Service 2004 DECEMBER

Manual SM3191EN

Allison Transmission
VOCATIONAL MODELS
1000 EVS 2100 EVS 2200 EVS 2500 EVS B 210
1000 HS 2100 HS 2200 HS 2500 HS B 220
1000 MH 2100 MH 2200 MH 2500 MH
1000 PTS 2100 PTS 2200 PTS 2500 PTS
1000 RDS 2100 RDS 2200 RDS 2500 RDS
1000 SP 2100 SP 2200 SP 2500 SP

Allison Transmission, General Motors Corporation

P.O. Box 894 Indianapolis, Indiana 46206-0894
www.allisontransmission.com

Printed in USA Copyright © 2004 General Motors Corporation

 INTRODUCTION

TRADEMARK USAGE
The following trademarks are the property of the companies indicated:
• Biobor JF® is the registered trademark for a biological inhibitor manufactured by Hammonds
Fuel Additives Company.
• DEXRON® is a registered trademark of General Motors Corporation.
• Loctite® is a registered trademark of the Loctite Corporation.
• Spiralock® is a registered trademark of Spiralock of Michigan.
• Teflon® is a registered trademark of the DuPont Corporation.
• TranSynd™ is a trademark of Castrol Ltd.
• 1000 Series™ is a trademark of General Motors Corporation.
• 2000 Series™ is a trademark of General Motors Corporation.
• 2400 Series™ is a trademark of General Motors Corporation.
• Windows™ is a trademark of Microsoft Corporation.
• Allison DOC™ and Allison Diagnostic Optimized Connection™ are trademarks of General
Motors Corporation.

NOTE:
This publication is revised periodically to include improvements,
new models, special tools, and procedures. A revision is indicated
by the date on the title page. Check with your Allison
Transmission service outlet for the currently applicable
publication. Additional copies of this publication may be
purchased from authorized Allison Transmission service outlets.
Look in your telephone directory under the heading of
Transmissions — Truck, Tractor, etc.

ii Copyright © 2004 General Motors Corp.

 IMPORTANT SAFETY NOTICE

IT IS YOUR RESPONSIBILITY to be completely familiar with the Warnings and

Cautions described in this Service Manual. These Warnings and Cautions advise against
the use of specific service methods that can result in personal injury, damage to the
equipment, or cause the equipment to become unsafe. It is, however, important to
understand that these Warnings and Cautions are not exhaustive. Allison Transmission
could not possibly know, evaluate, and advise the service trade of all conceivable ways in
which service might be done or of the possible hazardous consequences of each way.
Consequently, Allison Transmission has not undertaken any such broad evaluation.
Accordingly, ANYONE WHO USES A SERVICE PROCEDURE OR TOOL WHICH IS
NOT RECOMMENDED BY ALLISON TRANSMISSION MUST first be thoroughly
satisfied that neither personal safety nor equipment safety will be jeopardized by the
service methods selected.

Proper service and repair are important to the safe, reliable operation of the equipment.
The service procedures recommended by Allison Transmission and described in this
Service Manual are effective methods for performing service operations. Some of these
service operations require the use of tools specifically designed for the purpose. The
special tools should be used when and as recommended.

WARNINGS, CAUTIONS, AND NOTES

Three types of headings are used in this manual to attract your attention:

WARNING!
is used when an operating procedure, practice,
etc., which, if not correctly followed, could result
in personal injury or loss of life.

CAUTION:
is used when an operating procedure, practice,
etc., which, if not strictly observed, could result
in damage to or destruction of equipment.

NOTE:
is used when an operating procedure, practice, etc.,
is essential to highlight.

Copyright © 2004 General Motors Corp. iii

 LIST OF WARNINGS
This manual contains the following Warnings —

IT IS YOUR RESPONSIBILITY TO BE FAMILIAR WITH ALL OF THEM.

Operation with excessive loads can cause transmission damage and unexpected vehicle movement.
To help avoid injury, property damage, and/or transmission damage, do not exceed 11 800 kg
(26,000 lbs) GCW or the OEM vehicle rating, whichever is less.
If ignition is turned “OFF” and then “ON” while the CHECK TRANS light is displayed, the
transmission may remain in neutral until the code is cleared. Leave ignition “ON” until you are in
a safe place to stop.
For vehicles containing 1000 and 2000 Product Families transmissions with park pawl, each time
you park the vehicle or leave the operator’s station with the engine running, do the following.
• Bring the vehicle to a complete stop using the service brake.
• Make sure the engine is at low idle rpm.
• Put the transmission in P (Park).
• Engage the P (Park) range by slowly releasing the service brake.
• Apply the emergency brake and/or parking brake, if present, and make sure it is properly
engaged.
• If the operator’s station will be unoccupied with the engine running, chock the wheels and
take any other steps necessary to keep the vehicle from moving.
If this procedure is not followed, the vehicle can move suddenly and you or others could be injured.
For vehicles containing 2000 Product Family transmissions with auto-apply parking brakes, each
time you park the vehicle or leave the operator’s station with the engine running, do the following.
• Bring the vehicle to a complete stop using the service brake.
• Make sure the engine is at low idle rpm.
• Put the transmission in PB (Auto-Apply Parking Brake). Make sure that the parking brake is
properly engaged.
• Apply the emergency brake, if present, and make sure it is properly engaged.
• If the operator’s station will be unoccupied with the engine running, chock the wheels and
take any other steps necessary to keep the vehicle from moving.
If this procedure is not followed, the vehicle can move suddenly and you or others could be injured.
For vehicles containing 2000 Product Family transmissions without auto-apply parking brakes,
each time you park the vehicle or leave the operator’s station with the engine running, do the
following.
• Bring the vehicle to a complete stop using the service brake.
• Make sure the engine is at low idle rpm.
• Put the transmission in N (Neutral).
• Apply the emergency brake and/or parking brake and make sure they are properly engaged.
• If the operator’s station will be unoccupied with the engine running, chock the wheels and
take any other steps necessary to keep the vehicle from moving.
If this procedure is not followed, the vehicle can move suddenly and you or others could be injured.
Observe safety precautions during hydraulic pressure check procedures. All personnel must stand
clear of the vehicle. Take precautions against movement of the vehicle. Be sure that gauges
(vacuum, pressure, tachometer) have extended lines so that they can be read from inside the
vehicle.

iv Copyright © 2004 General Motors Corp.

 LIST OF WARNINGS
This manual contains the following Warnings —

IT IS YOUR RESPONSIBILITY TO BE FAMILIAR WITH ALL OF THEM.

To help avoid injury or property damage caused by sudden and unexpected vehicle movement, do
not start a stationary stall test until you:
• Put the transmission in P (Park) or N (Neutral)…and
• Apply the parking brake and service brake…and
• Chock the vehicle wheels and take any other steps necessary to keep the vehicle from
moving…and
• Warn personnel to keep clear of the vehicle and its path.

Use appropriate safety equipment such as safety glasses, safety shoes, and gloves.

Do not burn discarded Teflon® seals; toxic gases are produced by burning Teflon®.

Never dry bearings by spinning them with compressed air. A spinning bearing can disintegrate,
allowing balls or rollers to become lethal flying projectiles. Also, spinning a bearing without
lubrication can damage the bearing.

Avoid contact with the hot fluid or the sump when draining transmission fluid. Direct contact with
the hot fluid or the hot sump may result in bodily injury.

Chock wheels to prevent vehicle from moving when driveline is disconnected. This is not necessary
if vehicle is on a lift or jackstands.

Be sure the torque converter is moving rearward with the transmission as it is removed. Do not
allow the torque converter to become disengaged from the oil pump or to fall and injure yourself
or others.

The torque converter must be held to the torque converter housing by a retaining device such as
shipping brackets. Without the retaining device, the torque converter may slide forward,
disengaging the oil pump, or may fall completely out of the transmission causing personal injury
and/or property damage.

The 1000 and 2000 Product Families transmission dry weights are approximately 150 kg (330 lb).
To help avoid personal injury and/or property damage:
• Use caution when installing, removing, or moving the transmission.
• Get help when lifting the transmission. Assistance from a hoist or another person may be
required.
• Make sure that the lifting equipment can properly support the transmission.

If the transmission is not secured properly to the adapter plate, it could fall. To help avoid personal
injury and/or property damage:
• Use at least 5 bolts to support the transmission.
• Use M10 x 1.5 bolts with 19–25 mm (3⁄4–1 inch) thread engagement. If the proper bolt is not
used, the PTO bolt holes may be damaged.

Copyright © 2004 General Motors Corp. v

 LIST OF WARNINGS
This manual contains the following Warnings —

IT IS YOUR RESPONSIBILITY TO BE FAMILIAR WITH ALL OF THEM.

