Allison Transmission 1000 EVS Service Manual Download Page 5

 

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.

 

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 Te

fl

on

 

®

 

 seals; toxic gases are produced by burning Te

fl

on

 

®

 

.

Never dry bearings by spinning them with compressed air. A spinning bearing can disintegrate,
allowing balls or rollers to become lethal 

fl

ying projectiles. Also, spinning a bearing without

lubrication can damage the bearing.

Avoid contact with the hot 

fl

uid or the sump when draining transmission 

fl

uid. Direct contact with

the hot 

fl

uid 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.

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: ......

Reviews: