Allison Transmission 1000 EVS, Service Manual

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viii Copyright © 2004 General Motors Corp.
1000 AND 2000 PRODUCT FAMILIES SERVICE MANUAL
Paragraph Page Paragraph Page
2–9. TRANSISSION FLUID AND FILTER
CHANGE PROCEDURE
a. Drain Fluid . . . . . . . . . . . . . . . . . . . . . . . 2–9
b. Replace Control-Main Filter . . . . . . . . . . 2–9
c. Refill Transmission . . . . . . . . . . . . . . . . . 2–9
2–10. VENT ASSEMBLY
a. Location and Purpose . . . . . . . . . . . . . . 2–10
b. Maintenance . . . . . . . . . . . . . . . . . . . . . 2–10
2–11. MAIN PRESSURE CHECK
PROCEDURE. . . . . . . . . . . . . . . . . . . . . . . 2–10
2–12. TRANSMISSION STALL TEST AND
NEUTRAL COOL-DOWN CHECK
a. Purpose . . . . . . . . . . . . . . . . . . . . . . . . . 2–12
b. Stall Testing Preparation . . . . . . . . . . . . 2–12
c. Performing a Transmission
Stall Test . . . . . . . . . . . . . . . . . . . . . . . . 2–12
d. Driving Transmission Stall Test . . . . . . 2–13
e. Driving Transmission Stall Testing
Preparation. . . . . . . . . . . . . . . . . . . . . . . 2–13
f. Performing a Driving Transmission
Stall Test . . . . . . . . . . . . . . . . . . . . . . . . 2–14
g. Neutral Cool-Down Check Procedure . 2–14
h. Transmission Stall Test Results . . . . . . 2–14
2–13. FLUID LEAK DIAGNOSIS
a. Finding the Leak . . . . . . . . . . . . . . . . . . 2–15
b. Powder Method . . . . . . . . . . . . . . . . . . . 2–15
c. Black Light and Dye Method . . . . . . . . 2–16
d. Repairing the Leak . . . . . . . . . . . . . . . . 2–16
2–14. ON-VEHICLE MAINTENANCE . . . . . . . 2–16
Section 3. GENERAL OVERHAUL
INFORMATION
3–1. SCOPE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3–1
3–2. TOOLS AND EQUIPMENT
a. Improvised Tools and Equipment . . . . . 3–1
b. Special Tools . . . . . . . . . . . . . . . . . . . . . 3–1
c. Mechanic’s Tools and
Shop Equipment . . . . . . . . . . . . . . . . . . . 3–1
3–3. REPLACEMENT 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 Bearings . . . . . . . . . . . . . . . . . 3–9
d. Keeping Bearings Clean. . . . . . . . . . . . . 3–9
e. Inspecting Bearings . . . . . . . . . . . . . . . . 3–10
f. Inspecting Cast Parts and
Machined Surfaces . . . . . . . . . . . . . . . . 3–10
g. Inspecting Bushings and
Thrust Washers . . . . . . . . . . . . . . . . . . . 3–10
h. Inspecting Sealrings and Gaskets. . . . . 3–10
i. Inspecting Gears. . . . . . . . . . . . . . . . . . 3–11
j. Inspecting Splined Parts. . . . . . . . . . . . 3–11
k. Inspecting Threaded Parts . . . . . . . . . . 3–11
l. Inspecting Retaining Rings . . . . . . . . . . 3–11
m. Inspecting Springs. . . . . . . . . . . . . . . . . 3–11
n. Inspecting Clutch Plates . . . . . . . . . . . . 3–11
o. Inspecting Swaged and
Interference-Fit Parts . . . . . . . . . . . . . . 3–12
p. Inspecting Sealing Surfaces . . . . . . . . . 3–12
3–6. ASSEMBLY PROCEDURES
a. Parts Lubrication . . . . . . . . . . . . . . . . . . 3–12
b. Grease Used for Assembly . . . . . . . . . . 3–12
c. Sealing Compounds and
Nonsoluble Greases . . . . . . . . . . . . . . . 3–12
d. Clutches and Pistons . . . . . . . . . . . . . . 3–12
e. Threaded Plugs and Hydraulic
Fittings. . . . . . . . . . . . . . . . . . . . . . . . . . 3–12
f. Lip-Type Seals . . . . . . . . . . . . . . . . . . . 3–12
g. Butt-Joint/Overlap Sealrings . . . . . . . . 3–13
h. Bearings. . . . . . . . . . . . . . . . . . . . . . . . . 3–13
i. Electrical Components . . . . . . . . . . . . . 3–13
3–7. REMOVING (OR INSTALLING)
TRANSMISSION
a. Draining Transmission . . . . . . . . . . . . . 3–13
b. Disconnecting Controls . . . . . . . . . . . . 3–14
c. Uncoupling From Driveline,
Engine, and Vehicle . . . . . . . . . . . . . . . 3–14
d. Removing the Transmission. . . . . . . . . 3–14
e. Transmission Installation . . . . . . . . . . . 3–15
3–8. WEAR LIMITS. . . . . . . . . . . . . . . . . . . . . . 3–15
3–9. SPRING SPECIFICATIONS . . . . . . . . . . . 3–15
3–10. TORQUE SPECIFICATIONS . . . . . . . . . . 3–15