4k technician's guide

8/9/2019 4K Technician's Guide

1/82


2/82


3/82

INSPECTION AND ANALYSIS OF THE

ALLISON 4000/B 500 PRODUCT FAMILIES

© 2005 General Motors Corporation.A L L I S O N T R A N S M I S S I O N T E C H N I C I A N S ’ G U I D E

NOTICE: This guide is intended for use by technicians skilled in diagnosis and repair of automatic transmissions.Contact an authorized AllisonTransmission service outlet forfurther information orclarification if required. Allspecifications provided in thismanual are subject to changewithout notice.

Glossary Of Terms . . . . . . . . . . . 2

Introduction ToInspection & Analysis . . . . . . . . 3

General InspectionGuidelines for

Cast Parts & MachinedSurfaces . . . . . . . . . . . . . . . . . . 4

Gears . . . . . . . . . . . . . . . . . . . . 5

Splines . . . . . . . . . . . . . . . . . . . 6

Bearings . . . . . . . . . . . . . . . . 7-8 Bushings . . . . . . . . . . . . . . . . . 9

Retaining Rings . . . . . . . . . . 10

Thrust Washers . . . . . . . . . . . 11

Clutch Plates . . . . . . . . . . 12-13

Springs . . . . . . . . . . . . . . . . . 14

Valves and Valve Bores . . . . 15

Control Module . . . . . . . . . . 16-21

Torque ConverterModule . . . . . . . . . . . . . . . . . 22-27

Torque ConverterHousing Module . . . . . . . . . 28-30

Standard Rear Cover andP3 Planetary Module . . . . . 31-38

Retarder Module . . . . . . . . . 39-42

Close Ratio MainShaft Module . . . . . . . . . . . . . . 43

Wide Ratio MainShaft Module . . . . . . . . . . . . . . 44

P2 Planetary Module . . . . . 45-46

P1 Planetary Module . . . . . 47-48

Front Support & OilPump Module . . . . . . . . . . . 49-52

Rotating Clutch Module . . . 53-58

C3/C4 Clutch Module . . . . . 59-64

Main Housing . . . . . . . . . . . 65-66

C6 Adapter Housing . . . . . . 67-69

Wear Limits andSpring Data . . . . . . . . . . . . . 70-77


4/82

Abrade - Scrape off

Battering - Wear or damage due tohard usage or repeated blows

Brinelling - Permanent deformationof a bearing surface where rollers orballs contact a race; Results fromexcessive load or impact;Characterized by indentationson a bearing surface

Burr - Sharp metal extending

beyond normal surface

Chipped - Having a small piecebroken off

Cone - A shape whose base is acircle and whose sides taper upto a point

Crimped - Pinched or pressed together tightly

Crocus cloth - Fine grit cloth

Discoloration - Change in color

Distortion - Change from originalshape

Erosion - Gradual uneven removalof material

Fracture - A break or crack

Gall - Wear between parts suchthat metal transfer occurs

Grooves - Long narrowdepressions

Inadequate - Not enough

Light Stoning - Using amedium India oilstone toremove material

Metal Transfer - Metal from onecomponent embedded in a matingcomponent

Nick - Small notch

Pit - Local areas where material hasbeen removed

Porosity - Porous area where air,fluid, or light may pass through

Score - Deep scratch

Scuff - Wear due to two movingparts coming together with nolubricant

Spalled - Damage characterized bymetal flaking or breaking down ona wear surface; Similar to pittingdamage

Stripped - Threads broken ordamaged so part will not hold torque

TAN - Total Acid Number;Oil acidity should not change bymore then 3 from the new fluid TAN when oil sampling is used todetermine oil change intervals

Twisted - Bent from original shape

ALLISON 4000 / B 500 PRODUCT FAMILIES

GLOSSARY OF TERMS

2© 2005 General Motors Corporation.A L L I S O N T R A N S M I S S I O N T E C H N I C I A N S ’ G U I D E


5/82

The Technicians’ Guide isintended to provide additionalguidance with the inspection andanalysis of transmission parts.This guide should be used bytechnicians who overhaul Allison4000/B 500 automatictransmissions in conjunction withthe 4000/B 500 Service Manual(SM2457EN) when inspecting partsto determine their serviceabilityand reuse.

General Rework Guidelines

Replace parts that cannot bere-worked as outlined in thismanual and Service ManualSM2457EN. A soft stone or crocuscloth can be used to attemptremoval of “high spots” fromtransmission parts. After theattempted rework, the part mustmeet specification if it is going to

be reused. Some seal surfaces (for example the output yoke sealing surfaceand the converter pump hub sealing surface) cannot be reworked.Both of these seal surfaces have acontrolled finish that can result in afluid leak if the part is altered byrework.


INTRODUCTION TO INSPECTION & ANALYSIS

3© 2005 General Motors Corporation.

A L L I S O N T R A N S M I S S I O N T E C H N I C I A N S ’ G U I D E


6/82

A. Replace housings or other castparts that are cracked or broken.Inspect clutch housing sealingsurfaces for imperfections thatcould damage the piston seals orinterfere with mating parts.Inspect threaded holes for bad threads. Clean damaged threadswith the correct size tap.

B. Inspect all machined surfacesfor damage that could cause fluid leakage. Inspect mounting facesand bores for damage.

C. Inspect all fluid passages forobstructions, porosity, brokenlands, cracks and land surfaceimperfections.

D. Replace housings that havesplines worn beyond wear limits.Refer to the Wear Limits Table(7-1) in Service Manual SM2457EN.

NOTE: Some parts have Spiralock®threaded holes . A standard tap willeliminate the locking featurerequiring the reworked part to be

replaced. For repair, use aSpiralock® tap to repair Spiralock®threaded holes. As of this printing,the following parts have Spiralock®threaded holes:

Torque converter front coverflexplate adapter bolt holes and lockup clutch backplate boltholes.

Output shafts using a single boltfor flange or yoke retention.



GENERAL INSPECTION GUIDELINES FORCAST PARTS & MACHINED SURFACES

C. Fluid

Passages

A. CastPart

A. Housings

D. Splines

C. FluidPassages

B. MachinedSurfaces


7/82


GENERAL INSPECTION GUIDELINES FORGEARS



A. Inspect gears for damaged orbroken teeth. Inspect gear teeth forwear that has changed the originaltooth shape. If this condition is noted,replace the gear. Inspect gears for loadpattern and signs of distress. Anysigns of distress indicate the gear mayfail during operation. Reusingdistressed gears is an individualcustomer decision based onexperience. Backlash cannot be used to establish critical gear wear. Pits,scuffs, scores or galling are typicallyevident long before backlash exceedsspecification.

B. Inspect the thrust face of gearsfor damage. If these defects cannotbe removed with a soft stone, replacethe gear.

Check gears for

damaged ormissing teeth.

A. GearTeeth

B. Thrust FaceSurface

A. Gear

Teeth


8/82


A. Inspect splined parts fordamage. Remove burrs with a softstone. Spline wear is not considered harmful except where it affects thefit of the splined parts. Spline wearis determined by comparing feelergauge thickness with the thicknessof the worn area on the spline.

Replace parts having excessivespline wear. The maximummovement allowed at the splines is

0.38 mm (0.015 inches) if nototherwise listed in Wear LimitsTable 7-1 in Service ManualSM2457EN. Do not reuse a splined part that exceeds the published maximum spline wear. Backlashcannot be used to establish criticalspline wear. Accurate backlash

measurement requires the matingparts to be concentrically located.


GENERAL INSPECTION GUIDELINES FORSPLINES

Inspect splined partsfor burrs, damage

and excessive wear.

A. Splines


9/82



A. Replace the bearing if anyrollers/balls are rusted. Replace thebearing if balls/rollers have a feelingof looseness in the retainer or racecompared to a new bearing. Replacethe bearing if balls/rollers arediscolored from heat, lack of lubrication or debris lapping in the

balls/rollers. Replace the bearing if the balls/rollers are worn, galled orabraded. Replace the bearing if itcatches or feels rough after beingthoroughly cleaned.

B. Replace the bearing if anyraces are rusted. Replace thebearing if the bearing balls/rollershave a feeling of looseness in theraceway compared to a new

bearing. Replace the bearing if racesare discolored from heat, lack of lubrication or debris lapping in therace. Replace the bearing if theraces are worn, galled or abraded.Replace the bearing if it catches orfeels rough after being thoroughlycleaned.

C. Replace the bearing if anyretainer or retainer clip isfractured, bent, dented or missing.Replace the bearing if any retaineris rusted. Replace the bearing if there is a feeling of loosenessbetween the retainer and ball/rollercompared to a new bearing. Replacethe bearing if it catches or feelsrough after being thoroughlycleaned.


