1** 33.0 3034±3498**
(0.085) (0.630) (2.05) (1.30) (682.1±786.4)
2109±
C6 Spring Retainer 1.84 12.70 35.10 26.20
16 13 29501191 No Code 10 2331**
Assembly (0.072) (0.500) (1.382) (1.032)
(474±524)
TECHNICIANS’
17,A 53, 79, Solenoid Regulator 29502195 No Code 4 0.67 11.05 ² 6.5 3.45 3.2±4.2
88, 103 (0.026) (0.435) (0.26) (0.14) (0.72±0.94)
17,B 60, 75 Solenoid Regulator 29502195 No Code 4 0.67 11.05 ² 6.5 3.45 3.2±4.2
GUIDE
84, 109 (0.026) (0.435) (0.26) (0.14) (0.72±0.94)
17,C 61, 76 Solenoid Regulator 29502195 No Code 4 0.67 11.05 ² 6.5 3.45 3.2±4.2
89, 110 (0.026) (0.435) (0.26) (0.14) (0.72±0.94)
17,A/17,B 65/96 Accumulator Relay 29507455 Silver 12.8 1.28 11.68 43.6 20.0 47.3±52.3
WEAR LIMITS AND SPRING DATA
17,C 97 (0.050) (0.460) (1.72) (0.79) (10.6±11.8)

17,A/17,B 73/103 Overdrive 23049332 Orange 12 0.76 7.75 26.6 12.5 12.4±15.2
17,C 104 (0.030) (0.305) (1.05) (0.49) (2.79±3.42)
* Individual Springs
** For the complete Spring Assembly
² OD at larger end
(continued)
(continued) WEAR
Table 7–2. Spring Data (cont’d)

Spring Approx. Free
Length Under Load
ALLISON
17,A/17,B 111/119 Lockup Relay 23049326 No Code 10 1.37 14.10 42.1 17.0 49.2–60.2
17,C 120 (0.054) (0.555) (1.66) (0.67) (11.06–13.53)
17,A/17,B 115/123 Lube Regulator 23049327 Red 13 1.22 11.10 46.3 23.5 46.5–51.3
17,C 124 (0.048) (0.437) (1.82) (0.93) (10.5–11.5)
17,A/17,B 119/127 Main Regulator 29500963 Lt. Blue 15 2.87 22.0 98.5 54.6 305–337
TRANSMISSION
17,C 128 (0.113) (0.866) (3.88) (2.15) (68.6–75.8)
17,A/17,B 123/131 Control Main 23049325 Orange 10 1.83 14.8 44.6 24.2 131–145
17,C 132 (0.072) (0.583) (1.76) (0.95) (29.5–32.6)
17,A/17,B 133/141 C2 Latch 29501071 Lt. Green 11 1.32 11.43 41.3 19.0 64.1–78.3
17,C 142 (0.052) (0.450) (1.63) (0.75) (14.4–17.6)
17,A/17,B 137/145 Exhaust Back 23049391 No Code 17 0.61 7.80 29.2 18.2 2.40–2.94
TECHNICIANS’
17,C 146 (0.024) (0.307) (1.15) (0.72) (0.54–0.66)
17,A/17,B 141/149 C1 Latch 6885065 Blue 12 1.37 16.26 46.2 29.2 16.7–18.9
17,C 150 (0.054) (0.640) (1.82) (1.15) (3.75–4.25)
GUIDE
17,A/17,B 145/153 Converter Regulator 29507456 Pink 10.2 1.53 11.00 30.3 22.8 53.7–59.3
17,C 154 (0.060) (0.433) (1.19) (0.90) (12.1–13.3)
LIMITS AND SPRING DATA
83
NOTES

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

GN4064EN
GUIDE
TECH
GN4064EN
(5/05)

3K Technician&#39;s Guide

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TECHNICIANS’ GUIDE

INSPECTION AND ANALYSIS OF THE

Glossary of Terms . . . . . . . . . . . 2 P2 Planetary Module . . . . . 43-44

NOTICE: This guide is intended

ALLISON TRANSMISSION TECHNICIANS’ GUIDE i

Abrade - Scrape off Metal Transfer - Metal from one

Burr - Sharp metal extending Score - Deep scratch

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

Gall - Wear between parts such

Light Stoning - Using a

2 ALLISON TRANSMISSION TECHNICIANS’ GUIDE

The Technicians’ Guide is

General Rework Guidelines

ALLISON TRANSMISSION TECHNICIANS’ GUIDE 3

4 ALLISON TRANSMISSION TECHNICIANS’ GUIDE

Check gears for

A. Inspect gears for damaged or

Inspect splined parts

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

6 ALLISON TRANSMISSION TECHNICIANS’ GUIDE

A. Replace the bearing if any bearing. Replace the bearing if races

ALLISON TRANSMISSION TECHNICIANS’ GUIDE 7

General Bearing Handling When immersing in solvent, place

8 ALLISON TRANSMISSION TECHNICIANS’ GUIDE

Bushing wear is strongly

ALLISON TRANSMISSION TECHNICIANS’ GUIDE 9

A. Inspect retaining rings for Examine retaining

10 ALLISON TRANSMISSION TECHNICIANS’ GUIDE

A. Replace thrust washers if they

ALLISON TRANSMISSION TECHNICIANS’ GUIDE 11

12 ALLISON TRANSMISSION TECHNICIANS’ GUIDE

Note: Current friction plates - two Acceptable

ALLISON TRANSMISSION TECHNICIANS’ GUIDE 13

Reference the Service Manual

A. Inspect springs for permanent

Inspect springs for signs of

14 ALLISON TRANSMISSION TECHNICIANS’ GUIDE

Valves should move freely in

A. Valves must be free of nicks,

ALLISON TRANSMISSION TECHNICIANS’ GUIDE 15

A. Channel B. Solenoid C. Separator Plate

I. Turbine Speed D. Suction Filter

H. Stationary Clutch G. Main Valve F. Rotating Clutch

Oil Level Sensor Redesign - Main Filter Bore

ALLISON TRANSMISSION TECHNICIANS’ GUIDE 17

18 ALLISON TRANSMISSION TECHNICIANS’ GUIDE

Replace solenoids if they are visibly I. Replace the Supersession Information

ALLISON TRANSMISSION TECHNICIANS’ GUIDE 19

Identification Detail: Solenoid

Identification Detail: Overdrive Knock

20 ALLISON TRANSMISSION TECHNICIANS’ GUIDE

Exhaust Main Regulator Valve

C2 Latch C2 Latch Main Valve Control Main

ALLISON TRANSMISSION TECHNICIANS’ GUIDE 21

Current Converter Turbine Shaft

ALLISON TRANSMISSION TECHNICIANS’ GUIDE 23

A. Inspect the converter pump

24 ALLISON TRANSMISSION TECHNICIANS’ GUIDE

ALLISON TRANSMISSION TECHNICIANS’ GUIDE 25

Springs and rollers are

ALLISON TRANSMISSION TECHNICIANS’ GUIDE 27

A. Sealing & E. Retainer

ALLISON TRANSMISSION TECHNICIANS’ GUIDE 29

30 ALLISON TRANSMISSION TECHNICIANS’ GUIDE

3K Technician's Guide

3K Technician's Guide