Service 2005 OCTOBER

Manual SM4014EN

Allison Transmission
ALLISON 4TH GENERATION CONTROLS
VOCATIONAL MODELS
4000 EVS 4500 EVS 4700 EVS 4800 EVS B 500
4000 HS 4500 HS 4700 RDS 4800 SP T 425
4000 MH 4500 RDS 4700 SP T 450
4000 RDS 4500 SP T 525
4000 SP
4000 TRV

Allison Transmission, General Motors Corporation

P.O. Box 894 Indianapolis, Indiana 46206-0894
www.allisontransmission.com

Printed in USA Copyright © 2005 General Motors Corporation

 INTRODUCTION

ELECTRONIC CONTROL UNIT AND DIAGNOSTIC DATA READER/TOOL

DISPLAYS AND BUTTON NAMES
↑ (Up), ↓ (Down),
Shift Selector, Allison DOC™ button, and display names are printed in bold capital letters—↑
MODE, MONITOR, SELECT, etc.
Transmission range shifts are indicated by the letter or number on the shift selector, in bold text, followed by the
name of the range in parentheses—D (Drive), N (Neutral), etc.
References to diagnostic messages displayed are printed within double quotation marks (“OL,” “OK,” etc.).

TRADEMARK USAGE
The following trademarks are the property of the companies indicated:
• Allison DOC™ (Allison Diagnostic Optimized Connection Tool) is a trademark
of General Motors Corp.
• DEXRON® is a registered trademark of General Motors Corp.
• Biobor® JF is the registered trademark for a biological inhibitor manufactured by U.S. Borax
and Chemical Corporation.
• Loctite® is a registered trademark of the Loctite Corporation.
• Teflon® is a registered trademark of the DuPont Corporation.
• TranSyndTM is a trademark of Castrol, Ltd.
• Vespel® is a registered trademark of DuPont Corporation.

NOTE:
This publication is revised periodically to include improvements,
new models, special tools, and procedures. A revision is indicated
by the date on the title page. Check with your Allison
Transmission service outlet for the currently applicable
publication. Additional copies of this publication may be
purchased from authorized Allison Transmission service outlets.
Look in your telephone directory under the heading of
Transmissions—Truck, Tractor, etc.

ii Copyright © 2005 General Motors Corp.

 IMPORTANT SAFETY NOTICE

IT IS YOUR RESPONSIBILITY to be completely familiar with the Warnings and Cau-

tions described in this Service Manual. These Warnings and Cautions advise against the
use of specific service methods that can result in personal injury, damage to the equip-
ment, or cause the equipment to become unsafe. It is, however, 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 might be done or of the possible hazardous consequences of each way. Conse-
quently, Allison Transmission has not undertaken any such broad evaluation. Accord-
ingly, ANYONE WHO USES A SERVICE PROCEDURE OR TOOL WHICH IS NOT
RECOMMENDED BY ALLISON TRANSMISSION MUST first be thoroughly satisfied
that neither personal safety nor equipment safety will be jeopardized by the service
methods selected.
Proper service and repair are important to the safe, reliable operation of the equipment.
The service procedures recommended by Allison Transmission and described in this Ser-
vice Manual are effective methods for performing service operations. Some of these ser-
vice operations require the use of tools specifically designed for the purpose. The special
tools should be used when and as recommended.

WARNINGS, CAUTIONS, AND NOTES

Three types of headings are used in this manual to attract your attention:

WARNING!
is used when an operating procedure, practice,
etc., which, if not correctly followed, could result
in personal injury or loss of life.

CAUTION:
is used when an operating procedure, practice,
etc., which, if not strictly observed, could result
in damage to or destruction of equipment.

NOTE:
is used when an operating procedure, practice, etc.,
is essential to highlight.

Copyright © 2005 General Motors Corp. iii

 LIST OF WARNINGS
This manual contains the following Warnings —

IT IS YOUR RESPONSIBILITY TO BE FAMILIAR WITH ALL OF THEM.

If you leave the vehicle and the engine is running, the vehicle can move suddenly and you
or others could be injured. If you must leave the engine running, do not leave the vehicle
until you:
• Put the transmission in N (Neutral)…and
• Apply the parking brake and emergency brakes and make sure they are properly
engaged…and
• Chock the wheels and take any other steps necessary to keep the vehicle from moving.
Avoid contact with the hot fluid or the hot sump when draining transmission fluid. Direct
contact with the hot fluid or the hot sump may result in bodily injury.
DO NOT conduct a converter stall test until the following actions are taken. The parking
brake and/or emergency brakes must be set and properly engaged and the wheels must be
chocked. Warn personnel to keep clear of the vehicle and its travel path. Failure to do so
can cause serious injury.
Use appropriate safety equipment such as safety glasses, safety shoes, and gloves.
Do not burn discarded Teflon® seals; toxic gases are produced by burning Teflon®.
Never dry bearings by spinning them with compressed air. A spinning bearing can
disintegrate, allowing balls or rollers to become lethal flying projectiles. Also, spinning a
bearing without lubrication can damage the bearing.
DO NOT disconnect the hydraulic fluid line between the accumulator and the retarder
until air and hydraulic pressure have been bled from the retarder.
PREVENT PERSONAL INJURY: Use proper tools and lifting equipment when installing
or removing a transmission from the repair stand. Transmission dry weights are as
follows:
• 4000 and 4500 Models
Base transmission —377 kg (831 lbs)
With PTO provision —405 kg (893 lbs)
With retarder —411 kg (906 lbs)
With retarder and PTO provision —439 kg (968 lbs)
• 4700 and 4800 Models
Base transmission —493 kg (1087 lbs)
With PTO provision —521 kg (1149 lbs)
With retarder —529 kg (1162 lbs)
With retarder and PTO provision —555 kg (1224 lbs)
With retarder, PTO, and integral —496 kg (1032 lbs)
retarder sump cooler

iv Copyright © 2005 General Motors Corp.

 LIST OF WARNINGS
This manual contains the following Warnings —

IT IS YOUR RESPONSIBILITY TO BE FAMILIAR WITH ALL OF THEM.

Get help when lifting the control module. Assistance from a hoist or another person may
be required. The control module weighs approximately 25 kg (55 lb).
Get help when lifting the retarder module. Assistance from a hoist or another person may
be required. The retarder module weighs approximately 34 kg (75 lb).
Get help when lifting the C6 adapter housing module. Assistance from a hoist or another
person may be required. The C6 adapter housing module weighs approximately 68 kg
(150 lb).
Carefully release spring force. Piston springs are highly compressed. Personal injury can
occur if the spring force is not controlled.
Piston springs are highly compressed. Be extremely careful during removal and
installation. Personal injury can occur if the spring force is not controlled.
Place the P3 planetary assembly on its side to avoid possible injury while disassembling
the planetary.

Copyright © 2005 General Motors Corp. v

 INTRODUCTION
NOTES

vi Copyright © 2005 General Motors Corp.