GENERAL INSPECTION GUIDELINES FORBEARINGS

A. Rollers

B. Bearing

Race

C. Retainer

B. BearingRace

B. Bearing Race

(continued)

C. Retainer

C. Retainer


10/82


General Bearing Handling& Storage

Dirt is the greatest single enemyof any antifriction bearing.Cleanliness - using clean tools in aclean environment - is at the topof the list of good servicetechniques. Keep bearings sealed inoriginal containers. Do not allowanyone to open boxes and handlebearings. A new bearing, if notprotected, can quickly pick upenough dust even in an apparentlyclean place to seriously affect its lifeand operation. Minimize thepossibility of rusting or lubricantaging in storage by using the oldestbearings in stock first.

If any part of a bearing assemblyhas been compromised, replace alldetail parts in the assembly(example - races, retainers and thebearing itself). Most bearings failfrom preventable causes. Follow aregular system for inspection. Lookfor bearings with obvious damagefirst.

General Bearing Inspection

Do not try to judge the condition of a bearing until after cleaning. Donot spin bearings while cleaningthem. Rotate them slowly while

washing. Do not spin any bearingswith air pressure. Put bearingsunder axial pressure while rotatingto bring the balls and races firmly incontact with each other. For singlerow angular contact bearings,pressure must always be applied onthrust faces.

When immersing in solvent, placebearings in a wire basket so there isplenty of space for cleaner to reachall parts. Tanks should have ascreened false bottom to preventsettled debris from being stirred upinto the bearings. Agitate thebasket frequently until grease, oil orsludge is thoroughly loosened and can be flushed out. Blow solventout of bearings using dry, filtered air. Be careful not to spin the

bearing using air pressure.Lubricate bearings immediatelyafter drying to avoid rust.

NOTE: Wear eye protection and follow the appropriate safetyguidelines when using solvents toclean components.

Badly discolored rollers and racesare usually a sign of inadequatelubrication. Replace badlydiscolored bearings. Moderatelydiscolored rollers, cages and racesdo not necessarily mean that thebearing needs replacement.

Technicians should always try todetermine the root cause of failurewhen inspecting failed components.It’s important the root cause beidentified and repaired to avoid thesame failure in the future. Bearingsshould be replaced for thefollowing reasons:

Rusted rollers, balls or

raceways - rusted rollers, balls orraceways are usually caused bywater passing worn or defectiveseals, or by condensation inside thehousing.

Fractured races - a fractured racecan be caused by forcing a cocked bearing on or off a shaft. Anexcessively tight press fit can alsocause a race to fracture.

Worn, galled or abraded

surfaces - worn, galled or abraded

surfaces on a bearing may be theresult of a loose fit on a shaft or in ahousing. A locked bearing spinningon a shaft or in a housing can alsocreate this type of damage.

General feeling of roughness -

inspect for a general feeling of roughness which remainsunchanged by thorough cleaning.This condition generally indicatesdamage to raceways or rollers

caused by dirt, pitting, brinelling orcorrosion.

Catchy feeling - inspect for acatchy feeling at one or more pointswhich repeated flushing will notremove. This condition generallyindicates a spalled or fatigued spoton the race. Thorough flushing isnecessary to be sure the catchy orrough feeling is not caused byforeign debris in the bearing.

Excessive looseness - inspect forexcessive looseness which indicateslapping by dirt or an abrasivecontaminate in the lubricant. If indoubt, compare the end playagainst the end play of an identicalnew bearing. The races, balls and rollers will appear dull gray whenlapped by dirt.


GENERAL INSPECTIONGUIDELINES FOR BEARINGS(continued)


11/82



A. Inspect bushings for wearbeyond service limits. Replace anybushing which is excessively worn.Inspect bushings for discolorationand surface damage due to lack of lubrication. Replace any bushingwhich is damaged.

General Bushing Information

Mechanically, bushings are thesimplest type of journal bearing and are often referred to as “plain”bearings. A bushing is simply asleeve of bearing material, such asbronze or aluminum, in which acomponent rides. Bushing wear is

strongly influenced by the quantityand condition of the lubricant.Bushing bearing surfaces aresometimes grooved to betterdistribute lubrication across thebearing surface.

Some bushings are susceptible tomaterial leaching. This can becaused by oxidized oil that hasturned acidic combined with heatand mechanical loading. The TAN(Total Acid Number) of thetransmission oil should not changeby more than 3 from the baseline(new fluid) TAN. Changingtransmission oil per recommended change intervals or based on asuccessful oil sampling programwill help prevent material leaching.


GENERAL INSPECTION GUIDELINES FORBUSHINGS

Bushing wear is strongly

influenced by thequantity and condition

of the lubricant.

A. Bushing


12/82

1 0© 2005 General Motors Corporation.A L L I S O N T R A N S M I S S I O N T E C H N I C I A N S ’ G U I D E

A. Inspect retaining rings fordamage, distortion and excessivewear. Replace retaining rings if damage cannot be repaired using asoft stone or crocus cloth.


GENERAL INSPECTION GUIDELINES FORRETAINING RINGS

Examine retainingrings for damage,distortion orexcessive wear.

A. RetainingRings


13/82

1 1© 2005 General Motors Corporation.


A. Replace thrust washers if theyare worn beyond service limits.Replace thrust washers if they aregalled, abraded or distorted.Replace thrust washers if they aredamaged due to a lack of lubrication.


GENERAL INSPECTION GUIDELINES FORTHRUST WASHERS

A. ThrustWashers

ThrustWashers


14/82


A. ContactSurface

C. OilGroove

Depth

D. Spline

Teeth

A. Inspect friction plate contactfaces and splines for excessivewear, damage and coning. Inspectthe plates for burrs, pitted faces,cracks, distortion and damaged spline teeth.

B. Measure friction platethickness and coning. Reference

the Service Manual for minimumthickness and maximum coningspecifications. Do not reuse frictionplates that do not meet published specifications. If reused plates areslightly coned (withinspecification), make sure each plateis stacked with the cone facing thesame direction.

C. Measure friction plate oilgroove depth. Replace any platesthat are not within Service Manualminimum groove depthspecification.

D. Inspect spline teeth forexcessive wear and battering.Replace the clutch plate if damage

cannot be repaired using a soft

stone or crocus cloth. Replace theclutch plate if spline teeth arebroken or missing.

NOTE: Anti-freeze (glycol) and/orwater can adversely affect thebonding agent between the frictionmaterial and steel core. Replace anyfriction plates which have beenexposed to water and/or glycol.


GENERAL INSPECTION GUIDELINES FORCLUTCH PLATES

B. Clutch PlateThickness and

Coning

Check UsingFeeler Gauge

Thickness

Coned Plate

Flat Plate

(continued)

Oil grooves

appear shallowor worn away -

measure platethickness andgroove depth.

Spline teeth battered

and worn - may be anindication of drivelineissues. Replace

clutch plates andcheck driveline.


15/82



NOTE: The current clutch friction plateswere implemented April of 2000 startingwith s/n 6610062126. Current clutchfriction plates will have two or moremissing splines. Former friction plateswill either have one spline missing ornone missing. Any 4000/B 500 modeltransmission may be updated from formerC5 friction plates to current C5 frictionswithout recalibrating the transmissionECU. The rest of the clutches in the mainhousing (C1 through C4) must beupdated with current friction plates if

any other individual clutch besides C5 isupdated from former to current frictionplates. Any update from former frictionsto current frictions in C1 through C4 fora 4000 Series or B500 with a WTEC IIECU will require a new ECU calibrationfrom Allison Transmission. Any updatefrom former frictions to current frictionsin C1 through C4 for a 4000 Series orB500 with a WTEC III ECU with acalibration prior to October 25, 1999 willrequire an updated ECU calibration from

Allison Transmission. Do not intermixboth former and current friction plates ina clutch pack.

The P3 ring gear changed to a harder ringgear on s/n 6610027070. The current P3ring gear identifier is a groove machined around the outer diameter of the gear.The P3 ring gear with a groove identifierrequires the C5 friction with two missingsplines if updating from former C5frictions. If any 4000/B500 series modelwithout the harder ring gear (no grooveon O.D.) is being updated with current

C5 frictions, then it will require the C5friction that has three missing internalsplines. The C5 friction plate missingthree splines will exhibit spline wear if used with the current P3 ring gear with agroove identifier on the O.D. The formerP3 ring gear (no groove on O.D.) willexhibit premature wear if used with thecurrent C5 friction with two missinginternal splines. No ECU calibration isnecessary for updating C5 clutch plates.

A. Inspect reaction plates forexcessive wear, warping, coningand surface damage. Replace anyplate with wear exceeding servicelimits or with damage whichcannot be repaired using a softstone or crocus cloth..

B. Measure reaction platethickness and coning. Referencethe Service Manuals for minimumthickness and maximum coningspecifications. Do not reuse plates

that do not meet published specifications. If reused plates areslightly coned (withinspecification), make sure each plateis stacked with the cone facing thesame direction.

C. Inspect reaction plate tangsfor damage. Replace the plate if damage cannot be repaired using asoft stone or crocus cloth.


GENERAL INSPECTION GUIDELINES FOR(continued) CLUTCH PLATES

A. Contact

Surfaces

B. Thickness& Coning(see prior

page graphic)

C. Tangs

Acceptable

discoloration -reuse plates.

