Allison Transmission 1000 EVS Service Manual Download Page 20

1–8

Copyright © 2004 General Motors Corp.

1000 AND 2000 PRODUCT FAMILIES SERVICE MANUAL

2. At the same time these events occur, a required

OEM-supplied 

RANGE INHIBITED

 light,

mounted on the dash or near the shift selector,
is illuminated. This noti

fi

es the driver that

shifting is inhibited and the shift selector may
not respond to shifts requested. 

d. Allison DOC™ Personal Computer (PC)-

Based Diagnostic System. 

Allison Diagnostic Opti-

mized Connection™ (Allison DOC™) provides tabu-
lar, graphical, and chart displays of real-time and re-
corded TCM data. A Help system is incorporated into
the Allison DOC™ software. Allison Diagnostic Opti-
mized Connection™ (Allison DOC™) software and
interface devices are available through Allison Trans-
mission tool sources.

1. A PC serves as the receiver/transmitter/display

medium that allows the service technician to
communicate with the TCM. Typical trouble-
shooting activities performed are installation
checkout and diagnostic trouble code (DTC)
retrieval.

2. The Allison DOC™ Help system contains in-

formation for performing the following:

Display (retrieve) DTCs. Transmission 
diagnostic codes begin with P0, P1, U1, or 
U2 followed immediately by three 
additional numbers. For a complete list of 
codes and more detailed information, refer 
to 1000 and 2000 Product Families 
Electronic Troubleshooting Manual 
TS3192EN.

Clear diagnostic codes

Obtain transmission data such as input 
speed or sump 

fl

uid temperature

A solenoid test

Clutch diagnostics (including torque 
converter clutch)

e. Troubleshooting When No Diagnostic Codes 

Are Present

Always start with the basics:

— Make sure the shifter is in the appropriate 

range.

— Check the 

fl

uid level.

— Make sure batteries are properly connected 

and charged.

— Make sure throttle is closed and engine 

speed is below 900 rpm.

— Make sure electrical connections are 

properly made.

— Check support equipment for proper 

installation and operation.

If the shifting process is rough, give the shifts 
time to adapt to “converged” state before 
assuming there is a problem.

Refer to Section 7 “General Troubleshooting 
of Performance Complaints” in the 1000 and 
2000 Product Families Troubleshooting 
Manual TS3192EN.

— These troubleshooting charts list a variety 

of conditions that may or may not relate to 
the TCM.

— Some conditions and suggested checks 

include mechanical and hydraulic items.

If the troubleshooting charts refer you to a 
TCM check, use the diagnostic code 
troubleshooting information that best applies 
to the situation.

f. Troubleshooting Intermittent Diagnostic

Codes. 

Intermittent codes are a result of conditions

which are not always present.

1. When conditions causing the code exist, the

code is logged in memory. The code stays in
memory until it is manually cleared or cycled
out by forty code-free warm-up cycles.

2. When intermittently occurring codes exist,

check for the following items:

Dirty, damaged or corroded harness 
connectors and terminals

Terminals not fully seated in connectors

Damaged harnesses (due to poor routing, 
cha

fi

ng, excessive heat, tight bends, etc.)

Improperly mounted electronic control 
components

Poor connector seals (where applicable)

Exposed harness wires

EMI generating components and 
accessories

Loose ground connections

Summary of Contents for 1000 EVS

Page 1: ...Copyright 2004 General Motors Corporation Allison Transmission VOCATIONAL MODELS Service Manual 2004 DECEMBER SM3191EN 1000 EVS 2100 EVS 2200 EVS 2500 EVS B 210 1000 HS 2100 HS 2200 HS 2500 HS B 220 1...

Page 2: ...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...

Page 3: ...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...

Page 4: ...arking 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...

Page 5: ...hicle 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 n...

Page 6: ...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...

Page 7: ...N AND STORAGE a Storage New Transmissions Before Installation 1 9 b Preservation Methods 1 9 c One Year Storage Without Fluid 1 9 d One Year Storage With Fluid 1 9 1 7 RESTORING TRANSMISSION TO SERVIC...