 TABLE OF CONTENTS
Paragraph Page
Section 1. GENERAL INFORMATION
1–1. SCOPE OF MANUAL
a. Content And Organization. . . . . . . . . . . . 1–1
b. Illustrations. . . . . . . . . . . . . . . . . . . . . . . . 1–1
c. Maintenance Information . . . . . . . . . . . . 1–1
1–2. SUPPLEMENTARY INFORMATION . . . . 1–5
1–3. ORDERING PARTS
a. Transmission Nameplate . . . . . . . . . . . . . 1–5
b. Parts Catalog . . . . . . . . . . . . . . . . . . . . . . 1–5
1–4. GENERAL DESCRIPTION
a. Major Modules. . . . . . . . . . . . . . . . . . . . . 1–5
b. Unique Features. . . . . . . . . . . . . . . . . . . . 1–5
1–5. MAJOR COMPONENTS
a. Input Module . . . . . . . . . . . . . . . . . . . . . . 1–6
b. Torque Converter . . . . . . . . . . . . . . . . . . . 1–6
c. Power Takeoff . . . . . . . . . . . . . . . . . . . . . 1–6
d. Main Housing And Gear Module . . . . . . 1–6
e. Range Clutches . . . . . . . . . . . . . . . . . . . . 1–6
f. Control System . . . . . . . . . . . . . . . . . . . . 1–6
g. Transmission Fluid Filters . . . . . . . . . . . . 1–6
h. Transmission Fluid Coolers . . . . . . . . . . . 1–6
i. C6 Adapter Housing Module. . . . . . . . . . 1–6
j. Rear Cover . . . . . . . . . . . . . . . . . . . . . . . . 1–6
k. Output Retarder And Output Flange . . . . 1–6
1–6. 4000 PRODUCT FAMILY MODEL
DESIGNATION CODE . . . . . . . . . . . . . . . . 1–6
1–7. EXPLODED (DISASSEMBLED)
VIEWS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1–7
1–8. DIAGNOSIS
a. Before Starting . . . . . . . . . . . . . . . . . . . . . 1–7
b. CHECK TRANS Light . . . . . . . . . . . . . . 1–7
c. Entering Diagnostic Mode . . . . . . . . . . . 1–8
d. Diagnostic Codes . . . . . . . . . . . . . . . . . . . 1–8
e. Displaying Diagnostic Codes . . . . . . . . . 1–8
f. Diagnostic Code Displays . . . . . . . . . . . . 1–8
g. Exiting Diagnostic Mode . . . . . . . . . . . . 1–8
1–9. PRESERVATION AND STORAGE
a. Storage (New Transmissions,
Before Installation) . . . . . . . . . . . . . . . . . 1–8
b. Preservation Methods . . . . . . . . . . . . . . . 1–8
c. One Year Storage (Without Fluid). . . . . . 1–8
d. One Year Storage (With Fluid) . . . . . . . . 1–9
Copyright © 2005 General Motors Corp.
Paragraph Page
1–10. RESTORING TRANSMISSION
TO SERVICE
a. Transmission Exterior . . . . . . . . . . . . . . . 1–9
b. Sealed Breather And Openings . . . . . . . . 1–9
c. New Transmissions . . . . . . . . . . . . . . . . . 1–9
d. Stored Without Fluid . . . . . . . . . . . . . . . . 1–9
e. Stored With Fluid. . . . . . . . . . . . . . . . . . . 1–9
1–11. ELECTROMAGNETIC/RADIO
FREQUENCY INTERFERENCE . . . . . . . 1–10
1–12. OPERATING INSTRUCTIONS . . . . . . . . 1–10
1–13. SPECIFICATIONS AND DATA . . . . . . . . 1–10
Section 2. PREVENTIVE MAINTENANCE
2–1. SCOPE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2–1
2–2. PERIODIC INSPECTION AND CARE
a. Exterior Cleaning And Inspection. . . . . . 2–1
2–3. IMPORTANCE OF PROPER
FLUID LEVEL
a. Transmission Fluid . . . . . . . . . . . . . . . . . 2–1
b. Oil Level Sensor . . . . . . . . . . . . . . . . . . . 2–1
c. Electronic Controls And
Protection Circuits . . . . . . . . . . . . . . . . . . 2–1
2–4. ELECTRONIC FLUID LEVEL CHECK
(WHEN AN OPTIONAL OLS IS
PRESENT—FULL-FUNCTION
PUSHBUTTON OR LEVER SHIFT
SELECTORS)
a. Fluid Level Check Procedure . . . . . . . . . 2–2
2–5. MANUAL FLUID LEVEL CHECK
PROCEDURE
a. Preparation . . . . . . . . . . . . . . . . . . . . . . . 2–3
b. Consistency Of Readings . . . . . . . . . . . . 2–3
2–6. COLD CHECK
a. Purpose. . . . . . . . . . . . . . . . . . . . . . . . . . . 2–3
b. Cold Check Procedure . . . . . . . . . . . . . . . 2–3
2–7. HOT CHECK
a. Purpose. . . . . . . . . . . . . . . . . . . . . . . . . . . 2–4
b. Cold Check Procedure . . . . . . . . . . . . . . . 2–4
2–8. KEEPING FLUID CLEAN. . . . . . . . . . . . . . 2–4
2–9. FLUID RECOMMENDATIONS
a. Fluid Type . . . . . . . . . . . . . . . . . . . . . . . . 2–5
vii
 4000 PRODUCT FAMILIES SERVICE MANUAL—ALLISON 4 th GENERATION
Paragraph Page
2–10. FLUID AND FILTER
CHANGE INTERVALS
a. Fluid And Filter Changes . . . . . . . . . . . . 2–5
b. Fluid Analysis . . . . . . . . . . . . . . . . . . . . . 2–7
2–11. FLUID CONTAMINATION
a. Water . . . . . . . . . . . . . . . . . . . . . . . . . . . 2–7
b. Engine Coolant . . . . . . . . . . . . . . . . . . . . 2–7
c. Metal . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2–7
2–12. FLUID AND FILTER CHANGE
PROCEDURE
a. Drain Fluid . . . . . . . . . . . . . . . . . . . . . . . 2–7
b. Replace Filters. . . . . . . . . . . . . . . . . . . . . 2–8
c. Refill Transmission . . . . . . . . . . . . . . . . . 2–8
2–13. BREATHER
a. Location And Purpose. . . . . . . . . . . . . . . 2–8
b. Maintenance . . . . . . . . . . . . . . . . . . . . . . 2–9
2–14. TRANSMISSION STALL TEST AND
NEUTRAL COOL-DOWN CHECK
a. Purpose . . . . . . . . . . . . . . . . . . . . . . . . . . 2–9
b. Stall Testing Preparation. . . . . . . . . . . . . 2–9
c. Performing a Transmission Stall Test . 2–10
d. Driving Transmission Stall Test . . . . . . 2–10
e. Driving Transmission Stall Test
Preparation . . . . . . . . . . . . . . . . . . . . . . 2–10
f. Performing a Driving Transmission
Stall Test . . . . . . . . . . . . . . . . . . . . . . . . . 2–11
g. Neutral Cool-Down Procedure. . . . . . . 2–11
h. Transmission Stall Test Results . . . . . . 2–11
2–15. READING CLUTCH PRESSURES
a. Purpose . . . . . . . . . . . . . . . . . . . . . . . . . 2–12
b. Transmission And Vehicle Preparation . 2–12
c. Recording Data . . . . . . . . . . . . . . . . . . . 2–12
d. Comparing Recorded Data
To Specifications. . . . . . . . . . . . . . . . . . 2–13
2–16. FLUID LEAK DIAGNOSIS
a. Finding Leak . . . . . . . . . . . . . . . . . . . . . 2–16
b. Powder Method . . . . . . . . . . . . . . . . . . . 2–16
c. Black Light and Dye Method . . . . . . . . 2–16
d. Possible Points Of Fluid Leaks And
Their Causes . . . . . . . . . . . . . . . . . . . . . 2–16
e. Repairing Leak . . . . . . . . . . . . . . . . . . . 2–17
viii Copyright © 2005 General Motors Corp.
Paragraph Page
2–17. OUTPUT FLANGE/YOKE AND OIL
SEAL MAINTENANCE
a. Disassembly . . . . . . . . . . . . . . . . . . . . . 2–17
b. Assembly. . . . . . . . . . . . . . . . . . . . . . . . 2–18
2–18. ON-VEHICLE MAINTENANCE . . . . . . . 2–18
Section 3. GENERAL OVERHAUL
INFORMATION
3–1. SCOPE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3–1
3–2. TOOLS AND EQUIPMENT
a. Improvised Equipment . . . . . . . . . . . . . . 3–1
b. Special Tools . . . . . . . . . . . . . . . . . . . . . . 3–1
c. Mechanic’s Tools And
Shop Equipment . . . . . . . . . . . . . . . . . . . 3–1
3–3. REPLACEMENT PARTS
a. Ordering Information . . . . . . . . . . . . . . . 3–6
b. Parts Normally Replaced
at Overhaul . . . . . . . . . . . . . . . . . . . . . . . 3–6
3–4. CAREFUL HANDLING . . . . . . . . . . . . . . . 3–6
3–5. CLEANING AND INSPECTION
a. Dirt Causes Malfunction . . . . . . . . . . . . . 3–6
b. Cleaning Transmission, Parts . . . . . . . . . 3–6
c. Cleaning Bearings. . . . . . . . . . . . . . . . . . 3–6
d. Inspecting Bearings. . . . . . . . . . . . . . . . . 3–7
e. Keeping Bearings Clean . . . . . . . . . . . . . 3–7
f. Inspecting Cast Parts and
Machined Surfaces . . . . . . . . . . . . . . . . . 3–7
g. Inspecting Bushings and
Thrust Washers . . . . . . . . . . . . . . . . . . . . 3–7
h. Inspecting Sealrings and Gaskets . . . . . . 3–8
i. Inspecting Gears . . . . . . . . . . . . . . . . . . . 3–8
j. Inspecting Splined Parts . . . . . . . . . . . . . 3–8
k. Inspecting Threaded Parts. . . . . . . . . . . . 3–8
l. Inspecting Retaining Rings . . . . . . . . . . . 3–9
m. Inspecting Springs. . . . . . . . . . . . . . . . . . 3–9
n. Inspecting Clutch Plates . . . . . . . . . . . . . 3–9
o. Inspecting Swaged and
Interference-Fit Parts . . . . . . . . . . . . . . . 3–9
p. Inspecting Sealing Surfaces . . . . . . . . . . 3–9
 TABLE OF CONTENTS
Paragraph Page
3–6. ASSEMBLY PROCEDURES
a. Parts Lubrication . . . . . . . . . . . . . . . . . . . 3–9
b. Grease Used For Assembly . . . . . . . . . . . 3–9
c. Sealing Compounds And
Nonsoluble Greases . . . . . . . . . . . . . . . . . 3–9
d. Clutches And Pistons. . . . . . . . . . . . . . . . 3–9
e. Threaded Plugs And Hydraulic
Fittings . . . . . . . . . . . . . . . . . . . . . . . . . . 3–10
f. Coated Threaded Fasteners . . . . . . . . . . 3–10
g. Lip-Type Oil Seals. . . . . . . . . . . . . . . . . 3–10
h. Butt-Joint Sealrings . . . . . . . . . . . . . . . . 3–10
i. Bearings . . . . . . . . . . . . . . . . . . . . . . . . . 3–10
j. Bushings. . . . . . . . . . . . . . . . . . . . . . . . . 3–11
k. Electrical Components . . . . . . . . . . . . . 3–11
3–7. REMOVING TRANSMISSION
FROM VEHICLE
a. Drain Fluid. . . . . . . . . . . . . . . . . . . . . . . 3–11
b. Disconnecting Controls . . . . . . . . . . . . . 3–11
c. Uncoupling Transmission From
Vehicle And Engine Driveline. . . . . . . . 3–11
d. Removing The Transmission. . . . . . . . . 3–12
3–8. WEAR LIMITS . . . . . . . . . . . . . . . . . . . . . . 3–12
3–9. SPRING SPECIFICATIONS . . . . . . . . . . . 3–12
3–10. TORQUE SPECIFICATIONS . . . . . . . . . . 3–12
Section 4. TRANSMISSION DISASSEMBLY
4–1. SCOPE
a. Section . . . . . . . . . . . . . . . . . . . . . . . . . . . 4–1
b. Procedures . . . . . . . . . . . . . . . . . . . . . . . . 4–1
c. Illustrations. . . . . . . . . . . . . . . . . . . . . . . . 4–1
d. General Information. . . . . . . . . . . . . . . . . 4–1
e. Foldouts . . . . . . . . . . . . . . . . . . . . . . . . . . 4–1
4–2. DISASSEMBLY OF TRANSMISSION
a. Mounting Transmission
On Repair Stand. . . . . . . . . . . . . . . . . . . . 4–1
b. Removal Of Power Takeoff. . . . . . . . . . . 4–1
c. Removal Of External Parts . . . . . . . . . . . 4–1
d. Removal Of Integral Oil Cooler . . . . . . . 4–3
e. Removing Integral Retarder Sump Oil
Cooler. . . . . . . . . . . . . . . . . . . . . . . . . . . . 4–3
f. Removal Of Control Valve Module . . . . 4–4
g. Removal Of Torque Converter Module. . 4–4
h. Removal Of Converter
Housing Module . . . . . . . . . . . . . . . . . . . 4–6
i. Removal Of Retarder Module
(Except 4700 And 4800 Models). . . . . . . 4–6
Copyright © 2005 General Motors Corp.
Paragraph Page
j. Removal Of Retarder And Output Shaft
Module (4700 And 4800 Models) . . . . . . 4–7
k. Removal Of Rear Cover Module (Except
4700 And 4800 Models) . . . . . . . . . . . . . 4–7
l. Removal Of Rear Cover And Output
Shaft Module (4700 And 4800 Models) . 4–8
m. Removal Of C6 Adapter Housing
Module (4700 And 4800 Models) . . . . . . 4–8
n. Removal Of P3 Planetary Module
(4700 And 4800 Models). . . . . . . . . . . . . 4–9
o. Removal Of Main Shaft Module . . . . . . . 4–9
p. Removal Of P2 Module,
C5 Clutch Plates, And P1 Module. . . . . . 4–9
q. Removal Of Front Support/
Charging Pump Module And
Rotating Clutch Module . . . . . . . . . . . . 4–10
r. Removal Of C3/C4 Clutch Assembly
From Main Housing Module. . . . . . . . . 4–10
Section 5. MODULE REBUILD
5–1. SCOPE
a. Section . . . . . . . . . . . . . . . . . . . . . . . . . . . 5–1
b. Procedures . . . . . . . . . . . . . . . . . . . . . . . . 5–1
5–2. GENERAL INFORMATION FOR
MODULE REBUILD . . . . . . . . . . . . . . . . . . 5–1
5–3. TORQUE CONVERTER MODULE
a. Disassembly . . . . . . . . . . . . . . . . . . . . . . . 5–1
b. Assembly . . . . . . . . . . . . . . . . . . . . . . . . . 5–2
5–4. TORQUE CONVERTER HOUSING
MODULE (Models Without PTO Provision)
a. Disassembly . . . . . . . . . . . . . . . . . . . . . . . 5–4
b. Assembly . . . . . . . . . . . . . . . . . . . . . . . . . 5–4
5–5. TORQUE CONVERTER HOUSING
MODULE (Models With PTO Provision)
a. Disassembly . . . . . . . . . . . . . . . . . . . . . . . 5–4
b. Disassembly Of Bearing Retainer. . . . . . 5–4
c. Disassembly Of PTO Gear Assembly. . . 5–4
d. Assembly Of PTO Gear Assembly . . . . . 5–4
e. Assembly Of Bearing
Retainer Assembly. . . . . . . . . . . . . . . . . . 5–5
f. Assembly . . . . . . . . . . . . . . . . . . . . . . . . . 5–5
ix
 4000 PRODUCT FAMILIES SERVICE MANUAL—ALLISON 4 th GENERATION
Paragraph Page
5–6. FRONT SUPPORT AND OIL PUMP MODULE
a. Disassembly . . . . . . . . . . . . . . . . . . . . . . 5–5
b. Assembly Of Front Support . . . . . . . . . . 5–7
c. Assembly Of Pump Housing . . . . . . . . . 5–7
5–7. ROTATING CLUTCH MODULE
a. Disassembly . . . . . . . . . . . . . . . . . . . . . . 5–8
b. Assembly . . . . . . . . . . . . . . . . . . . . . . . . 5–11
5–8. C3/C4 AND MAIN HOUSING MODULE
a. Disassembly . . . . . . . . . . . . . . . . . . . . . 5–12
b. Assembly . . . . . . . . . . . . . . . . . . . . . . . . 5–13
5–9. MAIN SHAFT MODULE
a. Disassembly . . . . . . . . . . . . . . . . . . . . . 5–13
b. Assembly (Except 4700 And
4800 Models). . . . . . . . . . . . . . . . . . . . . 5–14
c. Assembly (4700 And 4800 Models) . . . 5–14
5–10. P1 PLANETARY MODULE
a. Disassembly . . . . . . . . . . . . . . . . . . . . . 5–14
b. Assembly. . . . . . . . . . . . . . . . . . . . . . . . 5–14
5–11. P2 PLANETARY MODULE
a. Disassembly . . . . . . . . . . . . . . . . . . . . . 5–15
b. Assembly. . . . . . . . . . . . . . . . . . . . . . . . 5–15
5–12. P3 PLANETARY MODULE
(4700 And 4800 Models)
a. Disassembly . . . . . . . . . . . . . . . . . . . . . 5–16
b. Assembly . . . . . . . . . . . . . . . . . . . . . . . 5–16
5–13. C6 ADAPTER HOUSING MODULE
(4700 And 4800 Models)
a. Disassembly Of Ring Gear and Hub
Assembly . . . . . . . . . . . . . . . . . . . . . . . 5–17
b. Disassembly . . . . . . . . . . . . . . . . . . . . . 5–17
c. Disassembly Of P4 Planetary Carrier
Assembly . . . . . . . . . . . . . . . . . . . . . . . 5–17
d. Disassembly Of Remaining C6 Parts . . 5–17
e. Assembly . . . . . . . . . . . . . . . . . . . . . . . 5–18
f. Assembly Of P4 Planetary Carrier
Assembly . . . . . . . . . . . . . . . . . . . . . . . 5–19
g. Assembly Of C6 Clutch . . . . . . . . . . . . 5–20
5–14. RETARDER AND P3 PLANETARY MODULE
a. Disassembly Of Retarder Valve Body . . 5–20
b. Disassembly Of Temperature Sensor . . 5–20
c. Disassembly Of Retarder Housing . . . . 5–21
d. Disassembly Of P3 Planetary
Carrier Assembly . . . . . . . . . . . . . . . . . 5–22
x Copyright © 2005 General Motors Corp.
Paragraph Page
e. Disassembly Of Retarder
Stator Assembly . . . . . . . . . . . . . . . . . . 5–22
f. Assembly Of Retarder Stator . . . . . . . . 5–23
g. Assembly Of P3 Planetary
Carrier Assembly . . . . . . . . . . . . . . . . . 5–23
h. Assembly Of Retarder Housing
Assembly. . . . . . . . . . . . . . . . . . . . . . . . 5–23
i. Assembly Of The Retarder Valve Body. 5–24
5–15. RETARDER AND OUTPUT SHAFT
MODULE (4700 And 4800 Models Equipped
With Retarder)
a. Disassembly Of Retarder Valve Body . 5–25
b. Disassembly Of Temperature Sensor . . 5–25
c. Disassembly Of Retarder Housing . . . . 5–25
d. Completion Of Retarder Housing
Disassembly . . . . . . . . . . . . . . . . . . . . . 5–26
e. Assembly Of Output Shaft Assembly . 5–26
f. Disassembly Of Retarder Stator
Assembly . . . . . . . . . . . . . . . . . . . . . . . . 5–26
g. Assembly Of Retarder Stator . . . . . . . . 5–26
h. Assembly Of Retarder Housing . . . . . . 5–27
i. Assembly Of Output Shaft Assembly. . 5–27
j. Completion Of Retarder Housing
Assembly . . . . . . . . . . . . . . . . . . . . . . . . 5–27
k. Assembly Of Retarder Valve Body . . . 5–28
5–16. REAR COVER MODULE (Models Equipped
With Rear Cover, Except 4700 And 4800
Models)
a. Disassembly. . . . . . . . . . . . . . . . . . . . . . 5–28
b. Disassembly Of P3 Planetary
Carrier Assembly . . . . . . . . . . . . . . . . . 5–29
c. Completion Of Rear Cover
Disassembly . . . . . . . . . . . . . . . . . . . . . 5–30
d. Beginning Rear Cover Assembly . . . . . 5–30
e. Assembly Of P3 Planetary
Carrier Assembly . . . . . . . . . . . . . . . . . 5–30
f. Completion Of Rear Cover Assembly . . 5–31
5–17. REAR COVER AND OUTPUT SHAFT
MODULE (4700 And 4800 Models Equipped
With Rear Cover)
a. Disassembly . . . . . . . . . . . . . . . . . . . . . 5–32
b. Disassembly Of Output Shaft
Assembly . . . . . . . . . . . . . . . . . . . . . . . 5–32
 TABLE OF CONTENTS
Paragraph Page
c. Completion Of Rear Cover
Disassembly . . . . . . . . . . . . . . . . . . . . . 5–32
d. Beginning Rear Cover Assembly . . . . . 5–32
e. Assembly Of Output Shaft
Assembly . . . . . . . . . . . . . . . . . . . . . . . . 5–33
f. Completion Of Rear Cover Assembly. . 5–33
5–18. CONTROL VALVE MODULE
a. Removal Of Filters. . . . . . . . . . . . . . . . . 5–34
b. Removal Of Electrical Components
And Sensors . . . . . . . . . . . . . . . . . . . . . . 5–35
c. Disassembly Of Solenoid Valve Body . 5–35
d. Disassembly Of C6 Control Valve
Body . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5–36
e. Disassembly Of Main
Valve Body. . . . . . . . . . . . . . . . . . . . . . . 5–36
f. Disassembly Of Channel Plate . . . . . . . 5–37
g. Assembly Of Channel Plate . . . . . . . . . 5–37
h. Assembly Of Main Valve Body. . . . . . . 5–37
i. Assembly Of C6 Control Valve Body. . 5–38
j. Assembly Of Solenoid Valve Body. . . . 5–38
k. Installation Of Electrical Components
And Sensors . . . . . . . . . . . . . . . . . . . . . . 5–38
l. Install Filters . . . . . . . . . . . . . . . . . . . . . 5–38
Section 6. TRANSMISSION ASSEMBLY
6–1. SCOPE
a. Section . . . . . . . . . . . . . . . . . . . . . . . . . . . 6–1
b. Procedures . . . . . . . . . . . . . . . . . . . . . . . . 6–1
c. Illustrations . . . . . . . . . . . . . . . . . . . . . . . 6–1
d. General Information . . . . . . . . . . . . . . . . 6–1
e. Foldouts . . . . . . . . . . . . . . . . . . . . . . . . . . 6–1
6–2. ASSEMBLY OF TRANSMISSION
a. Assembly Of Main Housing Module . . . 6–1
b. Installation Of Rotating Clutch Module. . 6–1
c. Installation Of Front Support/
Charging Pump Module. . . . . . . . . . . . . . 6–2
d. Installation Of P1 Planetary Module . . . . 6–2
e. Installation Of P2 Planetary Module . . . . 6–2
f. Installation Of C5 Clutch Pack . . . . . . . . 6–2
g. Installation Of Main Shaft Module
(Except 4700 And 4800 Models) . . . . . . 6–2
h. Installation Of Main Shaft Module
(4700 And 4800 Models) . . . . . . . . . . . . 6–3
Copyright © 2005 General Motors Corp.
Paragraph Page
i. Main Shaft Selective Shim
Measurement (Close Ratio Models) . . . . 6–3
j. Main Shaft Selective Shim
Measurement (Wide Ratio Models) . . . 6–4
k. Installation Of P3 Planetary Module
(4700 And 4800 Models With Retarder). . 6–5
l. Installation Of C6 Adapter Housing
Module (4700 And 4800 Models With
Retarder). . . . . . . . . . . . . . . . . . . . . . . . . . 6–5
m. P3 Planetary Selective Shim
Measurement (4700 And 4800 Models
With Retarder) . . . . . . . . . . . . . . . . . . . . 6–6
n. P3 Planetary Selective Shim
Measurement (4700 And 4800 Models
With Rear Cover) . . . . . . . . . . . . . . . . . . 6–7
o. Installation Of Remainder Of P3 Planetary
Module and C6 Adapter Housing Module
(4700 And 4800 Models) . . . . . . . . . . . . 6–8
p. Installation Of Tolerance Rings
Module (4700 And 4800 Models With
Retarder) . . . . . . . . . . . . . . . . . . . . . . . . . 6–9
q. Installation Of Retarder Module (Except
4700 And 4800 Models) . . . . . . . . . . . . . 6–9
r. Installation Of Retarder and Output
Shaft Module (4700 And 4800 Models
With Retarders) . . . . . . . . . . . . . . . . . . . 6–10
s. Installation Of Rear Cover Module
(Except 4700 And 4800 Models) . . . . . 6–11
t. Installation Of Rear Cover Module
(4700 And 4800 Models). . . . . . . . . . . . 6–11
u. Installation Of Converter Housing
Module . . . . . . . . . . . . . . . . . . . . . . . . . . 6–13
v. Installation Of Torque Converter
Module . . . . . . . . . . . . . . . . . . . . . . . . . . 6–13
w. Installation Of Control Module . . . . . . . 6–16
x. Installing Integral Oil Cooler. . . . . . . . . 6–16
y. Installing Integral Retarder Sump Oil
Cooler. . . . . . . . . . . . . . . . . . . . . . . . . . . 6–17
z. Installation Of Externally
Mounted Parts . . . . . . . . . . . . . . . . . . . . 6–18
aa. Installation Of Power Takeoff . . . . . . . . 6–19
ab. Removal Of Transmission
From Repair Stand . . . . . . . . . . . . . . . . . 6–19
xi
 4000 PRODUCT FAMILIES SERVICE MANUAL—ALLISON 4 th GENERATION