Excessive scoring -

replace plates.

Broken tangs -replace plates.


16/82


A. Inspect springs for permanentset and wear due to rubbingadjacent parts. Replace the spring if any of these defects are identified orif the spring fails to meet published service limits. Reference the SpringData Charts in Service ManualSM2457EN for spring identification

and service limit specifications.


GENERAL INSPECTION GUIDELINES FORSPRINGS

Inspect springs for signs ofoverheating, permanent set

or wear due to rubbingadjacent parts.

A. Springs

Reference the Service ManualSpring Data Charts for spring

identification and specifications.


17/82



A. Valves must be free of nicks,burrs and scoring and operatesmoothly in their bores withoutsticking. Dry valves must movefreely in their bores by their ownweight. Replace damaged valves. Asoft stone or crocus cloth can beused in an attempt to repair slight

irregularities.B. Valve bores must be free of nicks, burrs and scoring. No honingof any kind is allowed. A soft stoneor crocus cloth can be used in anattempt to repair slightirregularities.


GENERAL INSPECTION GUIDELINES FORVALVES & VALVE BORES

Valves should move freely intheir bores, when dry, undertheir own weight.

Valve bores mustbe free of nicks,

burrs and scoring.

A. Valves

B. Valve

Bores


18/82

A. Inspect the channel plate fordamage. All passages must be clearof debris. Inspect all machined surfaces for burrs, nicks or scoring.Light stoning and crocus cloth maybe used to eliminate minor highspots. If a channel plate cannot berepaired so that all machined

surfaces can seal correctly to theirmating parts, or if thread damagecannot be repaired, replace thechannel plate.

NOTE: Do not use impact guns (airwrenches, electric impactwrenches, etc.) when working withaluminum threads or when torquesequencing bolts.

B. Inspect bothseparatorplates for dents,nicks, burrs and other damage ordistortion.Replace theplate if it has

damage whichcannot berepaired using asoft stone orcrocus cloth. Allpassages mustbe clean and debris free.

A. ChannelPlate

B. SolenoidSeparator Plate

D. InternalWiring

Harness

C. Suction

FilterAssembly

E. Rotating

Clutch BodyAssembly

F. Main ValveBody AssemblyG. Stationary ClutchValve Body Assembly

H. Oil LevelSensor


CONTROL MODULE


B. Separator Plate

Separator plate and gasket installedon channel plate.(continued)


19/82


(continued) CONTROL MODULE



C. Replace the suction filterassembly during overhaul.

D. Replace or repair the controlmodule wiring harness if thewires, terminals orconnectors are visiblydamaged. Inspect themolded harness channel

for cracks or breaks.Replace the harness if the molded channel isdamaged. Check sumptemperature resistancefollowing the guidelinesand specifications listed in the Service Manualand TroubleshootingManual.

NOTE: Transmissions built prior toS/N 6610014067 used the formerdesign sump temperature sensor.Sensor resistance specifications

differ between the former and current designs. Be sure to use thecorrect resistance specificationchart for the sensor being checked.

Sump TemperatureSensor (TID 2, 3)

D Solenoid (C4)

C Solenoid (C3)

E Solenoid

(C5)

F Solenoid(Lockup)

Oil LevelSensor

FeedThroughStand-Off

C3 Pressure

Switch

A Solenoid(C1)

Feed

ThroughHarness

B Solenoid(C2)

G Solenoid(C2 Latch)

Identification Detail:

Internal Wiring Harness

Current TID2/TID3Harness

Former TID1Harness

TID1 SumpTemp. Sensor

(continued)

DustSeal

O-RingSeal

TID 2, 3Sump Temp.Sensor


20/82


CONTROL MODULE (continued)


E, F, G. Valves, valve body boresand oil passages must be free of debris, nicks, burrs, scoring and galling. Valves should move freelyin their bores, when dry, undertheir own weight. Repair or replacevalves and/or valve bodies failing tomeet these requirements.

Valve body machined surfacesmust be free of debris, nicks, burrsand scoring. Light stoning of thesemachined surfaces is permitted tocorrect minor defects. Replace anyvalve body that cannot be repaired.

Inspect all threaded holes fordamage and debris. Replace thevalve body if the thread damagecannot be repaired.

NOTE: Do not use impact guns (airwrenches, electric impactwrenches, etc.) when working withaluminum threads or when torquesequencing bolts.

Replace valve springs which arebroken, permanently set or worndue to rubbing adjacent parts.Reference the Spring Data Charts inthe Service Manual for springspecifications and identification.

Valve stops and retention pinsmust not be damaged or battered.Replace valve stops or pins whichhave damage that cannot beremoved using a soft stone orcrocus cloth.

Replace solenoids if they are visiblydamaged. Proper solenoid resistance is 3 to 4 ohms measured between the two solenoid terminals. Check resistancebetween each solenoid terminal and the solenoid body. Replace thesolenoid if resistance measures lessthan 100k ohms.

Supersession Information

Oil Drain Plug Redesign -SIL 5-WT-98, Rev. A

Current plug isbackward compatible

with all control

modules.


Oil Level Sensor Redesign -SIL 19-WT-99

Kit must be used when

replacing former sensor

with current sensor.

Current

Former

(continued)


21/82

Replace the C3 pressure switch if it is visibly damaged. Resistancebetween the two switch terminalsshould measure 20k ohms or higherwhen the switch is open (and nopressure is present). Resistancebetween the two terminals should not exceed 2 ohms when the switch

is closed (159 kPa-255 kPa or 23-37psi present).

H. Replace the optional oil levelsensor if it is determined it is notfunctioning correctly.





4” Channel

Plate

2” ChannelPlate


Suction Filter Redesign - SIL 1-WT-00

Replace theassembly

duringoverhaul.

Current

Former

(continued)


22/82


CONTROL MODULE (continued)

B Solenoid(C2)

F Solenoid(Lockup)

A Solenoid

(C1)

RotatingClutch ValveBody

SolenoidRegulatorValves

C3PressureSwitch

SolenoidRegulatorSprings

Identification Detail: Rotating Clutch Valve Body Assembly

D Solenoid(C4)

C Solenoid(C3)

E Solenoid(C5)

SolenoidRegulatorValves

SolenoidRegulatorSprings

StationaryValve Body

Overdrive KnockDown Valve

Identification Detail: Stationary Clutch Valve Body Assembly


AccumulatorRelay Valve

(continued)


23/82



ConverterRegulatorValve

ConverterRegulatorSpringConverter

RegulatorValve Stop

Main

RegulValve

ControlMain Valve

Control MainValve Spring

Control MainValve Stop

Main RegulatoValve Spring

Lube RegulatorValve

Lube RegulatorValve Spring

Lube RegulatorValve Stop

Main Regulator Valve

LockupValve

LockupValve Spring

LockupValve Stop

C1 Latch Valve

C2 LatchValve

Main ValveBody

G Solenoid

C1 Latch

Valve Spring

C2 LatchValveSpring

C1 LatchValve Stop

C2 LatchValve Stop

ExhaustBackfillValve Stop

ExhaustBackfill Valve


Converter Regulator Valve Stop Redesign -

SIL 12-WT-99



Identification Detail: Main Valve Body Assembly

Current

Stop

Former

Stop

(continued)


24/82

A. ConverterPump Exterior

A. Inspect the converter pumpexterior for dents and sealingsurface damage. Replace theconverter pump if damage cannotbe remove with a soft stone orcrocus cloth.

B. Inspect the converter pumphub for damage and excessive wear.

Minimum pump hub diameter is88.99 mm (3.504 inch). Inspect thepump hub tangs for cracks, impactdamage or broken tangs. Maximumallowable tang step wear is 0.31 mm(0.012 inch). On PTO-equippedmodels, check the splines insidethe hub for wear and damage.Maximum spline wear is 0.38 mm(0.015 inch).

NOTE: Do not use crocus cloth onthe converter pump hub. Polishingthe hub with crocus cloth can causeimproper input seal performanceresulting in fluid leakage.

NOTE: Pump hub tang breakage ordeformity accompanied by charging

pump bushing failure and ground sleeve wear is often caused by poortransmission fluid condition due toimproper maintenance intervals.Observation of proper fluid changeintervals is key to optimumtransmission life.

Inspect the pump hub tangs for cracks,

impact damage and broken tangs.

B. Drive Hub

B. DriveHub

ModelIdentifiers

(see chart)

Torque Converter ModelDesignation

Front Cover Sticker andConverter Paint Dot Color(Exterior Marker)

Engraved Letter Identifiers(Torus Ring of ConverterPump) Ink Stamped Letter(Exterior of Converter Pump)

Number of Stator Blades

Paint Dot Color on Stator

TC-521

Green

E

19

None

TC-531

Pink

D

19

None

TC-541

Blue

C

19

None

TC-551

Orange

B

19

None

TC-561

Yellow

A

19

None

4000 Product Family Torque Converter Identification Chart

(continued)


TORQUE CONVERTER MODULE



25/82

C. Inspect the torque converterfront cover mounting faces fordamage. Inspect the flexplateadapter bolt holes for stripped ordamaged threads.