Page 8: ...MENT PARTS a Ordering Information 3 9 b Parts Normally Replaced at Overhaul 3 9 3 4 CAREFUL HANDLING 3 9 3 5 CLEANING AND INSPECTION a Dirt Causes Malfunction 3 9 b Cleaning Parts 3 9 c Cleaning Beari...

Page 9: ...4 21 4 22 C3 CLUTCH PISTON ASSEMBLY REMOVAL 4 23 Section 5 MODULE REBUILD 5 1 TORQUE CONVERTER ASSEMBLY a Preliminary Inspection 5 1 b End Play Check 5 1 c Leak Test 5 2 d Inspection of Torque Convert...

Page 10: ...5 79 c C4 Clutch Component Inspection 5 80 d C5 Clutch Component Inspection 5 83 e P1 Ring Gear Inspection 5 85 5 13 MAIN SHAFT INSPECTION 5 85 5 14 P1 PLANETARY MODULE a P1 Planetary Module Disassemb...

Page 11: ...TER INSTALLATION 6 18 6 12 ROTATING CLUTCH ASSEMBLY INSTALLATION 6 19 6 13 CONVERTER HOUSING FRONT SUPPORT MODULE INSTALLATION 6 20 6 14 REAR COVER SELECTIVE SPACER INSTALLATION 2WD TRANSMISSIONS ONLY...

Page 12: ...netary 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...

Page 13: ...tor Valve d ModelYear 04i MY04i refer to SIL 3 1K2K 04 1000 and 2000 Product Families MY04i serial number breaks are S N 6310374684 Indianapolis S N 6320367833 Baltimore e MY04i Parts Changes MY04i pa...

Page 14: ...ired knowledge of the task through Formal instruction at Allison Transmission or a Distributor training facility On the job instruction by an Allison Transmission or Distributor representative Experie...

Page 15: ...ING BRAKE MOUNTING PROVISION OUTPUT SPEED SENSOR SELECTOR SHAFT CONTROL MAIN OIL FILTER V04779 03 00 SAE 6 BOLT PTO PAD DRIVE GEAR OPTIONAL AVAILABLE OIL FILL TUBE LOCATION TURBINE SPEED SENSOR OUTPUT...

Page 16: ...Number 6 Serial Number 1 V06183 DIV OF GENERAL MOTORS CORP DIV OF GENERAL MOTORS CORP INDIANAPOLIS INDIANA USA INDIANAPOLIS INDIANA USA XX XXXX XX XXXX XX XXXX XXXXXXXXXX XXXXXXXX XXXXXXXXXX XXXXX XX...

Page 17: ...ne block in some cases Flexplate drive is used for engine to transmission torque transfer 2 Torque Converter Several torque converters are available to match the transmissions to a wide variety of die...

Page 18: ...fluid lines need to be provided Heat is transferred from the transmission fluid to either water or air depending upon the cooler type used 9 Oil Fill Tube Dipstick Provisions All 1000 and 2000 Produc...

Page 19: ...M logs a diagnostic code in memory These diagnostic codes can be accessed through the PC based Allison DOC diagnostic systems NOTE Diagnostic codes can be logged without illuminating the CHECK TRANS l...

Page 20: ...ch e Troubleshooting When No Diagnostic Codes Are Present Always start with the basics Make sure the shifter is in the appropriate range Check the fluid level Make sure batteries are properly connecte...

Page 21: ...If additional storage time is required do the following at yearly intervals Wash all external grease from the transmission with mineral spirits Remove all tape from openings and the vent assembly Rep...

Page 22: ...k for proper fluid level Add or drain transmission fluid as required to obtain the proper level 1 8 OPERATING INSTRUCTIONS Detailed transmission operation information is in the 1000 and 2000 Product F...

Page 23: ...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...

Page 24: ...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...

Page 25: ...Speed 5000 rpm 5000 rpm 5000 rpm 5000 rpm Other Gross Vehicle Weight GVW 9000 kg 19 850 lbs 7500 kg 16 540 lbs 9980 kg 22 000 lbs 7500 kg 16 540 lbs Gross Combined Weight GCW 11 800 kg 26 000 lbs N A...

Page 26: ......

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