Paragraph Page Paragraph Page

Section 7. WEAR LIMITS AND Section 8. CUSTOMER SERVICE

SPRING DATA
8–1. OWNER ASSISTANCE. . . . . . . . . . . . . . . . 8–1
7–1. WEAR LIMITS DATA
8–2. SERVICE LITERATURE . . . . . . . . . . . . . . 8–2
a. Maximum Variations . . . . . . . . . . . . . . . 7–1
b. Cleaning and Inspection . . . . . . . . . . . . . 7–1

7–2. SPRING DATA

a. Spring Replacement . . . . . . . . . . . . . . . . 7–1
b. Inspection . . . . . . . . . . . . . . . . . . . . . . . . 7–1

xii Copyright © 2005 General Motors Corp.

 4000 PRODUCT FAMILIES SERVICE MANUAL—ALLISON 4 th GENERATION

LIST OF FOLDOUT ILLUSTRATIONS

(Back Of Service Manual)

CROSS-SECTION VIEWS
Foldout

1 4000 Product Family Transmission (Close Ratio)—Cross Section

2 4500 Model (Wide Ratio) Transmission With PTO Provision—Cross Section
3 4000 Product Family (Close Ratio) Transmission With Retarder—Cross Section
3,A 4700 and 4800 Model Transmission—Cross Section
3,B 4700 and 4800 Model Transmission With Retarder—Cross Section
3,C 4700 and 4800 Model Transmission With Retarder and PTO Provision—Cross Section

EXPLODED VIEWS
Foldout
4,A Flexplate and Adapter
4,B Torque Converter Module
5,A Converter Housing Module
5,B Converter Housing Module With PTO Provision
6,A Front Support and Charging Oil Pump Module
6,B Rotating Clutch Module
7 Main Housing Module
8 Main Shaft Module
9,A P1 Planetary Module
9,B P2 Planetary Module
9,C P3 Planetary Module and C6 Adapter Housing Module (4700 and 4800 Models)
10,A Rear Cover and P3 Planetary Module
10,B Rear Cover and Output Shaft Module (4700 and 4800 Models)
10,C Retarder and P3 Module
10,D Retarder and Output Shaft Module (4700 and 4800 Models)
11,A Control Module
11,B Control Module
12,A Output Flange and Yoke
12,B Support Equipment
12,C Integral Retarder Sump Cooler
13 4000 Product Family Hydraulic Schematic—Neutral

Copyright © 2005 General Motors Corp. xiii

 4000 PRODUCT FAMILIES SERVICE MANUAL—ALLISON 4 th GENERATION

NOTES

xiv Copyright © 2005 General Motors Corp.

 SECTION 1—GENERAL INFORMATION
1–1. SCOPE OF MANUAL T 400 Series:
• T 425
a. Content and Organization. This Service
Manual describes overhaul procedures for 4000 • T 450
Product Family transmissions with Allison 4th • T 525
Generation Controls. Power takeoff (PTO) and output
b. Illustrations
retarder options may be added to a base transmission
model. 1. The text is supported with line drawings and
cross-sectional views. Overhaul procedures are
• Detailed instructions are provided for
illustrated by line drawings. Cross-sections
disassembly in Section 4, rebuild in Section 5,
show the relationship of assembled parts.
and reassembly in Section 6.
Cross-sections, exploded views, and a
• Part inspection instructions are in Section 3. hydraulic schematic (transmission in Neutral)
• Wear limits and spring data are in Section 7. are on foldout pages in the back of the manual.
• Major transmission components and their 2. Illustrations show correct procedures for all
functions are explained in 3000 and 4000 models—including models not illustrated.
Product Families Principles of Operation
PO4016EN. c. Maintenance Information. Each task described
The 4000 Product Family consists of the following in this manual has been successfully completed by
transmission series and models (Figures 1–1 through service organizations and individuals. Not every
1–6): service organization or individual possesses the
required special tooling, training or experience to
Highway Series:
perform all described tasks. However, any task may be
• 4000 HS performed if the following conditions are met:
• 4500 HS
Rugged Duty Series: 1. The organization or individual has the
required knowledge of the task through:
• 4000 RDS
• 4700 RDS • Formal instruction at Allison Transmission
or a Distributor training facility.
Emergency Vehicle Series:
• 4000 EVS • On-the-job instruction by an Allison
• 4500 EVS
Transmission or Distributor representative.
• 4700 EVS • Experience in performing the task.
• 4800 EVS 2. The work environment is suitable to prevent
contamination or damage to transmission parts
Motorhome Series:
or assemblies.
• 4000 MH
3. Required tools and fixtures are available as
Truck Recreational Vehicle Series:
shown in Section 3 of this manual. Refer to
• 4000 TRV Figures 3–2 and 3–3 and Tables 3–1 and 3–2.
• 4500 TRV
4. Reasonable and prudent maintenance practices
Specialty Series: are used.
• 4000 SP
• 4500 SP NOTE:
• 4700 SP Service organizations and individuals are
• 4800 SP encouraged to contact their local Allison
Transmission Distributor for information and
Bus Series: guidance on any task outlined in this manual.
• B 500

Copyright © 2005 General Motors Corp. 1–1

 4000 PRODUCT FAMILIES SERVICE MANUAL—ALLISON 4 th GENERATION

PTO PROVISION
(TOP RIGHT POSITION)

SHIPPING
BRACKET (3)

MOUNTING
FEEDTHROUGH PAD
HARNESS
CONNECTOR
ENGINE SPEED
SENSOR

TURBINE SPEED
SENSOR
OUTPUT SPEED
SENSOR
FILL TUBE

COOLER PORTS NAMEPLATE

V07319.01.00

Figure 1–1. 4000 Product Family Transmission With PTO Provision (Except 4700 and 4800 Models)—Right-Rear View

FEEDTHROUGH
HARNESS
MOUNTING PAD
CONNECTOR
(BOTH SIDES)

PTO PROVISION
(BOTTOM LEFT POSITION)

MAIN-PRESSURE TAP
COOLER PORTS

V06830.01.00

Figure 1–2. 4000 Product Family Transmission With PTO Provision (Except 4700 and 4800 Models)—Left-Rear View

1–2 Copyright © 2005 General Motors Corp.