The 1000 and 2000 Product Families torque converter dry weights are approximately 29 kg (63 lb).
To help avoid personal injury and/or property damage:
• Use caution when installing, removing, or moving the torque converter.
• Get help when lifting the torque converter. Assistance from a hoist or another person may be
required.
• Make sure that the lifting equipment can properly support the torque converter.
The 1000 and 2000 Product Families converter housing/front support module dry weights are
approximately 27 kg (60 lb). To help avoid personal injury and/or property damage:
• Use caution when installing, removing, or moving the converter housing/front support
module.
• Get help when lifting the converter housing/front support module. Assistance from a hoist or
another person may be required.
• Make sure that the lifting equipment can properly support the converter housing/front
support module.
Always remove or install the P3 planetary carrier assembly by holding onto the output shaft.
Holding onto the P3 carrier assembly instead of the output shaft may allow the output shaft to fall
causing personal injury and/or property damage.
Exhaust all pressure from the torque converter before loosening the test fixture nut. Failure to
relieve the pressure could cause personal injury and/or property damage.
The rotating clutch housing and turbine shaft are held together by a retaining ring. Removal of the
retaining ring will allow the turbine shaft and the rotating clutch housing to move freely. Ensure
that the rotating clutch housing and the turbine shaft are restrained from moving when removing
the retaining ring. Personal injury and/or property damage may result from the movement of the
rotating clutch housing or the turbine shaft.
Pressing the P3 planetary carrier from the bearing race requires the P3 carrier to fall from the
bearing race. Ensure that the P3 carrier is safely caught when freed from the bearing race. An
uncontrolled fall of the P3 carrier could cause personal injury and/or property damage.

vi Copyright © 2004 General Motors Corp.

 TABLE OF CONTENTS
Paragraph Page Paragraph Page

Section 1. GENERAL INFORMATION 1–7. RESTORING TRANSMISSION

TO SERVICE
1–1. SCOPE OF MANUAL
a. Transmission Exterior . . . . . . . . . . . . . . 1–10
a. Transmission Product Families And
b. Sealed Vent Assembly and Openings . . 1–10
Model Years. . . . . . . . . . . . . . . . . . . . . . . 1–1
c. New Transmissions . . . . . . . . . . . . . . . . 1–10
b. Model Year 04 (MY04) . . . . . . . . . . . . . . 1–1
d. Stored Without Fluid . . . . . . . . . . . . . . . 1–10
c. MY04 Parts Changes . . . . . . . . . . . . . . . . 1–1
e. Stored With Fluid. . . . . . . . . . . . . . . . . . 1–10
d. Model Year 04i (MY04i). . . . . . . . . . . . . 1–1
1–8. OPERATING INSTRUCTIONS . . . . . . . . 1–10
e. MY04i Parts Changes . . . . . . . . . . . . . . . 1–1
f. Improved Shift Valve Body Casting . . . . 1–1 1–9. SPECIFICATIONS AND DATA . . . . . . . . 1–10
g. Vocational Models . . . . . . . . . . . . . . . . . . 1–1 1–10. ELECTROMAGNETIC/RADIO
h. Vocational Model Nomenclature. . . . . . . 1–2 FREQUENCY INTERFERENCE . . . . . . . 1–21
i. Content and Organization . . . . . . . . . . . . 1–2
j. Illustrations. . . . . . . . . . . . . . . . . . . . . . . . 1–2 Section 2. PREVENTIVE MAINTENANCE
k. Maintenance Information . . . . . . . . . . . . 1–2 2–1. SCOPE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2–1
1–2. SUPPLEMENTARY INFORMATION . . . . 1–2 2–2. PERIODIC INSPECTIONS AND CARE
a. Transmission Inspection . . . . . . . . . . . . . 2–1
1–3. ORDERING PARTS
b. Vehicle Inspection . . . . . . . . . . . . . . . . . . 2–1
a. Transmission Nameplate . . . . . . . . . . . . . 1–2
c. Welding . . . . . . . . . . . . . . . . . . . . . . . . . . 2–1
b. Parts Catalog . . . . . . . . . . . . . . . . . . . . . . 1–2
2–3. IMPORTANCE OF PROPER
1–4. GENERAL DESCRIPTION TRANSMISSION FLUID LEVEL . . . . . . . . 2–1
a. Transmission Design Features. . . . . . . . . 1–5
2–4. TRANSMISSION FLUID CHECK
b. General Description . . . . . . . . . . . . . . . . 1–7
a. Fluid Check Procedure . . . . . . . . . . . . . . 2–2
1–5. DIAGNOSIS b. Cold Check Procedure . . . . . . . . . . . . . . . 2–4
a. Before Starting . . . . . . . . . . . . . . . . . . . . . 1–7 c. Hot Check Procedure . . . . . . . . . . . . . . . . 2–4
b. CHECK TRANS Light . . . . . . . . . . . . . . 1–7 d. Consistency of Readings . . . . . . . . . . . . . 2–5
c. Range Inhibit Indicator . . . . . . . . . . . . . . 1–7 2–5. KEEPING FLUID CLEAN. . . . . . . . . . . . . . 2–5
d. Allison DOC™ Personal Computer
2–6. FLUID RECOMMENDATIONS . . . . . . . . . 2–5
(PC)-Based Diagnostic System . . . . . . . . 1–8
e. Troubleshooting When No Diagnostic 2–7. TRANSMISSION FLUID AND FILTER
Codes are Present. . . . . . . . . . . . . . . . . . . 1–8 CHANGE INTERVALS
f. Troubleshooting Intermittent a. Frequency. . . . . . . . . . . . . . . . . . . . . . . . . 2–6
Diagnostic Codes . . . . . . . . . . . . . . . . . . . 1–8 b. Abnormal Conditions. . . . . . . . . . . . . . . . 2–6
1–6. PRESERVATION AND STORAGE c. Fluid Analysis . . . . . . . . . . . . . . . . . . . . . 2–6
a. Storage (New Transmissions, 2–8. TRANSMISSION FLUID CONTAMINATION
Before Installation) . . . . . . . . . . . . . . . . . 1–9 a. Fluid Examination . . . . . . . . . . . . . . . . . . 2–6
b. Preservation Methods . . . . . . . . . . . . . . . 1–9 b. Water . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2–6
c. One Year Storage (Without Fluid). . . . . . 1–9 c. Engine Coolant. . . . . . . . . . . . . . . . . . . . . 2–9
d. One Year Storage (With Fluid) . . . . . . . . 1–9 d. Flush Oil Cooler. . . . . . . . . . . . . . . . . . . . 2–9

Copyright © 2004 General Motors Corp. vii

 1000 AND 2000 PRODUCT FAMILIES SERVICE MANUAL
Paragraph Page Paragraph Page

2–9. TRANSISSION FLUID AND FILTER 3–5. CLEANING AND INSPECTION

CHANGE PROCEDURE a. Dirt Causes Malfunction . . . . . . . . . . . . . 3–9
a. Drain Fluid . . . . . . . . . . . . . . . . . . . . . . . 2–9 b. Cleaning Parts . . . . . . . . . . . . . . . . . . . . 3–9
b. Replace Control-Main Filter . . . . . . . . . . 2–9 c. Cleaning Bearings . . . . . . . . . . . . . . . . . 3–9
c. Refill Transmission . . . . . . . . . . . . . . . . . 2–9 d. Keeping Bearings Clean. . . . . . . . . . . . . 3–9
2–10. VENT ASSEMBLY e. Inspecting Bearings . . . . . . . . . . . . . . . . 3–10
a. Location and Purpose . . . . . . . . . . . . . . 2–10 f. Inspecting Cast Parts and
b. Maintenance . . . . . . . . . . . . . . . . . . . . . 2–10 Machined Surfaces . . . . . . . . . . . . . . . . 3–10
2–11. MAIN PRESSURE CHECK g. Inspecting Bushings and
PROCEDURE. . . . . . . . . . . . . . . . . . . . . . . 2–10 Thrust Washers . . . . . . . . . . . . . . . . . . . 3–10
h. Inspecting Sealrings and Gaskets. . . . . 3–10
2–12. TRANSMISSION STALL TEST AND
i. Inspecting Gears. . . . . . . . . . . . . . . . . . 3–11
NEUTRAL COOL-DOWN CHECK
j. Inspecting Splined Parts. . . . . . . . . . . . 3–11
a. Purpose . . . . . . . . . . . . . . . . . . . . . . . . . 2–12
k. Inspecting Threaded Parts . . . . . . . . . . 3–11
b. Stall Testing Preparation . . . . . . . . . . . . 2–12
l. Inspecting Retaining Rings . . . . . . . . . . 3–11
c. Performing a Transmission
Stall Test . . . . . . . . . . . . . . . . . . . . . . . . 2–12 m. Inspecting Springs. . . . . . . . . . . . . . . . . 3–11
d. Driving Transmission Stall Test . . . . . . 2–13 n. Inspecting Clutch Plates . . . . . . . . . . . . 3–11
e. Driving Transmission Stall Testing o. Inspecting Swaged and
Preparation. . . . . . . . . . . . . . . . . . . . . . . 2–13 Interference-Fit Parts . . . . . . . . . . . . . . 3–12
f. Performing a Driving Transmission p. Inspecting Sealing Surfaces . . . . . . . . . 3–12
Stall Test . . . . . . . . . . . . . . . . . . . . . . . . 2–14 3–6. ASSEMBLY PROCEDURES
g. Neutral Cool-Down Check Procedure . 2–14 a. Parts Lubrication . . . . . . . . . . . . . . . . . . 3–12
h. Transmission Stall Test Results . . . . . . 2–14 b. Grease Used for Assembly . . . . . . . . . . 3–12
2–13. FLUID LEAK DIAGNOSIS c. Sealing Compounds and
a. Finding the Leak . . . . . . . . . . . . . . . . . . 2–15 Nonsoluble Greases . . . . . . . . . . . . . . . 3–12
b. Powder Method . . . . . . . . . . . . . . . . . . . 2–15 d. Clutches and Pistons . . . . . . . . . . . . . . 3–12
c. Black Light and Dye Method . . . . . . . . 2–16 e. Threaded Plugs and Hydraulic
d. Repairing the Leak . . . . . . . . . . . . . . . . 2–16 Fittings. . . . . . . . . . . . . . . . . . . . . . . . . . 3–12
2–14. ON-VEHICLE MAINTENANCE . . . . . . . 2–16 f. Lip-Type Seals . . . . . . . . . . . . . . . . . . . 3–12
g. Butt-Joint/Overlap Sealrings . . . . . . . . 3–13
Section 3. GENERAL OVERHAUL h. Bearings. . . . . . . . . . . . . . . . . . . . . . . . . 3–13
INFORMATION i. Electrical Components . . . . . . . . . . . . . 3–13
3–1. SCOPE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3–1 3–7. REMOVING (OR INSTALLING)
TRANSMISSION
3–2. TOOLS AND EQUIPMENT
a. Draining Transmission . . . . . . . . . . . . . 3–13
a. Improvised Tools and Equipment . . . . . 3–1
b. Disconnecting Controls . . . . . . . . . . . . 3–14
b. Special Tools . . . . . . . . . . . . . . . . . . . . . 3–1
c. Uncoupling From Driveline,
c. Mechanic’s Tools and
Engine, and Vehicle . . . . . . . . . . . . . . . 3–14
Shop Equipment . . . . . . . . . . . . . . . . . . . 3–1
d. Removing the Transmission. . . . . . . . . 3–14
3–3. REPLACEMENT PARTS e. Transmission Installation . . . . . . . . . . . 3–15
a. Ordering Information . . . . . . . . . . . . . . . 3–9
3–8. WEAR LIMITS. . . . . . . . . . . . . . . . . . . . . . 3–15
b. Parts Normally Replaced
at Overhaul . . . . . . . . . . . . . . . . . . . . . . . 3–9 3–9. SPRING SPECIFICATIONS . . . . . . . . . . . 3–15
3–4. CAREFUL HANDLING . . . . . . . . . . . . . . . 3–9 3–10. TORQUE SPECIFICATIONS . . . . . . . . . . 3–15

viii Copyright © 2004 General Motors Corp.

 TABLE OF CONTENTS
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Section 4. TRANSMISSION DISASSEMBLY Section 5. MODULE REBUILD

4–1. INSTALLATION OF TRANSMISSION 5–1. TORQUE CONVERTER ASSEMBLY
INTO REPAIR STAND . . . . . . . . . . . . . . . . 4–1 a. Preliminary Inspection. . . . . . . . . . . . . . . 5–1
b. End Play Check . . . . . . . . . . . . . . . . . . . . 5–1
4–2. INPUT SPEED SENSOR REMOVAL
(IF PRESENT). . . . . . . . . . . . . . . . . . . . . . . . 4–2 c. Leak Test . . . . . . . . . . . . . . . . . . . . . . . . . 5–2
d. Inspection of Torque Converter. . . . . . . . 5–3
4–3. TURBINE SPEED SENSOR REMOVAL . . 4–3
5–2. ELECTRONIC COMPONENT
4–4. OUTPUT SPEED SENSOR REMOVAL INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . 5–5
(2WD TRANSMISSIONS ONLY). . . . . . . . 4–3
5–3. CONVERTER HOUSING/FRONT
4–5. NSBU SWITCH REMOVAL SUPPORT MODULE DISASSEMBLY . . . 5–6
(IF PRESENT). . . . . . . . . . . . . . . . . . . . . . . . 4–3 5–4. TORQUE CONVERTER HOUSING
4–6. VENT REMOVAL . . . . . . . . . . . . . . . . . . . . 4–4 (WITHOUT COOLER MANIFOLD)
a. Disassembly . . . . . . . . . . . . . . . . . . . . . . . 5–9
4–7. TORQUE CONVERTER REMOVAL. . . . . 4–5 b. Assembly . . . . . . . . . . . . . . . . . . . . . . . . 5–10
4–8. CONVERTER HOUSING/FRONT 5–5. TORQUE CONVERTER HOUSING (DIRECT
SUPPORT MODULE REMOVAL . . . . . . . 4–6 MOUNT; WITHOUT COOLER MANIFOLD)
4–9. ROTATING CLUTCH ASSEMBLY a. Disassembly . . . . . . . . . . . . . . . . . . . . . . 5–11
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . 4–7 b. Assembly. . . . . . . . . . . . . . . . . . . . . . . . 5–11

4–10. OIL PAN AND SUCTION FILTER 5–6. TORQUE CONVERTER HOUSING
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . 4–8 (WITH COOLER MANIFOLD)
a. Disassembly . . . . . . . . . . . . . . . . . . . . . . 5–12
4–11. WIRING HARNESS ASSEMBLY
b. Assembly . . . . . . . . . . . . . . . . . . . . . . . . 5–13
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . 4–9
5–7. MAIN PUMP ASSEMBLY
4–12. CONTROL VALVE ASSEMBLY
a. Main Pump Disassembly. . . . . . . . . . . . 5–15
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . 4–10
b. Main Pump Inspection . . . . . . . . . . . . . . 5–16
4–13. REAR BALL BEARING REMOVAL . . . . 4–12 c. Main Pump Bushing Replacement . . . . 5–19
4–14. REAR COMPONENTS REMOVAL . . . . . 4–14 d. Main Pump Dowel Pin Replacement. . . 5–20
e. Wear Plate Inspection . . . . . . . . . . . . . . 5–21
4–15. PARK PAWL REMOVAL . . . . . . . . . . . . . 4–16 f. Main Pump Assembly . . . . . . . . . . . . . . 5–21
4–16. P2 PLANETARY MODULE AND MAIN 5–8. FRONT SUPPORT ASSEMBLY
SHAFT REMOVAL . . . . . . . . . . . . . . . . . . 4–16 a. Front Support Disassembly . . . . . . . . . . 5–22
4–17. C5 CLUTCH REMOVAL. . . . . . . . . . . . . . 4–17 b. Ground Sleeve Inspection . . . . . . . . . . . 5–27
c. Ground Sleeve Replacement . . . . . . . . . 5–28
4–18. P1 PLANETARY MODULE . . . . . . . . . . . 4–17
d. Ground Sleeve Needle Bearing
4–19. C4 CLUTCH REMOVAL. . . . . . . . . . . . . . 4–18 Replacement. . . . . . . . . . . . . . . . . . . . . . 5–30
e. Ground Sleeve Bushing Replacement . . 5–31
4–20. C4 CLUTCH PISTON ASSEMBLY
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . 4–20 f. Front Support Thrust Washer
Inspection . . . . . . . . . . . . . . . . . . . . . . . . 5–32
4–21. C3 CLUTCH REMOVAL. . . . . . . . . . . . . . 4–21 g. Front Support Assembly . . . . . . . . . . . . 5–32
4–22. C3 CLUTCH PISTON ASSEMBLY 5–9. CONVERTER HOUSING/FRONT
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . 4–23 SUPPORT MODULE ASSEMBLY. . . . . . 5–37

