Allison Transmission 1000 EVS, Service Manual

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Copyright © 2004 General Motors Corp. vii
Paragraph Page Paragraph Page
Section 1. GENERAL INFORMATION
1–1. SCOPE OF MANUAL
a. Transmission Product Families And
Model Years. . . . . . . . . . . . . . . . . . . . . . . 1–1
b. Model Year 04 (MY04) . . . . . . . . . . . . . . 1–1
c. MY04 Parts Changes . . . . . . . . . . . . . . . . 1–1
d. Model Year 04i (MY04i). . . . . . . . . . . . . 1–1
e. MY04i Parts Changes . . . . . . . . . . . . . . . 1–1
f. Improved Shift Valve Body Casting . . . . 1–1
g. Vocational Models . . . . . . . . . . . . . . . . . . 1–1
h. Vocational Model Nomenclature. . . . . . . 1–2
i. Content and Organization . . . . . . . . . . . . 1–2
j. Illustrations. . . . . . . . . . . . . . . . . . . . . . . . 1–2
k. Maintenance Information . . . . . . . . . . . . 1–2
1–2. SUPPLEMENTARY INFORMATION . . . . 1–2
1–3. ORDERING PARTS
a. Transmission Nameplate . . . . . . . . . . . . . 1–2
b. Parts Catalog . . . . . . . . . . . . . . . . . . . . . . 1–2
1–4. GENERAL DESCRIPTION
a. Transmission Design Features. . . . . . . . . 1–5
b. General Description . . . . . . . . . . . . . . . . 1–7
1–5. DIAGNOSIS
a. Before Starting . . . . . . . . . . . . . . . . . . . . . 1–7
b. CHECK TRANS Light . . . . . . . . . . . . . . 1–7
c. Range Inhibit Indicator . . . . . . . . . . . . . . 1–7
d. Allison DOC™ Personal Computer
(PC)-Based Diagnostic System . . . . . . . . 1–8
e. Troubleshooting When No Diagnostic
Codes are Present. . . . . . . . . . . . . . . . . . . 1–8
f. Troubleshooting Intermittent
Diagnostic Codes . . . . . . . . . . . . . . . . . . . 1–8
1–6. PRESERVATION 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 SERVICE
a. Transmission Exterior . . . . . . . . . . . . . . 1–10
b. Sealed Vent Assembly and Openings . . 1–10
c. New Transmissions . . . . . . . . . . . . . . . . 1–10
d. Stored Without Fluid . . . . . . . . . . . . . . . 1–10
e. Stored With Fluid. . . . . . . . . . . . . . . . . . 1–10
1–8. OPERATING INSTRUCTIONS . . . . . . . . 1–10
1–9. SPECIFICATIONS AND DATA . . . . . . . . 1–10
1–10. ELECTROMAGNETIC/RADIO
FREQUENCY INTERFERENCE . . . . . . . 1–21
Section 2. PREVENTIVE MAINTENANCE
2–1. SCOPE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2–1
2–2. PERIODIC INSPECTIONS AND CARE
a. Transmission Inspection . . . . . . . . . . . . . 2–1
b. Vehicle Inspection . . . . . . . . . . . . . . . . . . 2–1
c. Welding . . . . . . . . . . . . . . . . . . . . . . . . . . 2–1
2–3. IMPORTANCE OF PROPER
TRANSMISSION FLUID LEVEL . . . . . . . . 2–1
2–4. TRANSMISSION FLUID CHECK
a. Fluid Check Procedure . . . . . . . . . . . . . . 2–2
b. Cold Check Procedure . . . . . . . . . . . . . . . 2–4
c. Hot Check Procedure . . . . . . . . . . . . . . . . 2–4
d. Consistency of Readings . . . . . . . . . . . . . 2–5
2–5. KEEPING FLUID CLEAN. . . . . . . . . . . . . . 2–5
2–6. FLUID RECOMMENDATIONS . . . . . . . . . 2–5
2–7. TRANSMISSION FLUID AND FILTER
CHANGE INTERVALS
a. Frequency. . . . . . . . . . . . . . . . . . . . . . . . . 2–6
b. Abnormal Conditions. . . . . . . . . . . . . . . . 2–6
c. Fluid Analysis . . . . . . . . . . . . . . . . . . . . . 2–6
2–8. TRANSMISSION FLUID CONTAMINATION
a. Fluid Examination . . . . . . . . . . . . . . . . . . 2–6
b. Water . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2–6
c. Engine Coolant. . . . . . . . . . . . . . . . . . . . . 2–9
d. Flush Oil Cooler. . . . . . . . . . . . . . . . . . . . 2–9
TABLE OF CONTENTS