D. Inspect the front cover pilotfor damage and wear. Maximumpilot diameter is 61.77 mm (2.432

inches). Inspect the torqueconverter end plug and theretaining bolt for stripped ordamaged threads. Verify that thecorrect turbine shaft selective shimis installed following the ServiceManual procedures.

E. Inspect the engine starter ringgear for chipped, worn or brokenteeth.

F. Inspect the flexplate adaptermounting faces for surface damage.Replace the adapter if damagecannot be repaired using a softstone or crocus cloth. Inspect the

flexplate adapter bolt holes frostripped or damaged threads. Cleandamaged threads using the correctsize tap. Replace the adapter if damage cannot be repaired.

NOTE: The flexplate adapter boltholes use Spiralock® threads. ASpiralock® tap must be used whenrepairing damaged threads. Using astandard tap will destroy thelocking feature. If this occurs, thetorque converter front cover mustbe replaced.


TORQUE CONVERTER MODULE(continued)



C. FrontCover

MountingFace

Current

Plug

E. RingGear

D. PilotF. Flexplate

Adapter

Converter

Retaining BoltTurbine Shaft

Selective Shim


Converter Plug and FrontCover Update SIL-21-WT-98

Model Identifiers (see

chart previous page)

The current front cover has athreaded pilot to accept the

current converter plug. Plugsare not interchangeable

(continued)


26/82

A. Inspect the converter pumpinterior. Replace the assembly if the vanes are damaged, cracked orloose.

B. Replace the converter pumpassembly if the torus ring is looseor cracked.

C. Inspect the seal surfacebetween the converter pumpassembly and the front cover.Light stoning is permitted toremove slight irregularities.


TORQUE CONVERTER MODULE (continued)


A. Converter

Pump InteriorVanes

B. TorusRing

Replace the assembly if the vanes aredamaged, cracked or loose.

C. Seal Ring

Area

C. Front Cover-to-Converter PumpSealing Surface

(continued)


27/82

A. Converter

TurbineBlades

B. TorusRing

C. Rivets

D. Turbine Hu

E. SplinesTurbineAssembly

ExteriorTurbine

AssemblyInterior

A. Inspect the converter turbineassembly. Replace the assembly if the blades are cracked, broken orloose.

B. Inspect the torus ring. Replacethe turbine assembly if the torusring is loose or cracked.

C. Inspect the rivets. Replace theturbine assembly if the rivets areloose or cracked.

D. Inspect the converter turbinehub. Replace the converter turbineassembly if the hub is worn beyond limits. Minimum allowable hubdiameter is 66.69 mm (2.626inches). Inspect the sealring groovefor damage.

E. Inspect the hub splines fordamage and wear. Spline movmentbetween the lockup damper and turbine hub cannot exceed 0.38mm (0.015 inch). Replace theturbine assembly if splines areexcessively worn.

F. Inspect the thrust bearingfollowing the “General InspectionGuidelines for Bearings” section of this manual. Replace any thrustbearing failing these inspectionprocedures.


TORQUE CONVERTER MODULE(continued)



Inspect the hub splines and rivets for damage and wear.

Turbine hub

sealring groove -Sealring installed.

F. ThrustBearin

(continued)


28/82

A. Torque converter lockupclutch components fit inside thefront cover. Install a new turbinesealring in the converter cover borethen measure the sealring insidediameter. Replace the coverassembly if diameter exceeds 61.77mm (2.432 inch).

B. Inspect the converter coverbushing for damage. Replace thebushing if damage cannot beremoved with crocus cloth.Maximum allowable bushing insidediameter is 66.91 mm (2.634 inch).

C. Inspect the lockup clutchpiston for damage. Minimumallowable piston thickness is 6.53mm (0.257 inch).

D. Inspect the lockup clutchbackplate for damage, scoring and overheating. Minimum allowableplate thickness is 11.79 mm

(0.464 inch).NOTE: If the backplate is withinthickness limits but has surfacedamage due to metal transferbetween the backplate and lockupdamper, the plate may be reused byturning it over so that the lockupdamper has a new contact surface.

E. Replace the lockup clutchdamper if the friction surfaces areworn beyond service limits.Minimum allowable friction surfacethickness is 8.51 mm (0.335 inch).Maximum allowable damperdistortion is 0.51 mm (0.020 inch).Maximum allowable movementbetween the damper and converter

turbine splines is 0.38 mm (0.015inch). Replace the damper if any of these measurements are beyond allowable limits.

F. Inspect thrust bearingfollowing the “General InspectionGuidelines for Bearings” section of this manual. Replace any thrustbearing failing these inspectionprocedures.


TORQUE CONVERTER MODULE (continued)


A. Sealring

Bore

D. Backplate

B. Bushing

E. Lockup

Damper

FrontCover


Lockup Clutch Damper AssemblyUpdate SIL-4-WT-00, Rev. B

Current damper is backward

compatible with all torqueconverter assemblies. ECU

recalibration is not necessary.

C. Lockup

ClutchPiston

F. ThrustBearing

(continued)


29/82

L. Retaining

Ring

D. Star

PlateA. Stator

Race

F. Thrust

Bearing

E. Front StatorThrust Washer

G. Stator

Thrust Plate

B. Stator

Spring

C. Sta

Ro

A. Inspect the stator race fordamage. Replace the race if damagecannot be repaired using a soft stoneor crocus cloth.

B. Inspect the stator springs forcorrect spring height following perthe Service Manual. Replace anyspring which has a free length below17.8 mm (0.700 inch).

C. Inspect the stator rollers for

damage. Rollers should be smooth,round and defect-free. Replacedamage or worn rollers.

D. Inspect the star plate forexcessive wear. Replace the starplate if damage cannot be repaired using a soft stone or crocus cloth.

E. Inspect the front stator thrustwasher for wear beyond servicelimits. Replace the stator thrustwasher it is worn 0.40 mm (0.010

inch) or more. If it is within servicelimits, the thrust washer can beturned over and the un-worn surfacecan be used.

F. Inspect the thrust bearingsfollowing the “General InspectionGuidelines for Bearings” section of this manual. Replace any thrustbearings failing these inspectionprocedures.

G. Inspect the stator thrust platefor damage and wear. Replace the

plate if damage cannot be removed using a soft stone or crocus cloth.Minimum allowable plate thicknessis 9.45 mm (0.372 inch).

H. Inspect the stator and camassembly for damage. Replace thestator and cam assembly if damaged.

NOTE: Use care when cleaning thestator and cam assembly. Hot tank

temperatures may be high enough torelease the cam assembly from thestator.

I. Inspect the stator rollerpockets for wear and damage. Verifycorrect spring-to-roller orientation.Inspect the bottom of the campocket for wear. Replace the statorand cam assembly if it is worn 0.40mm (0.010 inch) or more in thebottom of the pocket.

J. Inspect tanged thrust bearingrace for damage. Replace anydamaged race.

K. Inspect shim for damage.Replace any damaged shims. Useprocedure for shim selection in 4000Series Service Manual.

L. Inspect the retaining ring fordamage and distortion. Replace anydistorted or damaged retaining rings


(continued) TORQUE CONVERTER MODULE



H. Stator Cam

and Assembly

K. Shim

J. Tanged ThrustBearing Race

I. RollerStatorPockets


30/82

A. Inspect for torque converterhousing damage. High spots may beremoved with crocus cloth or a softstone. Inspect threaded holes fordebris and thread damage. Replacethe torque converter housing if it iscracked, if it leaks from a damaged machined surface, or if it has thread damage which cannot be repaired.

B. Inspect the breather fordamage and obstructions. Replacethe breather if it is damaged. Cleanthe breather if it is blocked withdebris.

C. Replace the input speed sensorif the sensor body or electricalterminals are damaged. Speed sensor resistance is 300 ohms (plusor minus 30 ohms). Replace the

speed sensor if it does not meet theservice limit.

D. On PTO-equipped models,inspect the converter housingbearing bore for wear. Maximumallowable bearing bore insidediameter is 180.05 mm (7.088inches). Replace the housing if

damage cannot be repaired using asoft stone or crocus cloth.

E. Inspect the PTO bearingretainer mounting face surfaceand threads for damage. Replacethe housing if surface damagecannot be repaired using a softstone or crocus cloth. Replace thehousing if thread damage cannot berepaired.


TORQUE CONVERTER HOUSING MODULE


D. BearingBore

E. Retainer

MountingSurface

C. SpeedSensor &

Bore

B. Breather

B. Breather

A. Torque

ConverterHousing (PTO) A. Torque

Converter

Housing(Non-PTO)


31/82

F. PTO DriveAssembly

BearingRetainer

H. Oil

PumpDriveHub

M. PTO DriveGear Bearings

I. PTO Gear

Teeth

J. BearingSurfaces

L. Splines

F. On PTO-equipped models,inspect the PTO drive bearingretainer housing bore for damage.Replace the retainer if damagecannot be repaired using a softstone or crocus cloth. Replace theretainer housing if the bushing hasspun in the bushing bore.