Copyright © 2004 General Motors Corp. ix

 1000 AND 2000 PRODUCT FAMILIES SERVICE MANUAL
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5–10. ROTATING CLUTCH MODULE 5–13. MAIN SHAFT INSPECTION . . . . . . . . . . 5–85

a. Disassembly of Rotating Clutch 5–14. P1 PLANETARY MODULE
Module. . . . . . . . . . . . . . . . . . . . . . . . . . 5–40 a. P1 Planetary Module Disassembly . . . . 5–86
b. Turbine Shaft Inspection . . . . . . . . . . . . 5–47 b. P1 Planetary Carrier Assembly
Inspection . . . . . . . . . . . . . . . . . . . . . . . 5–86
c. Turbine Shaft Bushing Replacement . . 5–48
c. P2 Planetary Ring Gear Inspection . . . . 5–87
d. Rotating Clutch Housing Inspection . . . 5–49 d. P1 Planetary Carrier Bushing
e. Rotating Clutch Housing Bushing Replacement . . . . . . . . . . . . . . . . . . . . . 5–87
Replacement . . . . . . . . . . . . . . . . . . . . . 5–50 e. P1 Planetary Carrier Thrust Washer
f. Rotating Clutch Housing Tone Wheel Inspection . . . . . . . . . . . . . . . . . . . . . . . 5–88
Replacement . . . . . . . . . . . . . . . . . . . . . 5–51 f. P1 Planetary Module Assembly . . . . . . 5–88
g. C1 Clutch Friction Plate Inspection . . . 5–53 5–15. P2 PLANETARY MODULE
a. P2 Planetary Module Disassembly . . . 5–89
h. C1 Clutch Reaction Plate Inspection . . 5–54
b. P2 Planetary Carrier Assembly
i. C1 Clutch Backplate Inspection . . . . . . 5–55 Inspection . . . . . . . . . . . . . . . . . . . . . . . 5–89
j. C2 Clutch Friction Plate Inspection . . . 5–56 c. P3 Planetary Ring Gear Inspection . . . . 5–90
k. C2 Clutch Reaction Plate Inspection . . 5–57 d. P2 Planetary Carrier Bushing
Replacement . . . . . . . . . . . . . . . . . . . . . 5–90
l. C1 Piston Housing Inspection. . . . . . . . 5–57 e. P2 Planetary Module Assembly . . . . . . 5–91
m. Rotating Clutch Thrust Washer 5–16. P3 PLANETARY CARRIER ASSEMBLY
Inspection . . . . . . . . . . . . . . . . . . . . . . . 5–58
a. P3 Planetary Carrier Assembly
n. Assembly of Rotating Clutch Module . 5–58 Inspection . . . . . . . . . . . . . . . . . . . . . . . 5–91
b. P3 Planetary Carrier Bearing Race
5–11. MAIN HOUSING ASSEMBLY
Replacement . . . . . . . . . . . . . . . . . . . . . 5–92
a. Disassembly of Selector Shaft
5–17. REAR COVER ASSEMBLY
and Detent Lever . . . . . . . . . . . . . . . . . . 5–68
a. Disassembly. . . . . . . . . . . . . . . . . . . . . . 5–94
b. Assembly of Selector Shaft and b. Rear Cover Retaining Ring
Detent Lever . . . . . . . . . . . . . . . . . . . . . 5–71 Replacement . . . . . . . . . . . . . . . . . . . . . 5–96
c. Nameplate Replacement . . . . . . . . . . . . 5–73 c. Output Shaft Bushing Inspection
d. Main Housing Dowel Pin (2WD Transmissions Only) . . . . . . . . . 5–96
Replacement . . . . . . . . . . . . . . . . . . . . . 5–74 d. Output Shaft Bushing Inspection
(4WD Transmissions Only) . . . . . . . . . 5–96
e. Replacement of Fill Tube Plug . . . . . . . 5–74
e. Output Shaft Bushing Replacement . . . 5–97
f. Replacement of Vent Assembly . . . . . . 5–75 f. Assembly of Rear Cover . . . . . . . . . . . . 5–98
5–12. RING GEAR AND CLUTCH COMPONENT 5–18. OUTPUT YOKE INSPECTION . . . . . . . . 5–99
INSPECTIONS 5–19. CONTROL VALVE MODULE
a. C3 Clutch Component Inspection . . . . 5–75 a. Disassembly of Control
b. C3 Clutch Backplate Assembly Valve Assembly . . . . . . . . . . . . . . . . . 5–100
Thrust Plate Replacement . . . . . . . . . . . 5–79 b. Disassembly of Shift Valve Body. . . . 5–104
c. Disassembly of Modulated Main Valve
c. C4 Clutch Component Inspection . . . . . 5–80
Body . . . . . . . . . . . . . . . . . . . . . . . . . . 5–107
d. C5 Clutch Component Inspection . . . . . 5–83 d. A/B Solenoid Bracket Inspection . . . . 5–108
e. P1 Ring Gear Inspection . . . . . . . . . . . . 5–85 e. Assembly of Shift Valve Body . . . . . . 5–108

x Copyright © 2004 General Motors Corp.

 TABLE OF CONTENTS
Paragraph Page Paragraph Page

f. Disassembly of the Main Valve 6–16. TRANSMISSION END PLAY CHECK . . 6–25
Body . . . . . . . . . . . . . . . . . . . . . . . . . . . 5–111
g. Dowel Pin Replacement . . . . . . . . . . . 5–113 6–17. TORQUE CONVERTER
INSTALLATION . . . . . . . . . . . . . . . . . . . . 6–26
h. Assembly of the Main Valve Body . . . 5–114
i. Assembly of Control Valve 6–18. NSBU SWITCH INSTALLATION
Assembly . . . . . . . . . . . . . . . . . . . . . . . 5–115 (IF PRESENT). . . . . . . . . . . . . . . . . . . . . . . 6–28
j. Assembly of Modulated Main Valve
Body . . . . . . . . . . . . . . . . . . . . . . . . . . . 5–120 6–19. REAR SEAL INSTALLATION
(2WD TRANSMISSIONS ONLY). . . . . . . 6–31
Section 6. TRANSMISSION ASSEMBLY 6–20. OUTPUT NUT INSTALLATION
6–1. C3 CLUTCH INSTALLATION . . . . . . . . . . 6–1 (4WD TRANSMISSIONS ONLY). . . . . . . 6–31
6–2. P1 PLANETARY MODULE AND 6–21. VENT INSTALLATION . . . . . . . . . . . . . . 6–33
C4 CLUTCH INSTALLATION . . . . . . . . . . 6–3
6–22, INPUT SPEED SENSOR
6–3. C5 CLUTCH REACTION PLATE
INSTALLATION . . . . . . . . . . . . . . . . . . . . 6–33
SELECTION . . . . . . . . . . . . . . . . . . . . . . . . . 6–7
6–4. P2 PLANETARY MODULE AND 6–23. TURBINE SPEED SENSOR
MAIN SHAFT INSTALLATION . . . . . . . . 6–9 INSTALLATION . . . . . . . . . . . . . . . . . . . . 6–34
6–5. C5 CLUTCH INSTALLATION . . . . . . . . . 6–10 6–24. OUTPUT SPEED SENSOR
6–6. PARK PAWL INSTALLATION . . . . . . . . 6–11 INSTALLATION
(2WD TRANSMISSIONS ONLY). . . . . . . 6–34
6–7. OUTPUT SHAFT AND P3 PLANETARY
CARRIER ASSEMBLY 6–25. REMOVAL OF TRANSMISSION FROM
INSTALLATION . . . . . . . . . . . . . . . . . . . . 6–12 REPAIR STAND. . . . . . . . . . . . . . . . . . . . . 6–35
6–8. REAR COVER ASSEMBLY
INSTALLATION . . . . . . . . . . . . . . . . . . . . 6–12
Section 7. WEAR LIMITS AND
6–9. CONTROL VALVE ASSEMBLY SPRING DATA
INSTALLATION . . . . . . . . . . . . . . . . . . . . 6–15
6–10. WIRING HARNESS ASSEMBLY 7–1. WEAR LIMITS DATA
INSTALLATION . . . . . . . . . . . . . . . . . . . . 6–17
a. Maximum Variations . . . . . . . . . . . . . . . . 7–1
6–11. OIL PAN AND SUCTION FILTER
b. Cleaning and Inspection. . . . . . . . . . . . . . 7–1
INSTALLATION . . . . . . . . . . . . . . . . . . . . 6–18
6–12. ROTATING CLUTCH ASSEMBLY
7–2. SPRING DATA
INSTALLATION . . . . . . . . . . . . . . . . . . . . 6–19
a. Spring Replacement . . . . . . . . . . . . . . . . . 7–1
6–13. CONVERTER HOUSING/FRONT
SUPPORT MODULE INSTALLATION . . 6–20 b. Inspection . . . . . . . . . . . . . . . . . . . . . . . . . 7–1
6–14. REAR COVER SELECTIVE
SPACER INSTALLATION
Section 8. CUSTOMER SERVICE
(2WD TRANSMISSIONS ONLY). . . . . . . 6–22
6–15. REAR COVER SELECTIVE 8–1. OWNER ASSISTANCE . . . . . . . . . . . . . . . . 8–1
SPACER INSTALLATION
(4WD TRANSMISSIONS ONLY). . . . . . . 6–23 8–2. SERVICE LITERATURE. . . . . . . . . . . . . . . 8–2