 GENERAL INFORMATION

FILL TUBE

PTO PROVISION
(TOP RIGHT POSITION)
RETARDER

FEEDTHROUGH HARNESS
CONNECTOR

TORQUE CONVERTER
MODULE
NAMEPLATE

TURBINE-SPEED SENSOR

ENGINE-SPEED SENSOR
MOUNTING PAD
V07320.01.00

Figure 1–3. 4000 Product Family With PTO Provision and Retarder (Except 4700 and 4800 Models)—Right-Front View

MOUNTING PAD

OUTPUT-SPEED
PTO PROVISION SENSOR
(BOTTOM LEFT POSITION) RETARDER

MAIN-PRESSURE TAP
COOLER PORTS

ACCUMULATOR PORT V07334.01.00

Figure 1–4. 4000 Product Family With PTO Provision and Retarder (Except 4700 and 4800 Models)—Left-Rear View

Copyright © 2005 General Motors Corp. 1–3

 4000 PRODUCT FAMILIES SERVICE MANUAL—ALLISON 4 th GENERATION

BREATHER
PTO PROVISION

C6 ADAPTER
HOUSING

RETARDER

OUTPUT
MOUNTING PAD FLANGE

PTO PROVISION

MOUNTING PAD
V07333.01.00

Figure 1–5. 4000 Product Family With PTO Provision and Retarder (4700 and 4800 Models)—Left-Rear View

PTO PROVISION
(TOP RIGHT POSITION)

C6 ADAPTER
HOUSING

MOUNTING PAD

INPUT SPEED SENSOR

TURBINE
SPEED SENSOR

FILL T UBE

OUTPUT NAMEPLATE
SPEED SENSOR
V07332.01.00

Figure 1–6. 4000 Product Family With PTO Provision (4700 and 4800 Models)—Right-Rear View

1–4 Copyright © 2005 General Motors Corp.

 GENERAL INFORMATION
1–2. SUPPLEMENTARY Yellow Pages for your nearest authorized service
INFORMATION outlet. Listings are under Transmission—Truck or
Engines—Diesel.
Supplementary information will be issued, as required,
if any changes occur after publication of this manual. 1–4. GENERAL DESCRIPTION
Consult your dealer or distributor to be sure you have
the latest information. Allison 4000 Product Family transmissions are a
complete transmission system that includes all
1–3. ORDERING PARTS hardware needed for vehicle application.

a. Transmission Nameplate. The nameplate a. Major Modules. 4000 Product Family

(Figure 1–7) is located on the right side of the transmissions contain the following major modules:
transmission. The nameplate is imprinted with the
• Input Module
following:
• Main Housing and Gear Module
• Model number
• Control Module
• Serial number
• Output Module
• Data code
• C6 Adapter Module (4700 and 4800 models)
• TransID number
b. Unique Features. Features unique to 4000
• Engineering Feature Configuration Number
Product Family transmissions are:
(for Specialty Series vocation models)
• Three, four, five, six, or seven forward speed
Use all of these numbers when ordering replacement configurations
parts or requesting service information.
• Lockup clutch with torsional damper
b. Parts Catalog. Replacement parts are listed in • Integral retarder (optional)
the current 4000 Product Family Parts Catalog
PC2456EN. Do not order by the item numbers used on • Integral oil filters, serviceable without
exploded views in this manual. Use the Parts Catalog complete loss of transmission fluid
to determine the correct part number. Order all • Adaptive electronic closed-loop controls with
replacement parts from your distributor. Check the self-diagnostic capabilities

LTURAL
RICU IMP
AG L
D
AN

EM
E , A E ROSPACE

EN
T WORKERS O

General Motors Corp.

ENGINEERING FEATURE
BIL

DATA CODE
MO

AM
O ER
UT

Indianapolis, Indiana, USA

ICA
UNITED A

CONFIGURATION
TRANSMISSION 00A00 NUMBER FIELD
IDENTIFICATION
NUMBER
TIDA

S/N XXXXXXXXXX MODEL NUMBER FIELD

SERIAL NUMBER

V09468.01.01

Figure 1–7. Transmission Nameplate

Copyright © 2005 General Motors Corp. 1–5

 4000 PRODUCT FAMILIES SERVICE MANUAL—ALLISON 4 th GENERATION

1–5. MAJOR COMPONENTS • Shift selector

a. Input Module. The Input Module includes: • Sensors

• Engine adaptation • Wiring harness (customer-furnished)

• Torque converter
• Power takeoff gearing (optional)
b. Torque Converter
1. The torque converter includes a lockup clutch
and torsional damper for direct and smooth
transfer of engine power.
2. Torque converter models available are:
Torque Converter Model
TC 521
TC 531
TC 541
TC 551
TC 561
c. Power Takeoff. Direct, engine-driven PTO
gearing is available at two positions, except in the
4000 HS.
d. Main Housing and Gear Module. The Main
Housing and Gear Module include:
• Main Housing
• Oil pump charging system
• Three planetary gear sets
(four for 4700 and 4800 models)
• Two rotating clutches
• Three stationary clutches
(four for 4700 and 4800 models)
e. Range Clutches. Range clutches are multiple-
disc, wet-type clutches. Exhaust backfill pressure is
used to reduce fill time for quick response and smooth
shifts.
f. Control System. The control system is capable of
recognizing hydraulic and electronic conditions that
are not within the operating limits of the programmed
calibration. Some out-of-limit conditions can be
corrected by the control system. All out-of-limit
condition diagnostic codes are stored for later retrieval
by a technician.
The Electronic Control System includes:
• Transmission Control Module (TCM)
• Control module
The TCM is a high-speed digital computer that
receives information from the sensors and shift
selector. This information is processed and shift
commands are sent to the control module for range
selection.
g. Transmission Fluid Filters. Two disposable
external-access filters are part of the control module.
Each filter is in a separate cavity which permits
removal and replacement without complete loss of
transmission fluid.
h. Transmission Fluid Coolers. The 4000 Product
Family has provision for remote or integral
transmission fluid coolers.
i. C6 Adapter Housing Module. The C6 adapter
housing module is unique to the 4700 and 4800
models. It provides a seventh range and is located
between the main housing and rear cover/retarder.
j. Rear Cover. A rear cover is standard equipment
on the 4000 Product Family. The output shaft can be
provided with a variety of companion flanges or yokes.
k. Output Retarder and Output Flange. The
optional output retarder module replaces the standard
rear cover. An output flange or yoke is available for
use with the retarder.
1–6. 4000 PRODUCT FAMILY MODEL
DESIGNATION CODE
BUS – Bus Series
EVS – Emergency Vehicle Service
HS – Highway Series
MH – Motorhome Series
RDS – Rugged Duty Series
SP – Specialty Series
TRV – Truck Recreational Vehicle Series
7 or 8 – Widest Ratio Coverage (WRC)
5 – Wide Ratio (WR)
0 – Close Ratio (CR)
The following table lists the standard (STD) and
optional (OPT) features of each 4000 Product Family
model code designations:

1–6 Copyright © 2005 General Motors Corp.

 GENERAL INFORMATION

Maximum
Vocational Forward Deep Shallow
Model CR/WR Ranges PTO Retarder Sump Sump OLS

4000 EVS CR 6 STD OPT STD OPT STD

4000 HS CR 6 N/A OPT STD N/A STD
4000 MH CR 6 OPT OPT STD OPT STD
4000 RDS CR 6 STD OPT STD N/A STD
4000 SP CR 6 STD OPT STD OPT STD
4000 TRV CR 6 OPT OPT STD N/A STD
4500 EVS WR 6 STD OPT STD OPT STD
4500 HS WR 6 N/A OPT STD N/A STD
4500 RDS WR 6 STD OPT STD N/A STD
4500 SP WR 6 STD OPT STD OPT STD
4700 EVS WR 7 STD OPT STD OPT STD 1
4700 RDS WRC 7 STD OPT STD N/A STD 1
4700 SP WRC 7 STD OPT STD N/A STD
4800 EVS WRC 7 STD OPT STD OPT STD 1
4800 SP WRC 7 STD OPT STD N/A STD
B 500 CR 6 OPT OPT STD OPT STD
T 425 CR 5 OPT OPT STD OPT STD
T 450 CR 5 OPT OPT STD OPT STD
T 525 CR 5 OPT OPT STD OPT STD
1—OLS not available on 7-speed models with retarders.

1–7. EXPLODED a. Before Starting. Before attempting to repair the

(DISASSEMBLED) VIEWS
Exploded views illustrate 4000 Product Family
transmission parts in relation to each other. The parts
numbering system in the exploded views is used in all
procedures described in the text.
1–8. DIAGNOSIS
NOTE:
Refer to Allison 4th Generation Controls
Troubleshooting Manual (TS3989EN) for in-depth
troubleshooting procedures.
transmission, the faulty condition and its probable
cause should be identified.
b. CHECK TRANS Light. Continued illumination
of the CHECK TRANS light during vehicle operation
indicates the TCM has signaled a diagnostic code. At
start-up, the CHECK TRANS light will briefly
illuminate to indicate that the light is functioning
properly.
NOTE:
The Strip Pushbutton Shift Selector has no display
or diagnostic capabilities. Use the Allison DOC™
For PC–Service Tool to display diagnostic trouble
codes.

Copyright © 2005 General Motors Corp. 1–7

 4000 PRODUCT FAMILIES SERVICE MANUAL—ALLISON 4 th GENERATION
c. Entering Diagnostic Mode
1. Pushbutton Shift Selector
— When Oil Level Sensor (OLS) is present:
Press the ↑ (Up) and ↓ (Down) arrow keys
twice simultaneously. Diagnostics will be
displayed immediately. The display will list
the diagnostic codes logged by position
(d1, d2, d3, etc.).
— When OLS is not present: Press the ↑ (Up)
and ↓ (Down) arrow keys simultaneously.
The display will list the diagnostic codes
logged by position (d1, d2, d3, etc.).
2. Lever Shift Selector
— When OLS is not present—Press the
DISPLAY MODE button. Diagnostics will
be displayed immediately.
— When OLS is present—Press the
DISPLAY MODE button twice to enter
Diagnostic Mode. The display will list the
diagnostic codes logged by position (d1,
d2, d3, etc.).
d. Diagnostic Codes. Diagnostic codes can be
displayed on the display portion of the shift selector or
by using the Allison DOC™ For PC–Service Tool. A
diagnostic code is either active or historical. An active
code is any code that is current in the TCM decision-
making process. Historical codes are codes that are
retained in the TCM memory and will not necessarily
affect the TCM decision-making process. Active
codes are indicated on the shift selector by the MODE
ON indicator.
e. Displaying Diagnostic Codes. Press and release
the MODE button to sequentially display the logged
diagnostic codes.
f. Diagnostic Code Displays. The code list position
(d1, d2, d3, d4, and d5) is the first item displayed,
followed by the diagnostic trouble code (DTC). The
following example shows how DTC P0722 is
displayed on pushbutton and lever shift selectors:
SELECT MONITOR
d 1
P ounce) through the fill tube hole.
0 7
2 2
1–8 Copyright © 2005 General Motors Corp.
The display cycles continuously until the next code list
position is accessed by pressing the MODE button.
When all codes have been displayed by pressing the
MODE button, the first code will be redisplayed. Any
log position not containing a diagnostic code will
display “– –” at the DTC position. No codes are
logged after a “– –” display.
g. Exiting Diagnostic Mode
1. Press the same buttons used to enter the
diagnostic mode.
2. Select any range. The transmission will enter
the selected range if the range is not inhibited.
3. Turn off the ignition switch.
4. The TCM diagnostic mode is exited
automatically after approximately two minutes
have elapsed without an operator input.
1–9. PRESERVATION AND STORAGE
a. Storage (New Transmissions, Before Installation).
New transmissions are filled with transmission fluid
and drained before shipment. The residual fluid in the
transmission provides adequate protection to safely
store the transmission without further treatment for
one full year if stored indoors, in conditions of normal
climate, and with all shipping plugs installed.
b. Preservation Methods. When the transmission is
stored or inactive for an extended period (one or more
years), specific preservation methods are required to
prevent damage from rust, corrosion, and organic
growth in the transmission fluid. Preservation methods
described are for storage with or without transmission
fluid and in or out of a vehicle.
c. One Year Storage (Without Fluid)
1. Drain the transmission fluid.
2. Remove the breather and spray 30 ml (one
ounce) of VCI #10 (or equivalent) into the
transmission through the breather hole.
Re-install the breather. Also, spray 30 ml (one
3. Seal all openings and the breather with
moisture-proof tape.
 GENERAL INFORMATION
4. Coat all exposed, unpainted surfaces with
preservative grease such as petrolatum
(MIL-C-11796, Class 2).
5. If additional storage time is required, repeat
Steps (2) through (4) at yearly intervals.
d. One Year Storage (With Fluid)
1. Drain the fluid and replace the oil filter
elements.
2. Fill the transmission to operating level with a
mixture of one part VCI #10 (or equivalent) to
30 parts transmission fluid. Add 3 ml of
Biobor® JF (or equivalent) for each 10 liters
(1⁄ 4 teaspoon per gallon) of fluid in the system.
NOTE:
When calculating the amount of Biobor® JF
required, use the total volume of the system, not just
the quantity required to fill the transmission.
Include external lines, filters, and the cooler.
3. Operate the transmission in N (Neutral) for
approximately five minutes at 1500 rpm.
4. Make sure the transmission shifts through all
ranges and the lockup clutch activates.
5. Continue operating the transmission in neutral
at 1500 rpm until normal operating
temperature is reached.
CAUTION:
If the unit does not have a converter-out temper-
ature gauge, do not stall the converter.
6. If normal operating temperature is less than
107°C (225ºF), shift the transmission to
forward range and stall the converter. Do not
exceed 107°C (225ºF).
7. As soon as the transmission is cool enough to
touch, seal all openings and the breather with
moisture-proof tape.
Copyright © 2005 General Motors Corp.
8. Coat all exposed, unpainted surfaces with
preservative grease such as petrolatum
(MIL-C-11796), Class 2.
9. If additional storage time is required, repeat
Steps (2) through (8) at yearly intervals,
except, it is not necessary to drain the
transmission each year. Just add VCI #10 and
Biobor® JF (or equivalents).
1–10. RESTORING TRANSMISSION
TO SERVICE
CAUTION:
Whenever a transmission is overhauled or
exchanged, the Transmission Control Module
(TCM) must be “RESET TO UNADAPTED
SHIFTS”. This causes the TCM to erase previous
adaptive information and begin to adapt in Fast
Adaptive Mode from the base calibration. Use
the Allison DOC™ For PC–Service Tool and
select “RESET UNADAPTED SHIFTS”. Follow
the instructions in the Allison DOC™ For PC–
Service Tool User Guide GN3433EN to
accomplish the reset.
a. Transmission Exterior. Wash all external grease
from the transmission with mineral spirits.
b. Sealed Breather and Openings. Remove all tape
from openings and the breather.
c. New Transmissions. If the transmission is new,
drain the residual preservative oil. Refill the
transmission to the proper level with an Allison-
approved transmission fluid. Refer to Paragraph 2–10.
d. Stored Without Fluid. If the transmission was
prepared for storage without fluid, drain the residual
fluid and replace the oil filter elements. Refill the
transmission to the proper level with an Allison-
approved transmission fluid. Refer to Paragraph 2–10.
e. Stored With Fluid. If the transmission was
prepared for storage with fluid, it is not necessary to
drain and refill the transmission with new transmission
fluid. Check for proper fluid level. Add or drain
transmission fluid, as required, to obtain the proper
level.
1–9
 4000 PRODUCT FAMILIES SERVICE MANUAL—ALLISON 4 th GENERATION