G. Inspect the retainer housingbushing for damage and wear.Replace the bushing if damaged.Maximum allowable bushing insidediameter is 89.19 mm (3.511 inches).Replace the bushing if it is wornbeyond service limits.

H. Inspect the oilpump drive hub.Replace the drive hubif damage cannot berepaired using a softstone or crocus cloth.

I. Inspect the PTO drive gearteeth for chips, pitting and excessive wear. Replace the gear if damage cannot be repaired using asoft stone or crocus cloth.

NOTE: Some axial movement of thegear is normal, but movementshould not exceed 3.175 mm (0.125

inch). Replace the PTO bearings if axial movement exceeds servicelimit.

NOTE: Normal operating backlashafter PTO is installed is 0.1 mm to0.66 mm (0.004 to 0.026 inch).


(continued) TORQUE CONVERTER HOUSING MODULE



F. RetainerBore

G. Bushing

(continued)


32/82

I. PTO

GearTeeth

K. Splines

J. Inspect the PTO drive hubtangs for step wear, deformationand cracks. Replace the drive hub if tang step wear exceeds 0.38 mm(0.015 inch) or if either tang isdeformed or cracked.

NOTE: Drive hub tang breakage ordeformity accompanied by charging

pump bushing failure and ground sleeve wear is often caused by poortransmission fluid condition due toimproper maintenance intervals.Observation of proper fluid changeintervals is key to optimumtransmission life.

K. Inspect the drive hub splinesfor wear. Replace the drive hub if spline wear exceeds 0.38 mm(0.015 inch).

L. Inspect the PTO drive gearbearings following the “GeneralInspection Guidelines for Bearings”section of this manual. Replaceeither bearing as needed.


TORQUE CONVERTER HOUSING MODULE (continued)

Examine theoil pump

drive tangsfor excessive

battering.



33/82

A. Output

SpeedSensor

B. Rear CoverC. Piston

D. Spring

Pack

E. Retaining

Ring

F. Clutch Plates

A. Inspect the output speedsensor for damage. Replace anysensor that has body, terminal orconnector seat damage. Allowableoutput speed sensor resistance is300 ohms plus or minus 30 ohms.

B. Inspect the rear coverfollowing the “General Inspection

Guidelines for Cast Parts and Machined Surfaces” section of thismanual. High spots on machined surfaces can be removed using asoft stone or crocus cloth. Inspectthe slot on the back side of thehousing where the C5 piston tangindexes. Replace the rear cover if

damage to any machined surfacecannot be repaired using a softstone or crocus cloth. Replace therear cover if it is cracked.

C. Inspect the C5 clutch pistonfollowing the “General InspectionGuidelines for Cast Parts and Machined Surfaces” section of this

manual. Replace the piston if it failsto meet the inspection guidelines.Inspect the C5 piston tang forexcessive wear.

D. Inspect the C5 clutch springpack for damage due to rubbingadjacent parts and cracked orbroken pieces. Check springs forwear, breakage and damage.Reference the Spring Data Charts inthe Service Manual SM2457ENfor spring specifications and identification.

E. Replace the C5 retainingring if it is bent or distorted.


STANDARD REAR COVER &P3 PLANETARY MODULE



(continued)


34/82

F. Clutch

Plates

F. Inspect the C5 friction clutchplates following the “GeneralInspection Guidelines for FrictionPlates” section of this manual.Discard any plates that do not meetthe guidelines. Minimum allowablethickness for reuse is 3.48 mm(0.137 inch). Minimum oil groove

depth for reuse is 0.20 mm (0.0008inch). Maximum cone for reuse is0.25 mm (0.010 inch).

NOTE: Battered and worn splineteeth may be an indicator of driveline issues. Replace the clutchplates and check the driveline.

Inspect the C5 reaction clutchplates following the “GeneralInspection Guidelines for ReactionPlates” section of this manual.Discard any plates that do not meetthe guidelines. Minimum allowablethickness for reuse is 2.41 mm(0.095 inch). Maximum cone forreuse is 0.25 mm (0.010 inch).

NOTE: The current clutch frictionplates were implemented April of 2000 starting with s/n 6610062126.Current clutch friction plates willhave two or more missing splines.Former friction plates will eitherhave one spline missing or none

missing. Any 4000/B 500 modeltransmission may be updated fromformer C5 friction plates to currentC5 frictions without recalibratingthe transmission ECU. The rest of the clutches in the main housing(C1 through C4) must be updated with current friction plates if any

other individual clutch besides C5is updated from former to currentfriction plates. Any update fromformer frictions to current frictionsin C1 through C4 for a 4000 Seriesor B500 with a WTEC II ECU willrequire a new ECU calibration fromAllison Transmission. Any update


STANDARD REAR COVER &P3 PLANETARY MODULE (continued)



Former C5 FrictionPlate - one or nomissing splines.

Current C5

Friction Plate -missing two

splines.

C5 Friction Plate Update -SIL 4-WT-00, Rev. B and SIL 12-WT-03

Clutch plate identification is made bycounting the number of missing teeth.

(continued)


35/82


STANDARD REAR COVER &(continued) P3 PLANETARY MODULE




Use C5 frictionplate missing

3 internal teeth.

from former frictions to currentfrictions in C1 through C4 for a4000 Series or B500 with a WTECIII ECU with a calibration prior toOctober 25, 1999 will require anupdated ECU calibration fromAllison Transmission. Do notintermix both former and current

friction plates in a clutch pack.The P3 ring gear changed to aharder ring gear on s/n 6610027070.The current P3 ring gear identifieris a groove machined around theouter diameter of the gear. The P3ring gear with a groove identifierrequires the C5 friction with twomissing splines if updating fromformer C5 frictions. If any

4000/B500 series model withoutthe harder ring gear (no groove onO.D.) is being updated with currentC5 frictions, then it will require theC5 friction that has three missinginternal splines. The C5 frictionplate missing three splines willexhibit spline wear if used with the

current P3 ring gear with a grooveidentifier on the O.D. The former P3ring gear (no groove on O.D.) willexhibit premature wear if used withthe current C5 friction with twomissing internal splines. No ECUcalibration is necessary forupdating C5 clutch plates.

C5 Pressure

Oil Passage

Detail

(continued)

FORMER (NON-HARDENED)P3 RING GEAR

HARDENEDP3 RING GEAR

IDENTIFICATION

GROOVE

Use C5 frictionplate missing

2 internal teeth.

P3 Ring Gear Update -SIL 12-WT-03


36/82




A. P3 CarrierAssembly(Non-Retarder)

B. Tapered

RollerBearing

D. P3 PlanetarySpindle

E. ThrustWasher

G. PinionRoller

Bearing

I. Output ShaftExternalRetaining Ring

H. OutputShaftSpacer

J. Output Shaft

A. Verify a proper press fitbetween the P3 carrier and rearcover or retarder housing byinverting the carrier over a table orworkbench. If the P3 carrier fallsout of the rear cover or retarderhousing without using a press ormallet, the press fit between thetapered bearings and P3 carrier no

longer exists and the carrier mustbe replaced.

Inspect the P3 carrier for splinewear. Replace the carrier if splinewear exceeds 0.38 mm (0.015 inch).Inspect the pinion spindle bores inthe carrier and the pinion thrustsurfaces for excessive wear and damage. Replace the P3 carrier if a

spindle has more than 0.051 mm(0.002 inch) clearance in the bore.Inspect for thread damage on thecarrier hub. Replace the carrier if threads are damaged.

B. Inspect the tapered rollerbearings and races following the“General Inspection Guidelines for

Bearings” section of this manual.Replace any bearings failing to meetthe inspection guidelines. Bearingraces are located in the rear coverhousing and should also beinspected for wear and damage.

C. Inspect the P3 indexing ringfor step wear in the area where itcontacts the spindle. Replace the

indexing ring if it is broken or if ithas excess step wear or damagewhich cannot be repaired using asoft stone or crocus cloth. Indexingrings with acceptable wear can beflipped during reassembly so that anew contact surface is used.

Bearing races

located in rearcover.

F. PinionGear

C. IndexingRing

(continued)


37/82

D. Inspect planetary spindles forwear and damage. Discoloration isonly a concern if spindle surfacedamage exists.

E. Inspect the pinion gear thrustwashers for damage, distortion and signs of excessive wear. Minimumallowable thrust washer thickness

is 1.39 mm (0.054 inch). Replacedamaged or worn thrust washers.

F. Inspect the pinion gearsfollowing the “General InspectionGuidelines for Gears” section of thismanual. Replace any gears whichfail these inspection procedures orif the damage cannot be repaired using a soft stone.

G. Inspect the pinion rollerbearings following the “GeneralInspection Guidelines for Bearingssection of this manual. Replace anybearings which fail these inspectioprocedures.