Copyright © 2004 General Motors Corp. xi

 1000 AND 2000 PRODUCT FAMILIES SERVICE MANUAL

LIST OF FOLDOUT ILLUSTRATIONS

(Back of Service Manual)
CROSS-SECTION VIEWS
Foldout
1 1000 Product Family
2 2000 Product Family
3 2000 Product Family with Park Pawl
4 1000 Product Family Direct Mount with Transfer Case Adapter
EXPLODED VIEWS
5A SAE No. 3 Torque Converter Housing with Integral Cooling Ports
5B SAE No. 2 Torque Converter Housing with Manifold
5C SAE No. 3 Torque Converter Housing with Manifold
5D Direct Mount—Torque Converter Housing
6 Converter Housing/Front Support Module, Rotating Clutch Housing, and C3 Clutch Components
6A Converter Housing/Front Support Module Components
7 Front Support Module Components
8 Main Pump Assembly Components
9 Front Support Assembly Components
10 Rotating Clutch Assembly Components
11 Oil Pan and Suction Filter Components
12 Main Housing Components
13 C4 and C5 Clutch Components
14,A P1 Planetary Module, P2 Planetary Module, and Main Shaft Components
14,B P2 Planetary Module Components
14,C P3 Planetary Module
15,A P1 Planetary Carrier Assembly Components
15,B P2 Planetary Carrier Assembly Components
16,A P3 Planetary Assembly, Output Shaft, C5 Piston Return Assembly, and Park Pawl Components
16,B Rear Cover Assemblies
17 P3 Planetary Carrier Assembly
18A Rear Cover Assembly Components, 10 x 3
18B Rear Cover Assembly Components, Non-Park Brake
18C Rear Cover Assembly Components, Transfer Case
18D Rear Cover Assembly Components, 9 x 3
19A Control Valve Assembly Components
19B Shift Valve Body Assembly Components
19C Main Valve Body Assembly Components
19D Modulated Main Valve Body
20 Vent Hose and Yokes/Flanges
21 1000 and 2000 Product Families Hydraulic Schematic—Neutral/Park
22 1000 and 2000 Product Families Hydraulic Schematic—First Range
23 1000 and 2000 Product Families Hydraulic Schematic—Second Range
24 1000 and 2000 Product Families Hydraulic Schematic—Third Range
25 1000 and 2000 Product Families Hydraulic Schematic—Fourth Range
26 1000 and 2000 Product Families Hydraulic Schematic—Fifth Range
27 1000 and 2000 Product Families Hydraulic Schematic—Reverse (With N04 Software and Later)
28 1000 and 2000 Product Families Hydraulic Schematic—Reverse (Prior to and Including N04 Software)
29 1000 and 2000 Product Families Hydraulic Schematic—Default Reverse (“Limp Home”)
30 1000 and 2000 Product Families Hydraulic Schematic—Default Forward (3rd Range “Limp Home”)

xii Copyright © 2004 General Motors Corp.

 SECTION 1—GENERAL INFORMATION
1–1. SCOPE OF MANUAL e. MY04i Parts Changes. MY04i parts and former
parts are not interchangeable. Parts changed by MY04i
a. Transmission Product Families And Model are:
Years. The 1000 and 2000 Product Families include • Front Support Assembly and Bearing
the 1000/2000/2400 Series. The following provides
• Main Regulator Valve
guidance in distinguishing between the various
1000 and 2000 Product Families transmissions and • Converter Relief Valve
1000/2000/2400 Series transmissions models and the • Lube Regulator Valve
content of the various model years. Model Year and se-
rial number breaks identify engineering changes. • Lube Regulator Spring
• Lube Regulator Stop
b. Model Year 04 (MY04) (refer to SIL 13-1K2K-03).
MY04, June 2003, introduced modulated main pres- • Lube Regulator O-ring deleted
sure hardware and the associated calibration software. • C1 Clutch Backfill Valve
The serial number breaks for MY04 are:
• C1 Clutch Backfill Spring
• Indianapolis units:
• C1 Clutch Backfill Stop
— 6310292155 through 6310292563
• Converter Flow Valve
6310296468 through 6310296471
6310301450 through 6310301451 • Retaining Clip replaces a retaining pin
6310303122 through 6310303124 • Converter/Main Housing Separator Plate
6310307722—start of MY04 production • Pump Assembly
• Baltimore units: • Pump Wear Plate
— 6320218358 through 6320218387 f. Improved Shift Valve Body Casting. Serial
6320247492 through 6320248001 number breaks for 1000 and 2000 Product Families
6320269500—start of MY04 production improved Shift Valve Body casting are:
c. MY04 Parts Changes. MY04 parts and former • Indianapolis Units—6310368401
parts are not interchangeable. Parts changed by MY04
• Baltimore Units—6320354862
are:
• Internal Wiring Harness
g. Vocational Models (refer to WATCH 309). Be-
ginning January 2004, Allison Transmission began
• Separator Plate shipping new 1000 and 2000 Product Families trans-
• Modulated Main Body Assembly mission models for North America. 1000 and 2000
Product Families models are:
• Modulated Main Body
• Emergency Vehicle Series—1000 EVS,
• Shift Valve Body 2100 EVS, 2200 EVS, 2500 EVS
• Main Valve Body • Highway Series—1000 HS, 2100 HS,
• Control Main Valve
2200 HS, 2500 HS
• Motorhome Series—1000 MH, 2100 MH,
• Control Main Regulator and Control Main
2200 MH, 2500 MH
Relief Spring
• Pupil Transport/Shuttle Series—1000 PTS,
• Main Pressure Regulator Valve
2100 PTS, 2200 PTS, 2500 PTS
d. Model Year 04i (MY04i) (refer to SIL 3-1K2K-04). • Rugged Duty Series—1000 RDS, 2100 RDS,
1000 and 2000 Product Families MY04i serial number 2200 RDS, 2500 RDS
breaks are:
• Specialty Series—1000 SP, 2100 SP, 2200 SP,
• S/N 6310374684 (Indianapolis) 2500 SP
• S/N 6320367833 (Baltimore) • Bus Series—B210, B220

Copyright © 2004 General Motors Corp. 1–1

 1000 AND 2000 PRODUCT FAMILIES SERVICE MANUAL
h. Vocational Model Nomenclature. The first digit 2. The work environment is suitable to prevent
of the nomenclature indicates the product family— contamination or damage to transmission parts
1000, 2000. The second digit (0–4) indicates close or assemblies.
ratio, or (5) wide ratio.
3. The required tools and fixtures, listed in
i. Content and Organization. This Service Manual Table 3–1 (Section 3 of this manual), are avail-
describes overhaul procedures for 1000 and 2000 Prod- able.
uct Families automatic transmissions (Figures 1–1 and
1–2). All 1000 and 2000 Product Families vocational 4. Reasonable and prudent maintenance prac-
models are included in this manual as are all 1000/ tices are used.
2000/2400 Series transmissions.
• Major transmission components are described NOTE:
and their functions explained. Service organizations and individuals are
encouraged to contact their local Allison
• Detailed instructions are provided for
Transmission Distributor for information and
disassembly, rebuild, and re-assembly.
guidance on any task outlined in this manual.
• Part inspection instructions are in Section 3.

• Wear limits and spring data are in Section 7.

1–2. SUPPLEMENTARY
j. Illustrations
INFORMATION
1. The text is supported with line drawings, ex-
Supplementary information will be issued, as required,
ploded, and cross-sectional views. Overhaul
if any changes occur after publication of this manual.
procedures are illustrated by line drawings.
Check with your dealer or distributor to be sure you
Cross-sections show the relationship of assem-
have the latest information.
bled parts. Cross-sections and exploded views
are on foldout pages in the back of the manual.

2. Illustrations show correct procedures for all

1–3. ORDERING PARTS
models—including models not illustrated.
a. Transmission Nameplate. The nameplate (1)
k. Maintenance Information. Each task described (Figure 1–3) is located on the right side of the
in this manual has been successfully completed by transmission. The nameplate will be one of two styles
service organizations and individuals. Not every (Figures 1–4 and 1–5). Both nameplates are imprinted
service organization or individual possesses the with the transmission model, serial number,
required special tooling, training, or experience to transmission identification number, engineering group
perform all described tasks. However, any task may be number, engineering feature configuration number,
performed if the following conditions are met: and date of manufacture. Use all of these numbers
when ordering replacement parts or requesting service
1. The organization or individual has the required information.
knowledge of the task through:
b. Parts Catalog. Replacement parts are listed in
• Formal instruction at Allison Transmission Parts Catalog PC3062EN. Do not order by the item
or a Distributor training facility. numbers used on exploded views in this manual. Use
the Parts Catalog to determine the correct part number.
• On-the-job instruction by an Allison Order all replacement parts from your distributor or
Transmission or Distributor representative. authorized dealer. Check the Yellow Pages for your
nearest authorized service outlet. Listings are under
• Experience in performing the task. Transmission—Truck, Tractor, Etc.

1–2 Copyright © 2004 General Motors Corp.