1–11. ELECTROMAGNETIC/RADIO control devices, or power leads may create or be

FREQUENCY INTERFERENCE
All electrical and electronic systems generate
electromagnetic fields that can interfere with other
electronic systems. Allison Transmission’s electronic
transmission controls comply with Federal
Communications Commission (FCC) regulations and
other guidelines concerning emitted radio frequency
interference for transportation electronics. Some
radio-telephone or two-way communications radios
(land-mobile radio), or the manner in which they are
installed, can be affected by other vehicle components
or adversely affect vehicle operation. Manufacturers
and installers of EMI/RFI emitting equipment are
responsible for adhering to FCC regulations and other
guidelines concerning emitted radio frequency
interference for transportation electronics. Radio or
other two-way communication antenna, power, or
ground leads near the transmission wiring harness,
subject to electromagnetic interference (EMI) from the
transmission control system. Refer to the Allison 4th
Generation Controls Troubleshooting Manual
(TS3989EN) for detailed instructions regarding EMI
problems.
1–12. OPERATING INSTRUCTIONS
Detailed transmission operation information is in the
3000 and 4000 Product Families Principles of
Operation PO4016EN manual or in vocational model
Operator’s Manual. Refer to the latest revision.
1–13. SPECIFICATIONS AND DATA
The following specifications and data provide a
quick reference to the major characteristics of the
transmission.

Table 1–1. Specifications and Data Chart*

GEAR DATA:
Type Planetary helical, constant mesh
Range Close-Ratio† Wide-Ratio† Widest-Ratio Coverage†
First . . . . . . . . . . . . . . . . . . . . . . . . . 3.51:1 4.70:1 7.63
Second . . . . . . . . . . . . . . . . . . . . . . . 1.91:1 2.21:1 3.51
Third . . . . . . . . . . . . . . . . . . . . . . . . 1.43:1 1.53:1 1.91
Fourth . . . . . . . . . . . . . . . . . . . . . . . 1.00:1 1.00:1 1.43
Fifth . . . . . . . . . . . . . . . . . . . . . . . . . 0.74:1 0.76:1 1.00
Sixth. . . . . . . . . . . . . . . . . . . . . . . . . 0.64:1 0.67:1 0.74
Seventh . . . . . . . . . . . . . . . . . . . . . . — — 0.64
Reverse . . . . . . . . . . . . . . . . . . . . . . –4.80:1 –5.55:1 –4.80:1
ENGINE-DRIVEN POWER TAKEOFF PROVISION:
Positions . . . . . . . . . . . . . . . . . . . . . 8 o’clock and 1 o’clock (viewed from rear)
PTO Unit Ratings at the Transmission:
PTO Drive Gear . . . . . . . . . . . . . Maximum torque through one pad: 930 N·m (685 lb ft)
Maximum torque through both pads simultaneously: 1595 N·m (1175 lb ft)
NOTE: No more than 930 N·m (685 lb ft) allowed through any single pad.

* All data and specifications are subject to change without notice.

† Gear ratios do not include torque converter multiplication.

1–10 Copyright © 2005 General Motors Corp.

 GENERAL INFORMATION
Table 1–1. Specifications and Data Chart* (cont’d)

HYDRAULIC SYSTEM:
Fluid type . . . . . . . . . . . . . . . . . . . . TranSyndTM, MIL-PRF-2104, MIL-PRF-46167, MIL-PRF-21260,
DEXRON®-III, C-4 (refer to Paragraph 2–10.)
Filters, main and lube . . . . . . . . . . . Dual integral, replaceable cartridge type
4000 PRODUCT FAMILY SIZES:
With PTO drive Without PTO drive
Length (transmission mounting face to rear of output shaft)
without retarder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 854.0 mm (33.62 inch) 781.1 mm (30.75 inch)
with retarder. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 845.6 mm (33.29 inch) 772.6 mm (30.42 inch)
Length (transmission mounting flange to output flange
798.7 mm (31.45 inch) 725.7 mm (28.57 inch)
mounting face on P3 carrier) . . . . . . . . . . . . . . . . . . . . . . . . . .
Depth (standard sump, centerline to lowest point) . . . . . . . . . 374.7 mm (14.75 inch) 374.7 mm (14.75 inch)
Dry weight—add 16.0 kg (35.0 lb) if integral cooler is used
with retarder. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 439 kg (968 lb) 411 kg (906 lb)
without retarder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 405 kg (893 lb) 377 kg (831 lb)
with retarder and integral retarder sump cooler. . . . . . . . . . 469 kg (1032 lb) 441 kg (970 lb)

4700/4800 Models 4700/4800 Models

With PTO drive Without PTO drive
Length (transmission mounting face to rear of output shaft)
with retarder or rear cover . . . . . . . . . . . . . . . . . . . . . . . . . . 1104.1 mm (43.47 inch) 966.3 mm (38.04 inch)
Depth (standard sump, centerline to lowest point) . . . . . . . . . 378.2 mm (14.89 inch) 378.2 mm (14.89 inch)
Dry weight—add 16.0 kg (35.0 lb) if integral cooler is used
with retarder. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 554 kg (1324 lb) 527 kg (1162 lb)
without retarder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 521 kg (1149 lb) 493 kg (1087 lb)

* All data and specifications are subject to change without notice.

Copyright © 2005 General Motors Corp. 1–11

 4000 PRODUCT FAMILIES SERVICE MANUAL—ALLISON 4 th GENERATION

NOTES

1–12 Copyright © 2005 General Motors Corp.

 SECTION
PREVENTIVE
2—PREVENTIVE
MAINTENANCE
MAINTENANCE
2–1. SCOPE
Proper care and regular maintenance is necessary for
the transmission to meet its duty requirements.
Perform the maintenance procedures described in this
section on a regular basis to prevent premature
transmission or support equipment failure. Allison
transmissions are manufactured to provide long-term,
efficient service in their designed applications.
2–2. PERIODIC INSPECTION
AND CARE
a. Exterior Cleaning and Inspection
CAUTION:
DO NOT pressure-wash the transmission
electrical connectors. Water and detergent cause
the electrical contacts to corrode and become
faulty.
1. Clean and inspect the exterior of the
transmission at regular intervals. Severity of
service and operating conditions determine the
frequency of inspections.
2. Inspect the transmission for:
• Loose bolts—transmission and mounting
components.
• Fluid leaks—repair immediately.
• Loose, dirty, or improperly adjusted throttle
sensor linkage.
• Damaged or loose fluid hoses.
• Worn, frayed, or improperly routed
electrical harnesses.
• Bent, worn or out-of-phase driveline
U-joints and slip fittings.
2–3. IMPORTANCE OF PROPER
FLUID LEVEL
a. Transmission Fluid. Transmission fluid cools,
lubricates, and transmits hydraulic power. Always
maintain the correct fluid level. If the level is too low,
the torque converter and clutches do not receive
enough fluid and the transmission overheats. If the
Copyright © 2005 General Motors Corp.
level is too high, the fluid aerates causing the
transmission to shift erratically and overheat.
b. Oil Level Sensor. The optional oil level sensor
(OLS) allows the operator to determine the fluid level
from either a full-function pushbutton or a lever shift
selector. There is no fluid level reading capability for
an Allison 4th Generation Controls strip-type
pushbutton selector; use the Allison DOC™ For PC–
Service Tool to obtain fluid level data from the OLS.
NOTE:
• The oil level sensor compensates for transmission
fluid temperatures from 60–104°C (140–220°F).
Any temperature below 60°C (140°F) or above
104°C (220°F) will result in an “Invalid for
Display” condition.
• To accurately determine the transmission
fluid level with the dipstick, the transmission
fluid must be at normal operating tempera-
ture (71–93°C; 160–200°F).
c. Electronic Controls and Protection Circuits.
4000 Product Family transmission electronic controls
and protection circuits alert the operator to a
transmission malfunction or the need for service. The
electronic controls and protection circuits do not
replace regular, manual, fluid level checks. Confirm
the fluid level at the intervals specified in vehicle
service instructions.
2–4. ELECTRONIC FLUID LEVEL
CHECK (WHEN AN OPTIONAL
OLS IS PRESENT—FULL-
FUNCTION PUSHBUTTON OR
LEVER SHIFT SELECTORS)
NOTE:
The Allison 4th Generation Controls full-function
pushbutton and lever shift selectors can display two
characters at one time. One character is displayed
under the SELECT label and one under the
MONITOR label.
2–1
 4000 PRODUCT FAMILIES SERVICE MANUAL—ALLISON 4 th GENERATION
a. Fluid Level Check Procedure
1. Park the vehicle on a level surface and shift to
N (Neutral). Apply the parking brake.
2. To enter oil level display mode:
• Pushbutton shift selector—simultaneously
press the ↑ (Up) and ↓ (Down) arrow
buttons once.
• Lever shift selector—press the DISPLAY
MODE pushbutton once.
NOTE:
The TCM may delay the fluid level check until the
following conditions are met:
• The fluid temperature is above 60°C (140°F)
or below 104°C (220°F).
• The transmission is in neutral.
• The vehicle has been stationary for approxi-
mately two minutes to allow the fluid to settle.
• The engine is at idle.
Indication of a delayed fluid level check for Allison
4th Generation Controls is a flashing display under
SELECT label and a digit countdown from 8 to 1
under MONITOR label.
3. Correct fluid level is reported when “o L” is
displayed (o L” indicates the Oil Level Check
Mode), followed by “o K o K”. The “o K”
display indicates the fluid level is within the
correct fluid level zone. The sensor display and
the transmission dipstick may not agree
exactly because the oil level sensor
compensates for fluid temperature. Example:
“o L o K o K” indicates correct fluid level.
4. Low fluid level is reported when “o L” is
displayed followed by “L o” and a number.
“L o” indicates a low fluid level and the
number indicates the number of quarts of fluid
the transmission requires. Confirm a low fluid
level condition by making a manual fluid level
check. Example: “o L L o 0 2” indicates two
2–2 Copyright © 2005 General Motors Corp.
additional quarts of fluid will bring the fluid
level within the middle of the “O K” zone.
5. High fluid level (o L H I 0 #) is reported
when “o L” is displayed, followed by “H I”
and a number. “H I” indicates high fluid level
and the number indicates the number of
quarts the transmission is overfilled.
Example: “O L H I 0 1” indicates one quart
of fluid above the full level.
CAUTION:
A low or high fluid level causes overheating and
irregular shift patterns and if not corrected, can
damage the transmission.
6. Invalid for Display condition is reported when
“o L” is displayed, followed by “– –” and a
number. The displayed number is a fault code,
and indicates improper conditions or a system
malfunction. Example: “o L – – 70” indicates
an Invalid for Display condition and fault
code 70.
7. Invalid for Display is activated when
conditions do not allow the fluid level to be
determined. Review the following codes and
conditions, and correct as necessary. If these
conditions cannot be corrected, contact the
nearest distributor or dealer in your area (look
in the telephone directory for the Allison
Transmission service outlet nearest you.)
Code Cause of Code
“OL – – 0X” — Settling time too short
“OL – – 50” — Engine speed (rpm) too low
“OL – – 59” — Engine speed (rpm) too high
“OL – – 65” — N (Neutral) must be selected
“OL – – 70” — Sump oil temperature too low
“OL – – 79” — Sump oil temperature too high
“OL – – 89” — Output shaft rotation
“OL – – 95” — Sensor failure
 PREVENTIVE MAINTENANCE
NOTE:
Report sensor failure to a distributor or dealer
in your area. Refer to the Allison Transmission
website www.allisontransmission.com or a tele-
phone directory for the Allison Transmission dis-
tributor or dealer nearest you.
8. To exit the oil level display mode:
• Pushbutton shift selector—press any
pushbutton on the shift selector.
• Lever shift selector—press the DISPLAY
MODE button twice.
2–5. MANUAL FLUID LEVEL
CHECK PROCEDURE
WARNING!
If you leave the vehicle and the engine is running,
the vehicle can move suddenly and you or others
could be injured. If you must leave the engine
running, do not leave the vehicle until you have
completed all of the following procedures:
• Put the transmission in N (Neutral).
• Be sure the engine is at low idle (500–800 rpm).
• Apply the parking brake and emergency
brakes and make sure they are properly en-
gaged.
• Chock the wheels and take any other steps
necessary to keep the vehicle from moving.
a. Preparation. Clean all dirt from around the end
of the fluid fill tube before removing the dipstick. Do
not allow dirt or foreign matter to enter the
transmission. Dirt or foreign matter in the hydraulic
system may clog passages and cause undue
transmission part wear or sticking valves.
b. Consistency of Readings. Always test the fluid
level reading at least twice using the Hot Check and
Cold Check procedures in Paragraphs 2–6 and 2–7.
Consistency (repeatable readings) is important to
maintaining proper fluid level. If inconsistent readings
persist, inspect the transmission breather to be sure it
Copyright © 2005 General Motors Corp.
is not clogged. If readings are still inconsistent,
contact your nearest Allison distributor or dealer.
2–6. COLD CHECK (Figure 2–1)
CAUTION:
DO NOT start the engine until the presence of
sufficient transmission fluid has been confirmed.
Remove the transmission fluid dipstick and be
sure the static fluid level is near the HOT FULL
mark.
a. Purpose. The purpose of the Cold Check is to
determine if the transmission has enough fluid to be
operated safely until a Hot Check can be made.
b. Cold Check Procedure
1. Park the vehicle on a level surface, chock the
wheels, and apply the parking brake.
2. Run the engine at idle (500–800 rpm) for at
least one minute with the transmission in
N (Neutral). Shift to D (Drive), then shift to
R (Reverse) to clear the hydraulic system of
air. Then, shift to N (Neutral) and allow the
engine to idle.
3. With the engine running, remove the dipstick
from the tube and wipe clean.
4. Insert the dipstick into the tube and remove.
Read the fluid level. Repeat the procedure to
verify the reading.
5. If the fluid level is within the “COLD
CHECK” band, the transmission can be
operated until the fluid is hot enough to
perform a Hot Check. If the fluid level is not
within the “COLD CHECK” band, add or
drain as necessary to bring the fluid level to the
middle of the “COLD CHECK” band.
6. Perform a Hot Check at the first opportunity
after normal operating temperature is
reached—71–93°C (160–200°F).
2–3
 4000 PRODUCT FAMILIES SERVICE MANUAL—ALLISON 4 th GENERATION