H. Replace the output shaftspacer if it is bent, cracked or if it

is distorted in any way. An attempcan be made to repair some minordamage using a soft stone.

I. Inspect the output shaftexternal retaining ring. Replacethe retaining ring if it is distortedor fits loosely on the shaft.






P3 Carrier Update -

SIL 25-WT-01

Current P3 carriers use a drill point

hole and a Belleville spring washer.


Planetary Spindle and

Indexing Ring Updates -SIL 10-WT-00

Planetary spindles and indexing rings are

backward compatible. Current spindles arestamped with the number “2.” Indexing rings

are stamped with the identifier “HD5.”

P1 P2 P3

(continued


38/82


J. Inspect the output shaftfollowing the “General InspectionGuidelines for Cast Parts and Machined Surfaces” and the“General Inspection Guidelines forSplines” sections of this manual.Replace the output shaft if it failsthese inspection procedures.

Inspect the output shaft bushingfollowing the “General InspectionGuidelines for Bushings” section of this manual. Replace the bushing if it fails these inspection procedures.Maximum allowable bushing insidediameter is 36.14 mm (1.423 inch).




Flange / Yoke Retaining Bolt Update - Reference SIL 1-WT-99

Single Boltdesign

increasesclamp load.

Output spacersare notinterchangeable

between theformer and

current designs.


Service Kit for Two-Bolt Ouput - SIL 15-WT-98Kit Part Number: 29535910

J. Output Shaft

J. Inspect the output shaftbushing for damage.

* Note: Kit containsBelleville washers and

2 allen-head bolts toreplace original lockingtab and hex-head bolts.

(continued)


39/82





K. Replace the output bearinglocknut retainer whenever thelocknut is removed.

L. Inspect the Belleville springwasher for damage. Replace thewasher if it is distorted or thetang is worn.

M. Replace the output bearinglocknut if it is cracked, distorted,has damaged threads. The currentlocknuts have three buttons in thethreaded area. This nut should bereplaced if it does not have aminimum of 10 N.m (7.5 ft. lb.) of running torque when threadingthe nut.

(continued)

K. Locknut

Retainer

4000 SeriesWide RatioP3 CarrierAssembly

4000 SeriesClose RatioP3 CarrierAssembly

Former output bearinglocknut and retainer

M. OutputBearing

Locknut

L. Belleville

Spring


40/82






Bearing Retainer LocknutUpdate - Reference

SIL 25-WT-01

Currentbearing

retainerlocknuts

includethreelocking

buttons.


Output Yoke/Flange Update -Reference SIL 4-WT-03

Not all yoke / slinger combinationscan be used with all transmis-

sions. Rear cover design deter-mines yoke / slinger combination.


Rear Cover Update - Reference SIL 4-WT-03

Current rear cover has interior cut relief to accommodate5-ridge output seal. Former rear cover has interior cut relief to

accommodate 4-ridge output seal (reference Output Seal Update Supersession Information) .

Former: No cut relief Current: Cut relief on

the exterior for a wraparound slinger.

FormerOutput Seal

Current Output Seal (former standard/ retarder housing)

for S/N prior to 6610116108

Current Output Seal (current standard/ retarder housing) forS/N starting with 6610116108

Output Seal Update -Reference SIL 4-WT-03

Two seals are

currently available -to fit former andcurrent rear covers.

They are NOTinterchangeable.


41/82


RETARDER MODULE



A. Inspect the retarder housingfollowing the “General InspectionGuidelines for Cast Parts and Machined Surfaces” section of thismanual. High spots on machined surfaces can be removed using asoft stone or crocus cloth. Replacethe retarder housing if it is cracked

or if machined surface damagecannot be removed using a softstone or crocus cloth.

Install a “known good” rotorsealring in the retarder housing and measure sealring inside diameter. If the retarder housing is slightlygrooved or worn, place the sealringdirectly in the grooved or wornarea. Replace the housing if sealring

inside diameter is greater than139.72 mm (5.501 inches). A bearingrace fits into the housing and should be inspected for damage.

B. Inspect the stator housingfollowing the “General InspectionGuidelines for Cast Parts and Machined Surfaces” section of this

manual. Some light housingimperfections can be removed usinga soft stone. Discard and replace thehousing if damage is excessive.

NOTE: Transmissions built prior to January 1998 included two smallcheck balls and retainers located inthe retarder stator housing.Minimum allowable check ballmovement is 0.50 mm (0.020 inch).

Inspect the slot on the back sideof the housing where the C5 pistontang indexes for excessive wear.Replace the stator housing if damage to any machined surfacecannot be repaired using a softstone or crocus cloth. Replace thestator housing if it is cracked.

C. Inspect the retarder rotorfollowing the “General InspectionGuidelines for Cast Parts and Machined Surfaces” section of thismanual. Check for loose, cracked orbroken rivets. Replace the rotor if movement exists between thecenter hub and the vaned assembly.Inspect the rotor splines for wear.

B. Retarder StatorHousing

E. Autoflow Valve,Spring & Plug

C. RetarderRotor

F. Retarder TempSensor Assembly

A. RetarderHousing

G. Output Speed

Sensor

(continued)

D. P3 CarrierAssembly

(Retarder)


Retarder Exhaust Backfill Valve Update -Reference SIL 14-WT-02

The current stop is backwardcompatible with all 4000/B500 retarder -

equipped transmissions.

CurrentRetarderExhaustBackfillValve Stop

FormerRetarderExhaustBackfillValve Stop


42/82


Fluid FlowDetail


RETARDER MODULE (continued)

Spline wear cannot exceed 0.38 mm(0.015 inch). Replace the rotor if itexceeds this wear limit.

D. Reference the “Inspection and Analysis of the Standard RearCover” section of this manual for P3planetary carrier assembly details.

NOTE: Inspect retarder P3 carriersfor excessive step wear on thesplines of the P3 carrier hub.Replace those P3 carriers thatexhibit step wear.

E. Inspect the retarder autoflowvalve for wear and damage. Theautoflow valve must move freely inits bore, when dry, under its own

weight. Replace or repair theautoflow valve and/or retarderhousing as necessary. Crocus clothcan be used to remove slight highspots.

Inspect the autoflow valve springfor defects and permanent set.Reference the Spring Data Charts inService Manual SM2457 for springspecifications and identification.Replace the spring if it fails anyinspection procedures.

F. Inspect the retardertemperature sensor exterior fordefects. Replace the temperaturesensor if it is damaged. There aretwo temperature sensor types - TID

1 and post-TID 1 (TID 2 and TID 3).Resistance specifications varybetween the two sensor types. Besure to use the correctTroubleshooting Manual chart forthe sensor being tested. Replace thetemperature sensor if its measured resistance is not within

Troubleshooting Manualspecifications.

G. Inspect the output speedsensor for damage. Replace thesensor if it has body, terminal orconnector seat damage. Allowableoutput speed sensor resistance is300 ohms plus or minus 30 ohms.


Retarder Sump Cooling Feature - ReferenceSIL 25-WT-00, Rev. A

The sump cooling feature provides additional coolingwhen the retarder is active through either an additionalauxiliary cooler or the direct mount cooler for retardertransmissions.The direct mount cooler for retarder transmissionsworks as both the main cooler and auxiliary cooler.

(continued)

Main

ControlMain From

Cooler

To Cooler

C5 PressureExhaust

RetarderOut

Accumulator

Converter Out(To Cooler)

LubePressure

FromCooler

To Retarder

Control Main

Main

No SumpCoolingFeature

SumpCoolingProvision


43/82


(continued) RETARDER MODULE



A. Inspect the retarder controlvalve body following the “GeneralInspection Guidelines for CastParts and Machined Surfaces”section of this manual. All passagesmust be clean and debris free. Valvebores must be free of nicks, burrsand scoring. Crocus cloth or a soft

stone can be used to attemptremoval of slight irregularities,however no honing of any kind ispermitted.

B & H. Inspect the retardercontrol valve and exhaust backfillvalve for nicks, burrs, scoring and other damage. A soft stone orcrocus cloth can be used to attempt

removal of slight irregularities.Valves must move freely in theirbores, when dry, under their ownweight.

C & I. Replace the retardercontrol valve spring or exhaustbackfill spring for damage orpermanent set. Reference theSpring Data Charts in the ServiceManual for spring specificationsand identification.

D. Inspect the valve plug fordamage. Replace the plug if damagecannot be repaired using a softstone or crocus cloth.

E. Inspect the channel platefollowing the “General InspectionGuidelines for Cast Parts and Machined Surfaces” section of thismanual. Replace the channel plate ifit fails any of these inspectionprocedures or if it has damagewhich cannot be repaired using a

soft stone or crocus cloth.All passages must be clean and debris free.