 GENERAL INFORMATION

OIL VENT
(BREATHER) PARKING BRAKE
MOUNTING PROVISION
TURBINE SPEED
SENSOR
INPUT SPEED
SENSOR
OUTPUT SPEED SENSOR

NSBU SWITCH
SELECTOR SHAFT
SAE 6-BOLT
PTO PAD
(DRIVE GEAR OPTIONAL)
AVAILABLE
OIL FILL TUBE
LOCATION
CONTROL MAIN OIL FILTER

V04779.03.00

Figure 1–1. 1000 and 2000 Product Families Transmission—Left-Front View

INPUT SPEED
SENSOR
TURBINE SPEED
SENSOR

OIL VENT
(BREATHER)

OUTPUT SPEED
SENSOR

MOUNTING PAD
(SAE #3 HOUSING ONLY)
COOLER PORTS
AVAILABLE
OIL FILL TUBE
LOCATION
PROVISION FOR SAE 6-BOLT
CUSTOMER-SUPPLIED PTO PAD
SPEED SENSOR OR (DRIVE GEAR OPTIONAL)
TACHOGRAPH
(OPRIONAL) MAIN ELECTRICAL
CONNECTOR

V04780.01.04

Figure 1–2. 1000 and 2000 Product Families Transmission—Right-Rear View

Copyright © 2004 General Motors Corp. 1–3

 1000 AND 2000 PRODUCT FAMILIES SERVICE MANUAL

DIV. OF GENERAL MOTORS CORP.

INDIANAPOLIS, INDIANA, USA

MODEL DATE
XXXXXXXXXX XXXXX
SERIAL NO. EFCN TID
XXXXXXXXXX XXXXXXXX XX
XX–XXXX XX–XXXX XX–XXXX
XX–XXXX XX–XXXX XX–XXXX
XX–XXXX XX–XXXX XX–XXXX
XX–XXXX XX–XXXX XX–XXXX

V06183

Figure 1–3. 1000 and 2000 Product Families Transmission Nameplate Location

DIV. OF GENERAL MOTORS CORP.

INDIANAPOLIS, INDIANA, USA

MODEL DATE
XXXXXXXXXX XXXXX
SERIAL NO. EFCN TID
XXXXXXXXXX XXXXXXXX XX
XX–XXXX XX–XXXX XX–XXXX
XX–XXXX XX–XXXX XX–XXXX
XX–XXXX XX–XXXX XX–XXXX
XX–XXXX XX–XXXX XX–XXXX

V06533

Legend
(1) Model (Series) (4) Transmission Identification Number
(2) Date of Manufacture (5) Engineering Group Number
(3) Engineering Feature Configuration Number (6) Serial Number

Figure 1–4. 1000 and 2000 Product Families Transmission Nameplate Components

1–4 Copyright © 2004 General Motors Corp.

 GENERAL INFORMATION

ICULTURA
AGR L
D IM
AN

PL
E

EM
ILE AEROSPAC
UAW

ENT
WORKERS
933

OB
OM

OF
UT AM
DA ERI
UNITE CA

DIVISION OF GENERAL MOTORS CORP.

INDIANAPOLIS, INDIANA

MODEL XX–XXXX XX–XXXX

1000SERIES
DATE TID XX–XXXX XX–XXXX
XXXXX XX XX–XXXX XX–XXXX
SERIAL NO.
XXXXXXXXXX XX–XXXX XX–XXXX
EFCN
XXXXXXX XX–XXXX XX–XXXX

Legend
(1) Model (Series) (4) Engineering Feature Configuration Number
(2) Engineering Group Number (5) Serial Number
(3) Transmission Identification Number (6) Date of Manufacture

Figure 1–5. 1000 and 2000 Product Families Transmission Nameplate Components (Before March, 2000)

1–4. GENERAL DESCRIPTION the torque converter clutch (TCC) is automati-

cally engaged to provide direct drive from the
a. Transmission Design Features. Allison 1000 and engine to the transmission. Hydraulic fluid for
2000 Product Families (Figures 1–1 and 1–2) are converter charging pressure comes from the
torque-converter driven, electronically controlled, sump and is supplied by the input pump. The
fully automatic transmission systems. The 1000 and torque converter clutch is applied or released by
2000 Product Families transmissions have up to five changing direction of fluid in the torque con-
forward speeds, neutral, and reverse. The fifth range verter. An integral converter damper minimizes
has an overdrive gear ratio. The 1000 and 2000 Product the need for additional engine vibration control.
Families incorporate a variety of standard and optional 3. Planetary Gearing. The planetary gear train in-
design features. cludes three constant-mesh, helical gear plane-
tary sets. By the engagement of clutches in
1. Transmission-to-Engine Coupling. The con-
verter housings of 1000 and 2000 Product Fami- various combinations, the planetary sets act
lies transmissions mate directly to SAE No. 2 singly or together to provide five forward
or No. 3 flywheel housings or to the engine ranges, neutral, and reverse.
block in some cases. Flexplate drive is used for
engine-to-transmission torque transfer. 4. Clutches. Five clutches (two rotating and three
stationary) direct the flow of torque through
2. Torque Converter. Several torque converters are the transmission. All range clutches are hy-
available to match the transmissions to a wide draulically-actuated and spring-released, with
variety of diesel and gasoline engines. The automatic wear compensation. Clutches are
torque converter is a single-stage, polyphase, cooled by the transmission fluid. The transmis-
three-element unit, consisting of a pump, sta- sion electronic control module signals solenoid
tor, and turbine. At lower output speeds, the valves to apply and release clutches based on
torque converter multiplies torque and provides speed and power combinations and the range
a fluid coupling to the engine. At higher speeds, selected by the operator.

Copyright © 2004 General Motors Corp. 1–5

 1000 AND 2000 PRODUCT FAMILIES SERVICE MANUAL
5. Hydraulic System. A common hydraulic sys- dipstick provision on both sides of the
tem serves the torque converter and the trans- transmission. The fill tube and dipstick are
mission. Transmission fluid for all hydraulic OEM-installed and adapted as specified by the
operations, lubrication, and cooling comes vehicle manufacturer. A plug is installed in the
from the sump and is supplied by the charging unused location.
pump.
10. Parking Pawl/Parking Brake
6. Transmission Fluid Filtration. Fluid filtration
is provided by two filter systems. A suction fil-
• All 1000 models, 2200 models, 1000 Series™,
ter, located in the sump, provides general pro-
and 2400 Series™ transmissions have a
tection to the entire hydraulic system by
park pawl. The internal parking pawl is
filtering large particulates. A spin-on filter pro-
engaged by selection of the P (Park)
vides full-time protection for the control sole-
position on the shift selector. The parking
noids and multipass protection for the entire
pawl is not available on 2100 and 2500
system. The spin-on filter is externally located
models and 2000 Series™ models.
on the converter housing at the lower left front
of the transmission. • Some 1000 and 2000 Product Families
models are available with an optional rear
7. Electronic Controls
cover that accommodates an OEM-installed
• A microcomputer provides electronically- two-shoe, expanding-type drum brake. All
controlled automatic gear selection and parking brake controls and linkages are OEM-
automatic engagement of the torque supplied.
converter clutch. The microcomputer is an
independent controller and is referred to as 11. Power Takeoff. 1000 and 2000 Product
a Transmission Control Module, or TCM. Families transmissions, except Highway Series
and Pupil Transport/Shuttle Series, and all
• The electronic control system uses adaptive 1000/2000/2400 Series transmissions have a
logic to provide optimum shift quality. provision to drive a power takeoff (PTO) unit
Driving efficiency is improved by shifting mounted on the left and/or right side of the
at the exact programmed transmission shift transmission housing. The optional PTO drive
point for every engine/transmission/vehicle gear is driven by the transmission torque
combination. The electronic controls can be converter turbine, with speed and torque
customized for four-speed or five-speed reflecting engine input and the characteristics
operation to meet vocational requirements. of the torque converter. PTO units and
associated controls are provided by the vehicle
8. Remote Oil Cooler. Ports for remote-mount oil manufacturer and/or body builder.
cooler lines are located on the bottom surface
12. Output Yokes/Flanges. A variety of output
of the converter housing near the converter yokes or flanges are available to meet vehicle
housing/main housing splitline or on the right driveline requirements. Yokes or flanges are
side of the direct-mount converter housing. OEM-installed and are adapted as specified by
Remote oil-to-water coolers require plumbing the vehicle manufacturer.
for transmission fluid and engine-cooling
water. Remote oil-to-air coolers may also be
used and only transmission fluid lines need to WARNING!
be provided. Heat is transferred from the Operation with excessive loads can cause trans-
transmission fluid to either water or air mission damage and unexpected vehicle move-
depending upon the cooler type used. ment. To help avoid injury, property damage,
and/or transmission damage, do not exceed
9. Oil Fill Tube/Dipstick Provisions. All 1000 and 11 800 kg (26,000 lbs) GCW or the OEM vehicle
2000 Product Families models have a fill tube/ rating, whichever is less.

1–6 Copyright © 2004 General Motors Corp.