2–7. HOT CHECK (Figure 2–1)
WARNING!
If you leave the vehicle and the engine is running,
the vehicle can move suddenly and you or others
could be injured. If you must leave the engine
running, do not leave the vehicle until you have
completed all of the following procedures:
• Put the transmission in N (Neutral).
• Be sure the engine is at low idle (500–800 rpm).
• Apply the parking brake and emergency
brakes and make sure they are properly en-
gaged.
• Chock the wheels and take any other steps
necessary to keep the vehicle from moving.
CAUTION:
An accurate fluid level check cannot be made
unless the engine is idling (500–800 rpm) in
N (Neutral), the transmission fluid is at the
proper temperature, and the vehicle is on a level
surface.
a. Purpose. The purpose of the Hot Check is to
determine if the transmission has enough fluid to be
operated safely.
b. Procedure
4. Insert the dipstick into the tube and remove.
Read the fluid level. Repeat the procedure to
verify the reading.
5. If the fluid level is not within the “HOT
CHECK” band, add or drain as necessary to
bring the fluid level within the band. Safe
operating level is within the “HOT CHECK”
band on the dipstick (refer to Figure 2–1).
2–8. KEEPING FLUID CLEAN
CAUTION:
Containers or fillers that have been used for
antifreeze or engine coolant solution must
NEVER be used for transmission fluid.
Antifreeze and coolant solutions contain ethylene
glycol which, if put into the transmission, can
cause clutch plate failure.
Prevent foreign material from entering the
transmission by using clean containers, fillers, etc. Lay
the dipstick in a clean place while filling the
transmission.
Calibration level marking
locations with respect to FILL
transmission control module TUBE
splitline and fill tube
SCALE NONE
FULL
HOT

1. Operate the transmission in D (Drive) range

until normal operating temperature is reached:
DIMENSION A
• Sump temperature— SEE CHART
ADD
HOT

71–93°C (160–200°F) BELOW 132.6 mm

(5.22 in.)
DIMENSION B
COLD
FULL

• Converter-out temperature—
82–104°C (180–220°F) DIMENSION C
COLD
ADD

If a transmission temperature gauge is not

present, determine fluid level when the engine 13.8 mm (0.54 in.) REFERENCE DIMENSION D
water temperature gauge has stabilized and the DETERMINED BY
TRANSMISSION
transmission has been operated under load for CONTROL MODULE INSTALLATION
at least one hour. SPLITLINE

2. Park the vehicle on a level surface and shift to DIMENSION DIMENSION DIMENSION
A B C
N (Neutral). Apply the parking brake and 106.7 mm 76.2 mm 66.0 mm
chock the wheels. Allow the engine to idle (4.20 in.) (3.00 in.) (2.60 in.)
V02511.00.01
(500–800 rpm).
3. With the engine running, remove the dipstick
from the tube and wipe clean. Figure 2–1. Fluid Dipstick Markings

2–4 Copyright © 2005 General Motors Corp.

 PREVENTIVE MAINTENANCE
2–9. FLUID RECOMMENDATIONS Table 2–1. Transmission Fluid Preheating
Requirements
a. Fluid Type (Ambient Temperature Below
Viscosity Grade Which Preheat Is Required)
1. The hydraulic fluids (oils) used in Allison
ºC ºF
transmissions directly affect transmission
SAE 0W-20* or –30 –22
performance, reliability, and durability.
TranSyndTM
Recommended fluids for 4000 Product Family
applications are TranSyndTM, or other TES-295 DEXRON®-III –25 –13
fluid, and DEXRON®-III. Type C-4 fluids are SAE 10W –20 –4
also approved. SAE 15W-40W –15 5
SAE 30W 0 32
2. Some DEXRON®-III fluids are also qualified SAE 40W 10 50
as Type C-4 fluids. To be sure the fluid is
* Arctic as defined by MIL-PRF-46167B (was MIL-L-46167)
qualified for use in Allison transmissions, look
for a DEXRON®-III or Type C-4 fluid license,
or approval numbers on the fluid container, or 2–10. FLUID AND FILTER CHANGE
consult the lubricant manufacturer. Fluid types INTERVALS
such as Type F, and universal farm fluids may
or may not be properly qualified to use in your CAUTION:
Allison transmission. Consult your Allison
Transmission dealer or distributor before using Transmission fluid and filter change frequency is
determined by the severity of transmission
any fluid types except those fluids qualified for
service. More frequent changes may be necessary
use in Allison transmissions. than recommended in the general guidelines
when operating conditions create high levels of
CAUTION: contamination or overheating.
Disregarding minimum fluid temperature limits
can result in transmission malfunction or a. Fluid and Filter Changes. Change the main
reduced transmission life. filter after the first 8000 km (5000 miles) then follow
the recommended fluid and filter change intervals.
Table 2–2 is given only as a general guide for fluid and
3. When choosing the optimum viscosity grade of filter change interval.
fluid to use, duty cycle, preheat capabilities,
and/or geographical location must be taken Local conditions, severity of operation or duty cycle
into consideration. Table 2–1 lists the may require more or less frequent fluid change
minimum fluid temperatures at which the intervals that differ from the published
transmission may be safely operated. Preheat recommended fluid change intervals of Allison
with auxiliary heating equipment or by running Transmission. Transmission protection and fluid
the equipment or vehicle with the transmission change intervals can be optimized by the use of
in N (Neutral) for a minimum of 20 minutes fluid analysis. Filters must be changed at or before
before attempting range operation. recommended intervals.

Copyright © 2005 General Motors Corp. 2–5

 Table 2–2. Transmission Fluid and Filter Change

2–6
4000 Product Family
Schedule 1. Recommended Fluid and Filter Change Intervals (Non-TranSynd™/Non-TES 295 Fluid)
SEVERE VOCATION GENERAL VOCATION
Filters Filters
Lube/ Lube/
Fluid Main Internal Auxiliary Fluid Main Internal Auxiliary
12,000 Miles 12,000 Miles Overhaul 12,000 Miles 25,000 Miles 25,000 Miles Overhaul 25,000 Miles
(20 000 km) (20 000 km) (20 000 km) (40 000 km) (40 000 km) (40 000 km)
6 Months 6 Months 6 Months 12 Months 12 Months 12 Months
500 Hours 500 Hours 500 Hours 1000 Hours 1000 Hours 1000 Hours
NOTE: The following recommendations in Schedule 2 are based upon the transmission containing 100 percent of TranSynd™ fluid.
4000 Product Family Filter change intervals in Schedule 2 and 3 are only valid with the use of Allison Transmission Gold series filters.
Flushing Machines are not recommended due to inconsistencies in removing 100 percent of the used fluid.
4 inch Control Module (3.5 inch approximately)—Requires Filter Kit P/N 29540494
Schedule 2. Recommended Fluid and Filter Change Intervals (TranSynd™/TES 295 Fluid)
75,000 Miles 75,000 Miles Overhaul 75,000 Miles 150,000 Miles 75,000 Miles Overhaul 75,000 Miles
(120 000 km) (120 000 km) (120 000 km) (240 000 km) (120 000 km) (120 000 km)
36 Months 36 Months 36 Months 48 Months 36 Months 36 Months
3000 Hours 3000 Hours 3000 Hours 4000 Hours 3000 Hours 3000 Hours
2 inch Control Module (1.75 inch approximately)—Requires Filter Kit P/N 29540493

Copyright © 2005 General Motors Corp.

Schedule 3. Recommended Fluid and Filter Change Intervals (TranSynd™/TES 295 Fluid)
50,000 Miles 50,000 Miles Overhaul 50,000 Miles 150,000 Miles 50,000 Miles Overhaul 50,000 Miles
(80 000 km) (80 000 km) (80 000 km) (240 000 km) (80 000 km) (80 000 km)
24 Months 24 Months 24 Months 48 Months 24 Months 24 Months
2000 Hours 2000 Hours 2000 Hours 4000 Hours 2000 Hours 2000 Hours
NOTE: Change fluid/filters after recommended mileage, months, or hours have elapsed, whichever occurs first.
Severe Vocation: All Retarders, On/Off Highway, Refuse, Transit, and Intercity Coach with duty cycle greater than one (1) stop per mile.
General Vocation: Intercity Coach with duty cycle less than or equal to one (1) stop per mile and all other vocations.
Local conditions, severity of operation or duty cycle may require more or less frequent fluid change intervals that differ from the
published recommended fluid change intervals of Allison Transmission. Transmission protection and fluid change intervals can be optimized
4000 PRODUCT FAMILIES SERVICE MANUAL—ALLISON 4th GENERATION

by the use of fluid analysis. Filters must be changed at or before recommended intervals.
 PREVENTIVE MAINTENANCE
b. Fluid Analysis. Transmission protection and
fluid change intervals can be optimized by monitoring
fluid oxidation according to the tests and limits shown
in Table 2–3. Consult your local telephone directory
for fluid analysis firms. For consistent and accurate
fluid analysis, use only one fluid analysis firm. Refer
to the Technician’s Guide for Automatic Transmission
Fluid, GN2055EN, for additional information.
Table 2–3. Fluid Oxidation Measurement Limits
Test Limit
Viscosity ±25% change from new fluid
Total Acid Number +3.0* change from new fluid
* mg of KOH to neutralize a gram of fluid.
2–11. FLUID CONTAMINATION
CAUTION:
Contaminated fluid can leave the oil cooler
contaminated. The cleanliness of the oil cooler
affects the cleanliness of the transmission fluid. If
there is any doubt about the cleanliness of the
cooler, replace the cooler.
a. Water
1. At each fluid change, examine the drained
fluid for evidence of dirt or water. A normal
amount of condensation will appear in the fluid
during operation.
2. Obvious water contamination of the
transmission fluid requires inspecting and
pressure testing the cooler (heat exchanger) for
leaks between the water and fluid areas.
Transmission fluid in the water side of the
cooler (heat exchanger) is another sign of a leak.
NOTE:
Cooler water can also be contaminated by engine
oil; be sure to locate the correct source of cooler
water contamination.
b. Engine Coolant. Engine coolant (ethylene
glycol) in the transmission hydraulic system requires
Copyright © 2005 General Motors Corp.
immediate action to prevent malfunction and possible
serious damage. The transmission must be completely
disassembled, inspected, and cleaned. Remove all
traces of the coolant and varnish deposits resulting
from engine coolant contamination. Replace friction
clutch plates contaminated with engine coolant.
c. Metal
CAUTION:
If excessive metal contamination has occurred,
replace the oil cooler and visually inspect all
bearings in the transmission.
Metal particles in the fluid (except for the minute
particles normally trapped in the oil filter) may
indicate internal transmission damage. When these
particles are found in the sump, the transmission must
be disassembled and closely inspected to find the
source. Metal contamination requires complete
transmission disassembly. Clean all internal and
external hydraulic circuits, cooler, and all other areas
where the particles could lodge.
2–12. FLUID AND FILTER
CHANGE PROCEDURE
NOTE:
If only filters are being replaced, do not drain the
fluid.
a. Drain Fluid
WARNING!
Avoid contact with the hot fluid or the hot sump
when draining transmission fluid. Direct contact
with the hot fluid or the hot sump may result in
bodily injury.
1. Drain the transmission when the fluid is at
operating temperature—71–93°C (160–200°F).
Hot fluid flows quicker and drains more
completely.
2. Remove the drain plug from the control
module and allow the fluid to drain into a
suitable container.
3. Examine the fluid as described in
Paragraph 2–11.
2–7
 4000 PRODUCT FAMILIES SERVICE MANUAL—ALLISON 4 th GENERATION

