Allison Transmission 2000 Series Service Manual

Copyright © 2004 General Motors Corp. ix
TABLE OF CONTENTS
Paragraph Page Paragraph Page
Section 4. TRANSMISSION DISASSEMBLY
4–1. INSTALLATION OF TRANSMISSION
INTO REPAIR STAND . . . . . . . . . . . . . . . . 4–1
4–2. INPUT SPEED SENSOR REMOVAL
(IF PRESENT). . . . . . . . . . . . . . . . . . . . . . . . 4–2
4–3. TURBINE SPEED SENSOR REMOVAL . . 4–3
4–4. OUTPUT SPEED SENSOR REMOVAL
(2WD TRANSMISSIONS ONLY). . . . . . . . 4–3
4–5. NSBU SWITCH REMOVAL
(IF PRESENT). . . . . . . . . . . . . . . . . . . . . . . . 4–3
4–6. VENT REMOVAL . . . . . . . . . . . . . . . . . . . . 4–4
4–7. TORQUE CONVERTER REMOVAL. . . . . 4–5
4–8. CONVERTER HOUSING/FRONT
SUPPORT MODULE REMOVAL . . . . . . . 4–6
4–9. ROTATING CLUTCH ASSEMBLY
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . 4–7
4–10. OIL PAN AND SUCTION FILTER
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . 4–8
4–11. WIRING HARNESS ASSEMBLY
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . 4–9
4–12. CONTROL VALVE ASSEMBLY
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . 4–10
4–13. REAR BALL BEARING REMOVAL . . . . 4–12
4–14. REAR COMPONENTS REMOVAL . . . . . 4–14
4–15. PARK PAWL REMOVAL . . . . . . . . . . . . . 4–16
4–16. P2 PLANETARY MODULE AND MAIN
SHAFT REMOVAL . . . . . . . . . . . . . . . . . . 4–16
4–17. C5 CLUTCH REMOVAL. . . . . . . . . . . . . . 4–17
4–18. P1 PLANETARY MODULE . . . . . . . . . . . 4–17
4–19. C4 CLUTCH REMOVAL. . . . . . . . . . . . . . 4–18
4–20. C4 CLUTCH PISTON ASSEMBLY
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . 4–20
4–21. C3 CLUTCH REMOVAL. . . . . . . . . . . . . . 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 Converter. . . . . . . . 5–3
5–2. ELECTRONIC COMPONENT
INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . 5–5
5–3. CONVERTER HOUSING/FRONT
SUPPORT MODULE DISASSEMBLY . . . 5–6
5–4. TORQUE CONVERTER HOUSING
(WITHOUT COOLER MANIFOLD)
a. Disassembly . . . . . . . . . . . . . . . . . . . . . . . 5–9
b. Assembly . . . . . . . . . . . . . . . . . . . . . . . . 5–10
5–5. TORQUE CONVERTER HOUSING (DIRECT
MOUNT; WITHOUT COOLER MANIFOLD)
a. Disassembly . . . . . . . . . . . . . . . . . . . . . . 5–11
b. Assembly. . . . . . . . . . . . . . . . . . . . . . . . 5–11
5–6. TORQUE CONVERTER HOUSING
(WITH COOLER MANIFOLD)
a. Disassembly . . . . . . . . . . . . . . . . . . . . . . 5–12
b. Assembly . . . . . . . . . . . . . . . . . . . . . . . . 5–13
5–7. MAIN PUMP ASSEMBLY
a. Main Pump Disassembly. . . . . . . . . . . . 5–15
b. Main Pump Inspection . . . . . . . . . . . . . . 5–16
c. Main Pump Bushing Replacement . . . . 5–19
d. Main Pump Dowel Pin Replacement. . . 5–20
e. Wear Plate Inspection . . . . . . . . . . . . . . 5–21
f. Main Pump Assembly . . . . . . . . . . . . . . 5–21
5–8. FRONT SUPPORT ASSEMBLY
a. Front Support Disassembly . . . . . . . . . . 5–22
b. Ground Sleeve Inspection . . . . . . . . . . . 5–27
c. Ground Sleeve Replacement . . . . . . . . . 5–28
d. Ground Sleeve Needle Bearing
Replacement. . . . . . . . . . . . . . . . . . . . . . 5–30
e. Ground Sleeve Bushing Replacement . . 5–31
f. Front Support Thrust Washer
Inspection . . . . . . . . . . . . . . . . . . . . . . . . 5–32
g. Front Support Assembly . . . . . . . . . . . . 5–32
5–9. CONVERTER HOUSING/FRONT
SUPPORT MODULE ASSEMBLY. . . . . . 5–37

Allison Transmission 2000 Series Specifications

General

Brand	Allison Transmission
Model	2000 Series
Category	Microphone system
Language	English