 GENERAL INFORMATION
b. General Description. Several transmission
configurations are available within the 1000 and 2000 NOTE:
Product Families. The CHECK ENGINE light may serve the CHECK
TRANS function for vehicles which are compliant
1000* Heavy-duty automatic transmission with to industry On Board Diagnostics II (OBD-II) re-
parking pawl quirements.
Maximum GVW 19,850 lb
Maximum GCW 26,000 lb
3. When the CHECK TRANS light is “ON”,
2000 Heavy-duty automatic transmission shifts may be restricted by the Transmission
2100 without parking pawl Control Module (TCM) as follows:
2500* Maximum GVW 30,000 lb
Maximum GCW 30,000 lb WARNING!
2100 MH Heavy-duty automatic transmission with- If ignition is turned “OFF” and then “ON” while
2500 MH* out parking pawl the CHECK TRANS light is displayed, the trans-
Limited release in motorhome mission may remain in neutral until the code is
applications only cleared. Leave ignition “ON” until you are in a
safe place to stop.
Maximum GVW 28,000 lb
Maximum GCW 28,000 lb • When the TCM senses abnormal
1000 MH Heavy-duty automatic transmission with conditions.
2200 MH* parking pawl • The transmission may be locked in the
Limited release in motorhome range it was in when the problem was
applications only detected.
Maximum GVW 28,000 lb • The transmission may continue to operate
Maximum GCW 28,000 lb with inhibited shifting.
2200 Heavy-duty automatic transmission with • The TCM may not respond to shift selector
2400* parking pawl requests.
Maximum GVW 26,000 lb • Direction changes and shifts from neutral-
Maximum GCW 26,000 lb to-range may not occur.
* GVW rating, GCW rating, or OEM axle rating, whichever is less. • Whenever the CHECK TRANS light is
displayed, the TCM logs a diagnostic code
1–5. DIAGNOSIS in memory. These diagnostic codes can be
accessed through the PC-based Allison
NOTE: DOC™ diagnostic systems.
Refer to the TS3192EN, 1000 and 2000 Product Fam-
ilies Troubleshooting Manual, for in-depth trouble- NOTE:
shooting procedures. Diagnostic codes can be logged without illuminating
the CHECK TRANS light. This occurs when the
a. Before Starting. Before attempting to repair the TCM senses a problem, but determines the problem
transmission, identify the faulty condition and its won’t cause immediate transmission damage or
probable cause. dangerous performance.

b. CHECK TRANS Light c. Range Inhibit Indicator

1. The CHECK TRANS light is original equip- 1. Some conditions detected by the TCM cause
ment manufacturer (OEM)-supplied and usu- the transmission to be locked in one range.
ally located on the vehicle’s instrument panel. When this occurs, the torque converter clutch
2. The CHECK TRANS light is illuminated is automatically disengaged. Shifts out of
briefly during vehicle start-up as a bulb check. N (Neutral) may be inhibited.

Copyright © 2004 General Motors Corp. 1–7

 1000 AND 2000 PRODUCT FAMILIES SERVICE MANUAL
2. At the same time these events occur, a required — Make sure throttle is closed and engine
OEM-supplied RANGE INHIBITED light, speed is below 900 rpm.
mounted on the dash or near the shift selector, — Make sure electrical connections are
is illuminated. This notifies the driver that properly made.
shifting is inhibited and the shift selector may
not respond to shifts requested. — Check support equipment for proper
installation and operation.
d. Allison DOC™ Personal Computer (PC)- • If the shifting process is rough, give the shifts
Based Diagnostic System. Allison Diagnostic Opti- time to adapt to “converged” state before
mized Connection™ (Allison DOC™) provides tabu- assuming there is a problem.
lar, graphical, and chart displays of real-time and re-
corded TCM data. A Help system is incorporated into • Refer to Section 7 “General Troubleshooting
the Allison DOC™ software. Allison Diagnostic Opti- of Performance Complaints” in the 1000 and
mized Connection™ (Allison DOC™) software and 2000 Product Families Troubleshooting
interface devices are available through Allison Trans- Manual TS3192EN.
mission tool sources. — These troubleshooting charts list a variety
1. A PC serves as the receiver/transmitter/display of conditions that may or may not relate to
medium that allows the service technician to the TCM.
communicate with the TCM. Typical trouble- — Some conditions and suggested checks
shooting activities performed are installation include mechanical and hydraulic items.
checkout and diagnostic trouble code (DTC) • If the troubleshooting charts refer you to a
retrieval. TCM check, use the diagnostic code
troubleshooting information that best applies
2. The Allison DOC™ Help system contains in-
to the situation.
formation for performing the following:
f. Troubleshooting Intermittent Diagnostic
• Display (retrieve) DTCs. Transmission
Codes. Intermittent codes are a result of conditions
diagnostic codes begin with P0, P1, U1, or which are not always present.
U2 followed immediately by three
additional numbers. For a complete list of 1. When conditions causing the code exist, the
codes and more detailed information, refer code is logged in memory. The code stays in
to 1000 and 2000 Product Families memory until it is manually cleared or cycled
Electronic Troubleshooting Manual out by forty code-free warm-up cycles.
TS3192EN.
2. When intermittently occurring codes exist,
• Clear diagnostic codes check for the following items:
• Obtain transmission data such as input
speed or sump fluid temperature • Dirty, damaged or corroded harness
connectors and terminals
• A solenoid test
• Terminals not fully seated in connectors
• Clutch diagnostics (including torque
converter clutch) • Damaged harnesses (due to poor routing,
chafing, excessive heat, tight bends, etc.)
e. Troubleshooting When No Diagnostic Codes
Are Present • Improperly mounted electronic control
components
• Always start with the basics:
• Poor connector seals (where applicable)
— Make sure the shifter is in the appropriate
range. • Exposed harness wires
— Check the fluid level. • EMI generating components and
— Make sure batteries are properly connected accessories
and charged. • Loose ground connections

1–8 Copyright © 2004 General Motors Corp.

 GENERAL INFORMATION
3. To help locate intermittents, it sometimes helps d. One Year Storage (With Fluid)
to place the appropriate tester on the suspect
component or circuit and simulate operating 1. Drain the fluid and replace the oil filter elements.
conditions—wiggle, pull, bump, and bend 2. Fill the transmission to operating level with a
while watching the tester. mixture of one part VCI #10 (or equivalent) to
30 parts TranSynd™ or DEXRON®-III
1–6. PRESERVATION AND STORAGE transmission fluid. Add 3 ml of Biobor® JF (or
equivalent) for every 10 liters (1⁄4 teaspoon per
a. Storage (New Transmissions, Before Installa- gallon) of fluid in the system.
tion). New transmissions are filled with transmission
fluid and drained before shipment. The residual fluid NOTE:
in the transmission provides adequate protection to
safely store the transmission without further treatment When calculating the amount of Biobor® JF
for one full year if stored indoors, in conditions of nor- required, use the total volume of the system, not just
the quantity required to fill the transmission.
mal climate, and with all shipping plugs installed.
Include external lines, filters, and the cooler.
b. Preservation Methods. When the transmission is
stored or inactive for an extended period (one or more
years), specific preservation methods are required to 3. Operate the transmission for approximately
prevent damage from rust, corrosion, and organic five minutes at 1500 rpm with the transmission
growth in the transmission fluid. Preservation methods in neutral.
described are for storage with or without transmission 4. Make sure the transmission shifts through all
fluid. The methods are the same whether a transmis-
ranges and that the lockup clutch is also activated.
sion is in or out of a vehicle.
c. One Year Storage (Without Fluid) 5. Continue operating the transmission in neutral
at 1500 rpm until normal operating tempera-
1. Drain the fluid. ture is reached.
2. Remove the vent assembly per Paragraph 5–11f.
CAUTION:
3. Spray 30 ml (one ounce) of VCI #10 (or If the unit does not have a converter-out temper-
equivalent) into the transmission through the ature gauge, do not stall the converter.
vent assembly hole. Also, spray 30 ml (one
ounce) through the fill tube hole. 6. If normal operating temperature is less than
4. Install the vent assembly per Paragraph 5–11f. 107°C (225°F), shift the transmission to for-
ward range and stall the converter. Do not ex-
5. Seal all openings and the vent assembly with ceed 107°C (225°F).
moisture-proof tape.
7. As soon as the transmission is cool enough to
6. Coat all exposed, unpainted surfaces with pre-
touch, seal all openings and the vent assembly
servative grease such as petrolatum (MIL-C-
with moisture-proof tape.
11796, Class 2).
7. If additional storage time is required, do the 8. Coat all exposed, unpainted surfaces with pre-
following at yearly intervals. servative grease such as petrolatum (MIL-C-
11796), Class 2.
• Wash all external grease from the
transmission with mineral spirits. 9. If additional storage time is required, repeat
Steps 2 through 8 at yearly intervals, except, it
• Remove all tape from openings and the vent
is not necessary to drain the transmission each
assembly. year. Just add VCI #10 and Biobor® JF (or
• Repeat Steps (2) through (6). equivalents).