K. WiringHarness

A. RetarderValve

Body

G. RetarderSolenoid

H. ExhaustBackfill

Valve

I. ExhaustBackfill

ValveSpring

L. SolenoidCover

E. ChannelPlate

C. Retarder Control

Valve Spring

F. Separator

Plate

J. Exhaust

Backfill ValveStop & Pin

D. ValvePlug &Retaining

Ring

B. RetarderControl

Valve

(continued)


44/82



RETARDER MODULE (continued)

F. Inspect the separator plate fornicks, burrs, scoring and distortion(flatness). Replace the plate if damage cannot be repaired using asoft stone or crocus cloth.

G. Replace the retarder solenoidif the body, connector or terminalsshow visible signs of damage.Solenoid resistance should be 3 to 4ohms measured between the twosolenoid terminals. Checkresistance between each solenoid terminal and the solenoid body.Replace the solenoid if eitherreading is less than 100k ohmsresistance.

J. Inspect the exhaust backfillvalve stop for damage. Replace thestop if damage cannot be repaired using a soft stone or crocus cloth.Inspect the exhaust backfill valvepin for damage. Replace the pin if itis bent or has damage.

K. Replace or repair the wiringharness if the wires, terminals orconnectors are visibly damaged.Check the installed harness fortight bends or crimps which mightdamage harness wires.

L. Inspect the solenoid coverfollowing the “General InspectionGuidelines for Cast Parts and Machined Surfaces” section of thismanual. Replace the housing if itfails any of these inspectionprocedures.

ExhaustPressure

RetarderPressure

Pocket

MainPressure

ControlMain

Retarder

Pressure

Exhaust

Pressure

Pocket

RetarderPressure

Main

Pressure

ExhaustPressure

Exhaust

BackfillPressure

Exhaust

Pressure

Retarder

Pressure

MainPressure

(to FlowValve)

Main Pressure

(Feed)

Control Main

Pressure


45/82


CLOSE RATIO MAIN SHAFT MODULE



A. Main Shaft

H. P3Sun

Gear

D. ThrustBearing

F. Bearing

Spacer

G. Selective

ShimE. P2 Sun

Gear

I. Spiral

Retaining

Ring

B. Main

ShaftPilotsC. Journal

B. Main

ShaftPilots

A. Inspect the main shaftfollowing the “General InspectionGuidelines for Gears” and “GeneralInspection Guidelines for Splines”sections of this manual. Replace themain shaft if it fails any of theseinspection procedures.

B. Inspect the front and rear

main shaft pilots for damage. Thefront main shaft pilot fits inside theturbine shaft. The rear main shaftpilot fits inside the output shaft.Replace the main shaft if pilotoutside diameter is less than 35.92mm (1.414 inch).

C. Inspect the P2 bushing journalarea for damage. Replace the mainshaft if P2 planetary bushing

journal diameter is less than 52.98mm (2.085 inch).

D. Inspect the thrust bearingsfollowing the “General InspectionGuidelines for Bearings” section of this manual. Replace any bearingthat fails any of these inspectionprocedures.

E. Inspect the P2 sun gearfollowing the “General InspectionGuidelines for Gears” and “GeneralInspection Guidelines for Splines”sections of this manual. Replace thegear if it fails any of these inspectionprocedures.

F. Inspect the main shaft bearingspacer following the “GeneralInspection Guidelines for Cast Parts

and Machined Surfaces” and “General Inspection Guidelines forSplines” sections of this manual.Replace the spacer if it fails any of these inspection procedures.

G. Inspect the selective shim fordamage. Replace the shim if it isdistorted or if damage cannot be

removed by light stoning.H. Inspect the P3 sun gearfollowing the “General InspectionGuidelines for Gears” and “GeneralInspection Guidelines for Splines”sections of this manual. Replace thegear if it fails any of theseinspection procedures.

I. Replace the spiral retainingring if it is removed.

Close Ratio MainShaft Module


46/82



WIDE RATIO MAIN SHAFT MODULE

A. Main

Shaft

D. P2 SunGear

E. Thrust

Bearing

F. BearingSpacer

G. SelectiveShim

H. Spiral

RetainingRing

B. Main ShaftPilots

C. Journal

B. Main Shaft Pilots

A. Inspect the main shaftfollowing the “General InspectionGuidelines for Gears” and “GeneralInspection Guidelines for Splines”sections of this manual. Replace themain shaft if it fails any of theseinspection procedures.

B. Inspect the front and rear mainshaft pilots for damage. The frontmain shaft pilot fits inside theturbine shaft. The rear main shaftpilot fits inside the output shaft.Replace the main shaft if pilotoutside diameter is less than 35.92mm (1.414 inch).

C. “Inspect the P2 bushing journal for damage. Replace themain shaft if P2 planetary bushing journal diameter is less than 52.98mm (2.085 inch).

D. Inspect the P2 sun gearfollowing the “General InspectionGuidelines for Gears” and “General

Inspection Guidelines for Splines”sections of this manual. Replace thegear if it fails any of theseinspection procedures.

E. Inspect the thrust bearingsfollowing the “General InspectionGuidelines for Bearings” section of this manual. Replace any bearing thatfails any of these inspectionprocedures.

F. Inspect the main shaft bearingspacer following the “GeneralInspection Guidelines for CastParts and Machined Surfaces”“General Inspection Guidelines forSplines” sections of this manual.Replace the spacer if it fails any of these inspection procedures.

G. Inspect the selective shim fordamage. Replace the shim if it isdistorted or if damage cannot beremoved by light stoning.

H. Replace the spiral retainingring if it is removed.

Wide Ratio MainShaft Module


47/82

D. P3 RingGear

A. P2 Planetary

Carrier

E. IndexRing

F. Pinion ThrustWashers

G. PinionSpindle

H. Pinion

RollerBearings

I. PinionGear

J. RetainingRings

A. Inspect the P2 carrierfollowing the “General InspectionGuidelines for Cast Parts and Machined Surfaces” and the“General Inspection Guidelines forSplines” sections of this manual.Replace the carrier if any spindlehas more than 0.051 mm (0.002

inch) clearance in its bore.B. Inspect the P2 carrier bushingfor damage. Replace the bushing if damaged. Replace the bushing if inside diameter exceeds 53.23 mm(2.096 inches).

C. Inspect the carrier hub fordamage. Replace the carrier if damage cannot be repaired using asoft stone or crocus cloth.

D. Inspect the P3 ring gearfollowing the “General InspectionGuidelines for Gears” and “GeneralInspection Guidelines for Splines”sections of this manual. Replace thering gear if it fails any of theseinspection procedures.

E. Inspect the P2 indexing ring for

step wear in the area where itcontacts the spindle. Replace theindexing ring if it is broken or if ithas excessive step wear or damage.Indexing rings with acceptablewear can be flipped duringreassembly so that a new contactsurface is used.

F. Replace the pinion gear thrustwashers if they are damaged,distorted, galled or showing signs of

excessive wear. Minimum allowablethrust washer thickness is 1.40 mm(0.055 inch). Maximum allowablethrust washer step wear is 0.12 mm(0.005 inch).

G. Replace planetary spindles if they are worn or damaged.Discoloration is only a concern if

spindle surface damage exists.


P2 PLANETARY MODULE



B. Carrier

Bushing

C. CarrierHub

(continue


48/82



P2 PLANETARY MODULE (continued)

H. Inspect the pinion rollerbearings following the “GeneralInspection Guidelines for Bearings”section of this manual. Replace anybearing failing these inspectionprocedures.

I. Inspect the P2 pinion gearsfollowing the “General Inspection

Guidelines for Gears” section of thismanual. Replace any gear that failsthese inspection procedures or if damage cannot be removed using asoft stone.

J. Inspect the P2 carrierretaining rings for damage ordistortion. Replace any retainingrings with damage that cannot beremoved using a soft stone.

NOTE: Current P3 ring gears arehardened. Former P3 ring gearswere non-hardened. Each ring gearrequires a specific C5 clutch plate.There are two current versions of C5 clutch plates. Plates which aremissing two splined teeth must beused with the hardened P3 ring gear(identified by the groove on the

gear’s outside diameter). Platesmissing three splined teeth must beused with the non-hardened P3 ringgear (no identification groove).Reference the C5 clutch plate“Supersession Information” in thissection and SILs 12-WT-03 and4-WT-00, Revision B. The correctcurrent C5 clutch plate must beused with each ring gear to avoid transmission damage.


Planetary Spindle and Indexing RingUpdates - Reference SIL 10-WT-00

Planetary spindles and indexing rings arebackward compatible. Current spindles arestamped with the number “2.” Indexing ringsare stamped with the identifier “HD5.”

P1 P2 P3

FORMER (NON-HARDENED)P3 RING GEAR

HARDENED

P3 RING GEAR

IDENTIFICATION

GROOVE


P3 Ring Gear Update -SIL 12-WT-03

Use C5 friction

plate missing 2internal teeth.

Use C5 friction

plate missing3 internal teeth.