b. Replace Filters (Figure 2–2)
CAUTION:
Do not interchange filters for the deep and
shallow sump. Installation of the wrong filter can
cause damage to the transmission.
1. To replace the oil filters remove twelve bolts 6,
two filter covers 5, two gaskets 4, two
O-rings 3, two O-rings 2, and two filters 1
from the bottom of the control module.
2. When reinstalling parts lubricate and install
new O-rings 2 and 3 on each cover 5. Lubricate
O-ring inside filter 1 and push filter onto each
cover 5. Install new gasket 4 on each cover 5
and align holes in gasket with holes in cover.
4. Install six bolts 6 into each cover 5 and tighten
them to 51–61 N·m (38–45 lb ft).
c. Refill Transmission
1. If removed, inspect the drain plug. Replace the
O-ring. Install the drain plug and tighten it to
25–32 N·m (18–25 lb ft).
2. After refill, determine if fluid level is correct
(refer to Paragraphs 2–5 through 2–7). Table
2–4 shows typical transmission fluid capacity.
NOTE:
The quantity of refill fluid will be less than the
transmission fluid capacity due to fluid remaining
in the external circuits and transmission cavities.
Use Table 2–4 as a guideline for determining fluid
quantity during refill.

CAUTION:
Table 2–4. Transmission Fluid Capacity
Do not use the bolts to draw filter covers to the
sump. This can damage the covers, seals, or sump.
4000 Product Family
3. Install filter 1 and cover 5 assemblies into the Item Being Filled Capacity*
filter compartment. Index each filter/cover 48.0 liters
assembly to the holes in the channel plate/ 4.00 inch Sump PTO Provision
51.0 quarts
sump. Push the filter/cover assemblies in by
hand to seat the seals. 45.0 liters
4.00 inch Sump No PTO Provision
48.0 quarts
41.0 liters
2.00 inch Sump PTO Provision
43.0 quarts
38.0 liters
LUBE
MAIN 2.00 inch Sump No PTO Provision
40.0 quarts

Additional Fill For Cooler*

1.0 liter
Direct-mount Non-retarder
1.1 quart

Additional Fill For Retarder Accumulator*

7 9
1
8 0.5 liter
Remote Accumulator
0.5 quart
2
3 * Does not include hoses or fittings.
4
5
6 LUBE
MAIN 2–13. BREATHER
V07321.02.00
a. Location and Purpose. The breather is located
Figure 2–2. Filter Change on top of the transmission converter housing. It serves

2–8 Copyright © 2005 General Motors Corp.

 PREVENTIVE MAINTENANCE
to prevent air pressure buildup within the transmission
and must be kept clean and open.
b. Maintenance
1. The amount of dust and dirt encountered will
determine the frequency of breather cleaning.
Use care when cleaning the transmission
exterior. Spraying steam, water, or cleaning
solution directly at the breather can force the
water or cleaning solution into the
transmission.
2. Always use a properly sized wrench to remove
or replace the breather. Pliers or a pipe wrench
can crush or damage the breather’s stem and
produce metal chips which could enter the
transmission.
2–14. TRANSMISSION STALL TEST
AND NEUTRAL COOL-DOWN
CHECK
a. Purpose. Stall testing is performed to determine
if a vehicle performance complaint is due to an engine
or transmission malfunction. Stall testing is a trouble-
shooting procedure only—never perform a stall test as
a general examination or during routine maintenance.
Transmission stall speed is the maximum engine rpm
attainable when the engine is at full throttle and the
torque converter turbine is not moving, or “stalled.”
After a transmission stall test, compare the actual full
throttle engine speed at torque converter turbine stall
with specifications established by the vehicle manu-
facturer.
NOTE:
Engine speed data can be obtained from the vehicle
manufacturer, or from the equipment dealer or dis-
tributor. Some engine manufacturers provide a
programmable parameter to limit engine speed
when the transmission output speed is 0 rpm, such
as at a stop. This parameter should be set to a higher
value than the expected transmission stall speed be-
fore performing a stall test.
b. Stall Testing Preparation. If a transmission stall
test is to be performed, make sure the following
Copyright © 2005 General Motors Corp.
preparations have been made before conducting the
transmission stall test.
1. The manufacturer concurs with performing a
full-throttle transmission stall test.
2. The engine programmable parameter for 0 rpm
transmission output speed is set higher than the
value expected at transmission stall speed.
3. The vehicle is in an area in which a transmis-
sion stall test can be safely performed.
4. Make sure the fuel control linkage goes to full
throttle and does not stick when released.
5. Make sure the engine air induction system and
exhaust system have no restrictions.
6. Install a temperature gauge with the probe in
the transmission converter out (to cooler) line.
Allison DOC™ displays sump temperature
only.
7. Perform a Cold Check of the transmission fluid
level and adjust as necessary.
8. Connect Allison DOC™ to the vehicle
diagnostic data connector or install an accurate
tachometer (do not rely on the vehicle
tachometer).
9. Install wheel chocks.
10. A driver is in the driver’s position.
11. The vehicle’s service/park brakes are fully ap-
plied.
WARNING!
To help avoid personal injury, such as burns,
from hot transmission fluid and/or to help avoid
equipment damage, do not stall the torque con-
verter for more than ten seconds maximum and
monitor transmission fluid temperature. Imme-
diately return the engine to idle if converter out
(to cooler) temperature exceeds 150ºC (300ºF).
Operating the transmission at high engine power
at transmission stall or near stall conditions
causes a rapid rise in the transmission fluid tem-
perature. The fluid in the transmission torque
converter is absorbing all of the engine power
and the vehicle cooling system cannot dissipate
the excessive heat load. Extended operation un-
der high heat load conditions causes transmis-
sion and cooling system damage, and can
possibly fail hydraulic lines causing leaking high
temperature fluid.
2–9
 4000 PRODUCT FAMILIES SERVICE MANUAL—ALLISON 4 th GENERATION
WARNING!
To help avoid personal injury and equipment
damage while conducting a transmission stall
test, the vehicle must be positively prevented
from moving. Apply the parking brake, the ser-
vice brake, and chock the wheels securely. Warn
personnel to keep clear of the vehicle and its
travel path.
c. Performing a Transmission Stall Test
1. Start the engine. While in neutral let the trans-
mission warm to normal operating tempera-
ture:
— Sump temperature: 71–93ºC (160–200ºF)
— Converter out temperature: 82–104ºC
(180–220ºF)
2. Perform a Hot Check of the transmission fluid
level and adjust as necessary.
3. Turn OFF all engine accessories.
4. Use Allison DOC™ For PC–Service Tool to
select fourth range. Using fourth range reduces
the torque imposed on the transmission and
driveline. Do not perform a transmission stall
test in Reverse.
CAUTION:
To help avoid transmission or driveline damage,
full throttle transmission stall tests must never be
performed in reverse range (all models) or low
ranges (7-speed models).
5. Notify personnel in the area to keep clear of
the vehicle.
6. Slowly increase engine rpm until engine speed
stabilizes.
7. Record engine speed.
CAUTION:
The transmission stall test procedure causes a
rapid rise in transmission fluid temperature that
can damage the transmission. Never maintain a
stall condition once engine speed stabilizes or
converter out (to cooler) temperature exceeds
150ºC (300ºF). During a stall condition, con-
verter out temperature rises much faster than in-
ternal (sump) temperature. Never use sump fluid
temperature to determine the length of the stall
condition. If the stall test is repeated, do not let
the engine overheat.
2–10 Copyright © 2005 General Motors Corp.
8. Record converter out (to cooler) temperature.
9. Reduce engine speed to idle and shift the trans-
mission to N (Neutral).
10. Raise engine speed to 1200–1500 rpm for
two minutes to cool the transmission fluid.
11. At the end of two minutes, record converter out
(to cooler) temperature.
d. Driving Transmission Stall Test
NOTE:
If the vehicle is equipped with a smoke controlled or
an emission controlled engine or engine control
programming inhibits engine acceleration, the
following transmission stall test procedure can be
used.
CAUTION:
To help avoid personal injury and/or equipment
damage, a driving transmission stall test must be
performed by a trained driver and a qualified
technician.
e. Driving Transmission Stall Testing Prepara-
tion. If a transmission stall test is to be per-
formed, make sure the following preparations
have been made before conducting the transmis-
sion stall test.
1. The manufacturer concurs with performing a
full-throttle stall test.
2. Engine programmable parameter for 0 rpm
output speeds are set higher than value ex-
pected for stall speed.
3. The vehicle is in an area in which a transmis-
sion stall test can be safely performed.
4. Make sure the fuel control linkage goes to full
throttle and does not stick when released.
5. Inspect the engine air induction system and ex-
haust system for restrictions.
6. Perform a Cold Check of the transmission fluid
level and adjust as necessary.
7. Install a temperature gauge with the probe in
the transmission converter out (to cooler) line.
Allison DOC™ displays sump temperature
only.
 PREVENTIVE MAINTENANCE
8. Install an accurate tachometer (do not rely on
the vehicle tachometer).
9. Connect Allison DOC™ to the vehicle diag-
nostic data connector.
f. Performing a Driving Transmission Stall Test
1. Start the engine while in Neutral and let the
transmission warm to normal operating tem-
perature
— Sump temperature:
71–93ºC (160–200ºF)
— Converter out temperature:
82–104ºC (180–220ºF)
2. Perform a Hot Check of the transmission fluid
level and adjust as necessary.
3. Turn OFF all engine accessories.
4. While located in isolated area, begin the driv-
ing transmission stall test.
5. Select a hold range that will limit road speed
(usually 2nd or 3rd range). Never perform a
driving stall test in Reverse or Low range
(7-speed models).
6. Operate the engine at 100 percent full throttle,
maximum governed speed.
7. With the engine at maximum governed speed,
begin gradually applying the vehicle service
brakes while maintaining 100 percent full
throttle.
8. When the vehicle comes to a complete stop,
record engine speed.
CAUTION:
The transmission stall test procedure causes a
rapid rise in transmission fluid temperature that
can damage the transmission. Never maintain a
stall condition once engine speed stabilizes or
converter out (to cooler) temperature exceeds
150ºC (300ºF). During a stall condition, con-
verter out temperature rises much faster than in-
ternal (sump) temperature. Never use sump fluid
temperature to determine the length of the stall
condition. If the stall test is repeated, do not let
the engine overheat.
9. Record converter out (to cooler) temperature.
10. Reduce engine speed to idle and shift the trans-
mission to N (Neutral).
Copyright © 2005 General Motors Corp.
11. Raise engine speed to 1200–1500 rpm for two
minutes to cool the transmission fluid. At the
end of two minutes, record converter out (to
cooler) temperature
g. Neutral Cool-Down Check Procedure
1. At the end of two minutes, converter out (to
cooler) fluid temperature should return to
within normal operating temperature range.
2. If the transmission fluid does not cool within
two minutes, the cause could be a stuck torque
converter stator or an issue with the transmis-
sion cooler, lines, or fittings.
h. Transmission Stall Test Results
NOTE:
Environmental conditions, such as ambient
temperature, altitude, engine accessory loss
variations, etc., affect engine performance/power.
Due to such conditions, stall speed can vary from
specification by +/-150 rpm and still be accepted as
within published stall speed.
If engine speed with the transmission stalled is more
than 150 rpm below the stall speed specified, an en-
gine issue is indicated.
If engine speed with the transmission stalled is more
than 150 rpm above specification, a transmission issue
is indicated.
Conditions that can exist to cause stall speed to be
150 rpm above specification could be:
— Transmission fluid cavitation or aeration.
Verify proper fluid level using the oil level
sensor, if equipped, or dipstick.
— Slipping clutch.
— Torque converter malfunction.
— Sticking/damaged torque converter valve
A low stall speed that is at least 33 percent lower than
the published stall speed could indicate an engine is-
sue or a freewheeling stator in the torque converter.
2–11
 4000 PRODUCT FAMILIES SERVICE MANUAL—ALLISON 4 th GENERATION
2–15. READING CLUTCH
PRESSURES
a. Purpose. Reading individual clutch pressures
helps to determine if a transmission malfunction is due
to a mechanical or an electrical problem. Properly
making these pressure readings requires transmission
and vehicle (or test stand) preparation, recording of
data, and comparing recorded data against
specifications provided.
NOTE:
Determine if there are diagnostic codes set that are
related to the transmission difficulty you are
evaluating. Proceed to make mechanical
preparations for reading clutch pressures only after
codes have first been evaluated.
b. Transmission and Vehicle Preparation
CAUTION:
Be sure that the hydraulic fittings have the same
thread as the plugs removed (7⁄16-20 UNF-2A).
These fittings must be straight thread, O-ring
style. Failure to use properly threaded fittings
will damage the control module.
1. Remove the plug from the pressure tap and
install a hydraulic fitting and a pressure gauge
or transducer at each location where
measurement is desired (refer to Figure 2–3 or
Figure 2–4). Pressure gauge set J 26417-A is
available for this purpose. Refer to Table 2–5
for pressure levels expected.
2. Provide for engine speed to be monitored. (The
Allison DOC™ For PC–Service Tool may be
used.)
3. Be sure that transmission sump fluid
temperature can be measured. (The Allison
DOC™ For PC–Service Tool may be used.)
4. Be sure that the transmission has enough fluid
for cold operation until an operating
temperature fluid level can be set.
2–12 Copyright © 2005 General Motors Corp.
C3
C5
MAIN
LU
C2
C4
C1
V07322.00.02
Figure 2–3. Clutch Pressure Check Points
(Except 4700 and 4800 Models)
5. Bring the transmission to normal operating
temperature of 71–93ºC (160–200ºF). Inspect
for fluid leaks in the circuits being tested.
Repair leaks as needed. Be sure that fluid level
is correct.
c. Recording Data
1. The Allison DOC™ For PC–Service Tool
allows reading of individual range clutch
pressures with the vehicle stationary. Clutch
Test instructions are located in the Action
Request section of the Allison DOC™ For PC–
Service Tool User Guide, GN3433EN. Follow
instructions to read clutch pressures in
individual ranges.
NOTE:
Read lockup clutch pressure by driving the vehicle in
a range where lockup can be obtained. Record the
pressure values at the engine speed and sump fluid
temperature values shown in Table 2–5. The lockup
clutch is functioning correctly when engine speed
and turbine speed values are equal as recorded
from the Allison DOC™.
 PREVENTIVE MAINTENANCE
2. Operate the transmission at the conditions
shown in Table 2–5 and record engine speed,
transmission sump fluid temperature, main
pressure, and clutch pressures in the ranges
where a problem is suspected.
6. Return the transmission to its original
configuration. (Remove instrumentation and
reinstall any components removed for the
pressure testing.)