Copyright © 2004 General Motors Corp. 1–9

 1000 AND 2000 PRODUCT FAMILIES SERVICE MANUAL
1–7. RESTORING TRANSMISSION and refill the transmission with new transmission fluid.
TO SERVICE Check for proper fluid level. Add or drain transmission
fluid, as required, to obtain the proper level.
a. Transmission Exterior. Wash all external grease
from the transmission with mineral spirits.

b. Sealed Vent Assembly and Openings. Remove 1–8. OPERATING INSTRUCTIONS

all tape from openings and the vent assembly.

c. New Transmissions. If the transmission is new, WARNING!

drain the residual preservative oil. Refill the
transmission to the proper level with TranSynd™ or Operation with excessive loads can cause trans-
mission damage and unexpected vehicle move-
DEXRON®-III transmission fluid.
ment. To help avoid injury, property damage,
d. Stored Without Fluid. If the transmission was pre- and/or transmission damage, do not exceed
pared for storage without fluid, drain the residual fluid 11 800 kg (26,000 lbs) GCW or the OEM vehicle
rating, whichever is less.
and replace the oil filter elements. Refill the transmission
to the proper level with TranSynd™ or DEXRON®-III
transmission fluid.
Detailed transmission operation information is in the
1000 and 2000 Product Families Principles of Operation
CAUTION: Manual, PO3065EN, or the 1000 and 2000 Product
When a transmission has been stored, the TCM Families operator’s manuals. Refer to the latest edition.
must be reset to unadapted shifts. Resetting to
unadapted shifts erases previous shift adapta-
tions and allows the transmission to begin using
Fast Adaptive mode to regain adapted shifts. Use
1–9. SPECIFICATIONS AND DATA
Allison DOC™ to reset to unadapted shifts. The following specifications and data provide a quick
reference to the major characteristics of the transmis-
e. Stored With Fluid. If the transmission was pre- sion. More detailed information may be obtained from
pared for storage with fluid, it is not necessary to drain Tech Data Book SA3018EN.

1–10 Copyright © 2004 General Motors Corp.

 Table 1–1. Specifications and Data Chart for 1000 and 2000 Product Families

Max Net
Input Max Net Full Load
Torque Input Max Net Governed
Without Torque Input Max Turbine Speed Max Output
SEM With SEM Power Torque (Min–Max) Max GVW Max GCW Shaft Speed

N·m lb ft N·m lb ft kW hp N·m lb ft rpm kg lbs kg lbs rpm

1000 HS 746 550 766 565 254 340 1152 850 2200–4600 8845 19,000 11 800 26,000 5000
1000 RDS 746 550 766 565 254 340 1152 850 2200–4600 8845 19,000 11 800 26,000 5000
1000 PTS 746 550 766 565 254 340 1152 850 2200–4600 8845 19,000 11 800 26,000 5000
1000 EVS 746 550 766 565 254 340 1152 850 2200–4600 8845 19,000 11 800 26,000 5000
1000 MH 746 550 766 565 254 340 1152 850 2200–4600 10 000 22,000 11 800 26,000 5000
1000 SP 746 550 N/A N/A 254 340 1152 850 2200–4600 10 000 22,000 11 800 26,000 5000
B 210 746 550 766 565 254 340 1152 850 2200–4600 11 800 26,000 N/A N/A 5000
2000 MH N/A N/A 813 600 224 300 1152 850 2200–4600 12 700 28,000 12 700 28,000 4500
2100 HS 746 550 766 565 254 340 1152 850 2200–4600 11 800 26,000 11 800 26,000 4500

Copyright © 2004 General Motors Corp.

2100 RDS 746 550 766 565 254 340 1152 850 2200–4600 11 800 26,000 11 800 26,000 4500
GENERAL INFORMATION

2100 PTS 746 550 766 565 254 340 1152 850 2200–4600 11 800 26,000 11 800 26,000 4500
2100 EVS 746 550 766 565 254 340 1152 850 2200–4600 11 800 26,000 11 800 26,000 4500
2100 MH 746 550 766 565 254 340 1152 850 2200–4600 11 800 26,000 11 800 26,000 4500
2100 SP 740 545 N/A N/A 224 300 1150 850 2200–4600 12,000 26,500 13 600 30,000 4500
2200 HS 746 550 766 565 254 340 1152 850 2200–4600 11 800 26,000 11 800 26,000 4500
2200 RDS 746 550 766 565 254 340 1152 850 2200–4600 11 800 26,000 11 800 26,000 4500
2200 PTS 746 550 766 565 254 340 1152 850 2200–4600 11 800 26,000 11 800 26,000 4500

1–11
 Table 1–1. Specifications and Data Chart for 1000 and 2000 Product Families (cont’d)

1–12
Max Net
Input Max Net Full Load
Torque Input Max Net Governed
Without Torque Input Max Turbine Speed Max Output
SEM With SEM Power Torque (Min–Max) Max GVW Max GCW Shaft Speed

N·m lb ft N·m lb ft kW hp N·m lb ft rpm kg lbs kg lbs rpm

2200 EVS 746 550 766 565 254 340 1152 850 2200–4600 11 800 26,000 11 800 26,000 4500
2200 MH 746 550 766 565 254 340 1152 850 2200–4600 11 800 26,000 11 800 26,000 4500
2200 SP 740 545 N/A N/A 224 300 1150 850 2200–4600 11 800 26,000 11 800 26,000 4500
B 220 576 425 630 465 149 200 1017 750 2200–4600 11 800 26,000 N/A N/A 4500
2500 HS 746 550 766 565 224 300 1152 850 2200–4600 15 000 33,000 15 000 33,000 4500
2500 RDS 746 550 766 565 224 300 1152 850 2200–4600 15 000 33,000 15 000 33,000 4500
Refuse 746 550 766 565 224 300 1152 850 2200–4600 15 000 33,000 15 000 33,000 4500
2500 PTS 746 550 766 565 224 300 1152 850 2200–4600 15 000 33,000 15 000 33,000 4500
2500 EVS 746 550 766 565 224 300 1152 850 2200–4600 15 000 33,000 15 000 33,000 4500

Copyright © 2004 General Motors Corp.

2500 MH 746 550 766 565 224 300 1152 850 2200–4600 15 000 33,000 15 000 33,000 4500
GENERAL INFORMATION

2500 SP 740 545 N/A N/A 224 300 1152 850 2200–4600 15 000 33,000 15 000 33,000 4500
 GENERAL INFORMATION
Table 1–1. Specifications And Data Chart*

INPUT/OUTPUT RATINGS (1000 Models):

Refuse
Input Speed** General*** (On-Highway) Motorhome Transit Bus
Max Full Load Gov. Speed 4600 rpm 4600 rpm 4600 rpm 4600 rpm
Min Full Load Gov. Speed 2200 rpm 2200 rpm 2200 rpm 2200 rpm
Max Idle Speed in Drive 900 rpm 900 rpm 900 rpm 900 rpm
Min Idle Speed in Drive 500 rpm 500 rpm 500 rpm 500 rpm
Input Power
254 kW 254 kW 254 kW 134 kW
Maximum Net
(340 hp) (340 hp) (340 hp) (180 hp)
Input Torque
705 N·m 705 N·m 705 N·m 603 N·m
Maximum Net
(520 lb ft) (520 lb ft) (520 lb ft) (445 lb ft)
Turbine Torque
1152 N·m 1152 N·m 1152 N·m 1017 N·m
Maximum Net
(850 lb ft) (850 lb ft) (850 lb ft) (750 lb ft)
Output Shaft Speed
Maximum Speed 5000 rpm 5000 rpm 5000 rpm 5000 rpm
Other
9000 kg 7500 kg 9980 kg 7500 kg
Gross Vehicle Weight (GVW)
(19,850 lbs) (16,540 lbs) (22,000 lbs) (16,540 lbs)
11 800 kg 11 800 kg
Gross Combined Weight (GCW) N/A N/A
(26,000 lbs) (26,000 lbs)
Min Vehicle N/V Ratio
Output rpm/kmph 24 24 24 24
(Output rpm/mph) (38) (38) (38) (38)
Max Vehicle N/V Ratio
Output rpm/kmph 38 38 38 38
(Output rpm/mph) (62) (62) (62) (62)
Max Angular Rotation of Output
Shaft After Static Apply of Park 18.5 Degrees 18.5 Degrees 18.5 Degrees 18.5 Degrees
Provision

* All data and specifications are subject to change without notice.

** Engines with full load governed speed greater than 3800 rpm require Shift Energy Management (SEM) and additional calibration development.
*** Includes truck, school buses, one-way rental trucks, and road sweepers.
NOTE: Values with English units shown in parentheses ( ) are for reference purposes only. Conversions between Metric and English units are not
necessarily equivalent.

Copyright © 2004 General Motors Corp. 1–13