4000 SeriesClose RatioP2 CarrierAssembly

4000 SeriesWide Ratio

P2 CarrierAssembly


49/82

A. P1

PlanetaryCarrier

B. P2RingGear

C. IndexRing

D. Pinion

ThrustWashers

E. Pinion

Spindle

G. Pinion RollerBearings

F. PinionGear

H. RetainingRing

A. Inspect the P1 carrier followingthe “General Inspection Guidelinesfor Cast Parts and Machined Surfaces” and the “GeneralInspection Guidelines for Splines”sections of this manual. Replace thecarrier if any spindle has more than0.051 mm (0.002 inch) clearance in

its bore.Thrust bearings fit on both sides of the P1 carrier. Inspect the thrustbearings following the “GeneralInspection Guidelines for Bearings”section of this manual. Replace anybearing that fails any of theseinspection procedures.

B. Inspect the P2 ring gearfollowing the “General InspectionGuidelines for Gears” and the“General Inspection Guidelines forSplines” sections of this manual.Replace the ring gear if it fails anyof these inspection procedures.

C. Inspect the P1 indexing ring

for step wear in the area where itcontacts the spindle. Replace theindexing ring if it is broken or if ithas excessive step wear or damage.Indexing rings with acceptablewear can be flipped duringreassembly so that a new contactsurface is used.


P1 PLANETARY MODULE



Thrust

bearinginspection.

(continued)


50/82



P1 PLANETARY MODULE (continued)

D. Replace the pinion gear thrustwashers if they are damaged,distorted, galled or showing signs of excessive wear. Minimum allowablethrust washer thickness is 1.39 mm(0.054 inch).

E. Replace planetary spindles if they are worn or damaged.Discoloration is only a concern if spindle surface damage exists.

F. Inspect the P1 pinion gearsfollowing the “General InspectionGuidelines for Gears” section of thismanual. Replace any gear that failsthese inspection procedures or if damage cannot be removed using asoft stone.

G. Inspect the pinion rollerbearings following the “GeneralInspection Guidelines for Bearings”section of this manual. Replace anybearing failing these inspectionprocedures.

H. Inspect the P1 carrier retainingrings for damage or distortion.Replace any retaining rings withdamage that cannot be removed using a soft stone.


Planetary Spindle and Indexing Ring Updates -

SIL 10-WT-00

Planetary spindles and indexing rings are backward

compatible. Current spindles are stamped with the number

“2.” Indexing rings are stamped with the identifier “HD5.”

P1 P2 P3


51/82

A. Front Support

Assembly

D. PTO-ModelGround

Sleeve

F. ChargingPump

Housing

(PTO Model)

H. RollerBearing

G. Main

PressureRelief Ball& Spring J. Wear

Plate

D. Non-PTO ModelGround Sleeve

E. BushingJournal

I. Charging PumpGear Set

A. Inspect the front supportassembly following the “GeneralInspection Guidelines for CastParts and Machined Parts” sectionof this manual. Replace theassembly if it fails any of theseinspection procedures. If theground sleeve has rotated in the

front support, replace bothcomponents (the ground sleeve and the front support assembly). If theground sleeve is replaced, check thefront support for flatness afterground sleeve installation. Replacethe front support if it is more than0.051 mm (0.002 inch) from flat.

B. Replace the front support if the sleeve has damage that cannotbe repaired using a soft stone orcrocus cloth. Minimum allowablefront support sleeve diameter is119.81 mm (4.717 inches).

C. Inspect the three sealringgrooves on the front support

assembly hub for nicks, burrs,cracks and other damage.


FRONT SUPPORT &OIL PUMP MODULE




Redesigned Charging PumpGear Set - SIL 13-WT-04

Orange bushing identifies

current gear set.

C. Sealring Grooves

B. FrontSupport

Sleeve

B. Front

SupportSleeve

Former

Current

(continued)


52/82



FRONT SUPPORT & OIL PUMP MODULE (continued)

Oil PassageDetail

LubePressure Main

Pressure

Lockup Pressure

ConverterOut

Converter In

Pump

Suction

C1Pressure

D. Inspect the ground sleevefollowing the “General InspectionGuidelines for Splines” section of this manual. Replace the shaft if itfails any of these inspectionprocedures.

E. Inspect the journal area wherethe charging pump driven gear

bushing rides. Replace the shaft if the journal is damaged or galled.Minimum allowable journaldiameter is 66.67 mm (2.265inches).

NOTE: Ground sleeve galling istypically an indicator of poortransmission fluid condition due toimproper maintenance intervals.Observation of proper fluid change

intervals is key to optimumtransmission life.

Inspect the area in the groundsleeve where the turbine shaftsealrings ride for grooves, scoringand other wear or damage. Installnew sealrings in the ground sleeveand measure the end gap. If the

ground sleeve is grooved or worn,place the sealrings directly in thegrooved or worn area. Maximumallowable sealring end gap is 1.01mm (0.039 inches). Replace theground sleeve if any of the seal ringend gaps exceeds this specification.

NOTE: When replacing the ground sleeve, total shaft runout cannotexceed 0.30 mm (0.012 inch) once itis pressed into the front support.

C2Pressure

(continued)

C1 Pressure

C2 Pressure

Front support oil passagedetail - outside hub.


53/82

F. Inspect the charging pumphousing following the “GeneralInspection Guidelines for CastParts and Machined Parts” sectionof this manual. Replace the housingif it fails any of these inspectionprocedures. Replace the chargingpump housing if gear cavity depth

exceeds 19.04 mm (0.750 inches).Replace the charging pump housingif gear cavity diameter exceeds150.25 mm (5.915 inches).

G. Replace the main pressurerelief ball if it is damaged. Inspectthe main pressure relief springfollowing the “General InspectionGuidelines for Springs” section of this manual. Replace the spring if itis bent, broken, distorted or showssigns of wear from rubbing adjacent

parts. Reference the Spring DataCharts in the Service Manual forspring identification and specifications.

H. The roller bearing fits insidethe back of the front support hub.Inspect this bearing following the“General Guidelines for Bearings”section of this manual. Replace thebearing if it fails any of theseinspection procedures.


(continued) FRONT SUPPORT & OIL PUMP MODULE



(continued)

Oil passage detail -inside hub.

Lube Lockup ConverterOut

C1Pressure

C2 Pressure

Indexing

AlignmentArrow

Flat on

GroundSleeve


54/82


Ground sleeve oilpassage detail.


FRONT SUPPORT & OIL PUMP MODULE (continued)

Lube

Lockup

Converter Out

C2 Pressure

C1

Pressure

I. Replace the charging pumpgear set if the sides, faces or gearteeth are damaged. Replace the gearset if the inside gear shows damageor battering at the point where thetorque converter drive tangs (or thePTO drive hub tangs) index intothe gear. Replace the gear set if the

bushing inside diameter exceeds57.30 mm (2.256 inch). Minimumallowable outside diameter of theouter gear is 149.94 mm (5.903inch).

NOTE: Install the pump gear set inthe oil pump housing to performthe following inspections and measurements.

Maximum allowable clearancebetween the installed gear set and mounting face of the pump housingis 0.10 mm (0.004 inch). This isoften referred to as pump gear sideclearance. Maximum allowable geartooth tip clearance (the gapbetween a tooth on the outer gear

and a tooth on the inner gear) is0.15 mm (0.006 inch). Themaximum allowable clearancebetween the outer gear and thepump housing is 0.30 mm (0.012inch).

J. Replace the wear plate if it isgalled or moderately scored. Payparticular attention to the areawhere the charging pump gear setrides. Minimum allowable wearplate thickness is 4.70 mm (0.0185inch). Replace the wear plate if it isworn past service limits or if it has

damage that cannot be repaired using a soft stone or crocus cloth.


55/82

A. Inspect the turbine shaftfollowing the “General InspectionGuidelines for Cast Parts and Machined Surfaces” section of thismanual. Replace the turbine shaft if it fails any of these inspectionprocedures. Maximum allowablespline wear is 0.38 mm (0.015 inch).

B. Inspect the turbine shaftbushing following the “GeneralInspection Guidelines for Bushings”section of this manual. Replace thebushing if it fails any of theseinspection procedures. Maximumallowable bushing inside diameteris 36.14 mm (1.423 inch).

C. Inspect the bearing journal area for damage.Replace the turbine shaft if damage cannot be repaired with a light stone or crocuscloth.

D. Inspect the three sealringgrooves for damage. Replace the

turbine shaft if damage cannot berepaired with a light stone orcrocus cloth. Install three newsealrings and check end gap.Minimum end gap allowed is 0.65mm (0.026 inch). Replace turbineshaft if end gap is below minimum.

E. Inspect the rotating drumfollowing the “General InspectionGuidelines for Cast Parts and

Machined Surfaces” and “GeneralInspection Guidelines for Splines”sections of this manual. Replace thedrum if it fails any of theseinspection procedures. Maximumallowable spline wear is 0.38 mm0.015 inch).

F. Inspect the rotating clutchhub following the “GeneralInspection Guidelines for CastParts and Machined Surfaces” and


ROTATING CLUTCH MODULE


A L L I S O N T R A N S M I S S I O N T E C H N

4k technician's guide

Documents