d. Comparing Recorded Data To Specifications LOCKUP

PRESSURE TAP C6 PRESSURE TAP
1. Be sure that engine speed and transmission (On left side of
adapter housing,
sump fluid temperatures were within the near the bottom)
values specified in Table 2–5. MAIN
C5
C4
C3
2. Compare the main pressure and clutch pressure
C1 C2
data, recorded in Step B, with the MAIN

specifications in Table 2–5.

LUBE
3. If clutch pressures are within specifications,
return the transmission and vehicle to their DRAIN PLUG
original configuration and proceed with
electrical troubleshooting. OIL FILTER
COVERS
4. If clutch pressures are not within specification, LUBE PRESSURE
take corrective action to replace the internal TAP CLUTCH PRESSURE
TAPS
parts of the transmission necessary to correct V05596.01.00

the problem.
5. Reread pressure values after the transmission Figure 2–4. 4700 and 4800 Models Clutch Pressure
has been repaired. Check Points (4700 and 4800 Models)

Copyright © 2005 General Motors Corp. 2–13

 Table 2–5. Main Pressure and Clutch Pressure Specifications

2–14
(Sump Fluid Temperature 71–93°C; 160–200°F)
Pressure Specifications
Transmission Model/Test Engine Clutches Main Range Clutch* Lockup Clutch*
Type rpm Range Applied kPa (psi) kPa (psi) kPa (psi)
4000 Product Family—Idle 580–620 Neutral C5 1515–2055 1440–2055 3.5 min
Main Mod OFF (220–300) (210–300) (0.5 min)
Neutral C5 1310–1725 1235–1725 3.5 min
Main Mod ON (190–250) (180–250) (0.5 min)
Reverse C3, C5 1450–2055 1375–2055 3.5 min
Main Mod OFF (210–300) (200–300) (0.5 min)
Reverse C3, C5 1170–1585 1095–1585 3.5 min
Main Mod ON (170–230) (160–230) (0.5 min)
Low C (4000 7-Speed) C1, C6 1240–1725 1165–1725 3.5 min
Main Mod OFF (180–250) (170–250) (0.5 min)
Low C (4000 7-Speed) C1, C6 870–1340 795–1340 3.5 min
Main Mod ON (125–195) (115–195) (0.5 min)
1C C1, C5 1240–1725 1165–1725 3.5 min
Main Mod OFF (180–250) (170–250) (0.5 min)
1C C1, C5 870–1340 795–1340 3.5 min
Main Mod ON (125–195) (115–195) (0.5 min)
2C C1, C4 1240–1725 1165–1725 3.5 min
Main Mod OFF (180–250) (170–250) (0.5 min)
2C C1, C4 870–1340 795–1340 3.5 min

Copyright © 2005 General Motors Corp.

Main Mod ON (125–195) (115–195) (0.5 min)
* To pass this specification, measured clutch pressures must be within 75 kPa (10 psi) of actual measured main pressure and still be within the minimum and maximum value of
this specification.
4000 PRODUCT FAMILIES SERVICE MANUAL—ALLISON 4 th GENERATION
 Table 2–5. Main Pressure and Clutch Pressure Specifications (cont’d)
(Sump Fluid Temperature 71–93°C; 160–200°F)
Pressure Specifications
Transmission Model/Test Engine Clutches Main Range Clutch* Lockup Clutch*
Type rpm Range Applied kPa (psi) kPa (psi) kPa (psi)
4000 Product Family—High 1780–1820 Neutral C5 1805–2055 1730–2055 160–240
Speed Main Mod OFF (260–300) (250–300) (23–35)
Neutral C5 1415–1725 1340–1725 160–240
Main Mod ON (205–240) (195–240) (23–35)
Reverse C3, C5 1805–2055 1730–2055 160–240
(260–300) (250–300) (23–35)
Low C (4000 7-Speed) C1, C6 1550–1795 1475–1795 160–240
(225–260) (215–260) (23–35)
1C C1, C5 1550–1795 1475–1795 160–240
(225–260) (215–260) (23–35)
2C C1, C4 1550–1795 1475–1795 160–240
(225–260) (215–260) (23–35)
2L C1, C4, LU 1080–1365 1005–1365 160–240
(155–200) (145–200) (23–35)
3C C1, C3 1550–1795 1475–1795 160–240
(225–260) (215–260) (23–35)
3L C1, C3, LU 1080–1365 1005–1365 160–240
(155–200) (145–200) (23–35)
4C C1, C2 1550–1795 1475–1795 125–200

Copyright © 2005 General Motors Corp.

(225–260) (215–260) (18–30)
4L C1, C4, LU 1080–1365 1005–1365 125–200
(155–200) (145–200) (18–30)
PREVENTIVE MAINTENANCE

5C C2, C3 1550–1795 1475–1795 125–200

(225–260) (215–260) (18–30)
5L C2, C3, LU 1080–1365 1005–1365 125–200
(155–200) (145–200) (18–30)
6C C2, C4 1345–1590 1270–1590 125–200
(195–230) (185–230) (18–30)
6L C2, C4, LU 1035–1235 960–1235 125–200
(150–180) (140–180) (18–30)
* To pass this specification, measured clutch pressures must be within 75 kPa (10 psi) of actual measured main pressure and still be within the minimum and maximum value of
this specification.

2–15
 4000 PRODUCT FAMILIES SERVICE MANUAL—ALLISON 4 th GENERATION
2–16. FLUID LEAK DIAGNOSIS
Most fluid leaks can be located and repaired by
visually finding the leak and replacing or repairing the
necessary parts. On some occasions, a fluid leak may
be difficult to locate or repair. The following
procedure may help in locating and repairing most
leaks.
a. Finding The Leak
1. Identify the fluid. Determine whether it is
engine oil, automatic transmission fluid, or
hydraulic fluid from a specific vehicle system.
2. Operate the vehicle to reach normal operating
temperature and park the vehicle. After a few
minutes, look for dripping fluid to identify the
approximate location of the leak.
3. Visually inspect around the suspected area.
Inspect all gasket mating surfaces for leaks. A
mirror is useful for finding leaks in areas that
are hard to reach.
4. If the leak still cannot be found, clean the
suspected area with a degreaser, steam, or
spray solvent. Completely clean and dry the
area. Operate the vehicle for several miles at
normal operating temperature and varying
speeds. After operating, visually inspect the
suspected leak area. If the leak is not located,
use the powder or black light and dye methods.
b. Powder Method
1. Clean the suspected area.
2. Apply an aerosol-type white powder, such as
foot powder, to the suspected area.
3. Operate the vehicle under normal operating
conditions.
4. Visually inspect the suspected area and trace
the leak path over the white powder surface to
the source.
c. Black Light and Dye Method
NOTE:
A dye and black light kit is available for finding
leaks. Refer to the manufacturer’s directions when
using the kit. Refer to kit directions for the color of
the fluid and dye mix.
2–16 Copyright © 2005 General Motors Corp.
1. Pour the specified amount of dye into the
transmission fill tube.
2. Operate the vehicle under normal operating
conditions as directed in the kit.
3. Direct the black light toward the suspected
area. The dyed fluid will appear as a brightly
colored path leading to the source.
d. Possible Points of Fluid Leaks
and Their Causes
1. Transmission mating surfaces:
• Bolts improperly tightened
• Improperly installed or damaged gasket
• Mounting face damaged
2. Housing:
• Filler pipe seal damaged or missing
• Filler pipe bracket dislocated
• Oil cooler connector fittings loose or
damaged
• Output shaft seals worn or damaged
• Pressure port plugs loose
• Porous casting
3. Converter end:
• Converter seal damaged
• Seal lip cut (inspect converter hub for
damage)
• Garter spring missing from seal
• Converter leak in weld area
• Damaged or missing converter O-ring seal
• Porous casting
4. Breather or fill tube:
• Overfilled—incorrect dipstick
• Plugged breather
• Water or coolant in fluid—fluid will appear
milky
• Incorrect electronic fluid level indication
• Drain-back holes plugged
 PREVENTIVE MAINTENANCE
5. Gaskets:
• Fluid level/pressure is too high
• Plugged vent or drain-back holes
• Improperly tightened fasteners or dirty/
damaged threads
• Warped flanges or sealing surface
• Scratches, burrs, or other damage to a
sealing surface
• Output shaft surface scratched, nicked, or
damaged
• Loose or worn bearing causing excess seal
wear
e. Repairing the Leak. Once the leak has been
located and traced to its source, repair the leaking
components. If a gasket is replaced, but the sealing
flange is bent, the new gasket will not repair the leak.
The bent flange must also be repaired.

• Damaged or worn gasket 2–17. OUTPUT FLANGE/YOKE AND

• Cracked or porous casting OIL SEAL MAINTENANCE
• Improper sealant used (where applicable) a. Disassembly (Figures 2–5 and 2–6)

6. Seals: 1. Remove one bolt 8, retainer plug 7, O-ring 6,

and O-ring 5.
• Fluid level/pressure is too high
• Plugged vent or drain-back holes 2. Remove flange 3 or yoke 4. Inspect journal
sealing area. Minimum journal area diameter is
• Damaged seal bore 85 mm (3.346 inch).
• Damaged or worn seal 3. Inspect slinger 2. Replace if damaged.
• Improper installation 4. Remove oil seal 1 using tool J 24171-A or
• Cracks in component equivalent.

1
2
3

4
5
6
7
8

V06834.01.00

Figure 2–5. Output Flange and Oil Seal (Except 4700 and 4800 Models)

Copyright © 2005 General Motors Corp. 2–17

 4000 PRODUCT FAMILIES SERVICE MANUAL—ALLISON 4 th GENERATION

b. Assembly (Figure 2–5 and 2–6) 2–18. ON-VEHICLE MAINTENANCE

1. Install oil seal 1 using installer J 37031-A
(except 4700 and 4800 models) or J 43024 (4700 The following may be serviced or removed with the
and 4800 models), and J 8092 or equivalent. transmission mounted in the vehicle. Refer to the
indicated paragraph for removal instructions:
2. If removed, use special tool J 46150 to press a
new slinger 2 onto the flange or yoke.
3. Install flange 3 or yoke 4. Item Paragraph
4. Install O-ring 5 on plug 7. PTO(s) 4–2b
5. Insert bolt 8 through retainer plug 7. Oil Fill Tube 4–2c(2)
6. Install an O-ring 6 over the threaded end of Remote Cooler Manifold 4–2c(3)
bolt 8 so that the O-ring seats against the Input, Turbine, and
retainer plug. Output Speed Sensor 4–2c(7)
7. Install retainer plug 7 into the yoke or flange. Control Module 4–2f
Tighten bolt 8 to 70–80 N·m (51–60 lb ft).

1
2
3

4
5
6
7
8

V05578.01.00

Figure 2–6. Output Flange and Oil Seal (4700 and 4800 Models)

2–18 Copyright © 2005 General Motors Corp.

 SECTION 3—GENERAL OVERHAUL INFORMATION
3–1. SCOPE
This section provides general information for
transmission overhaul. The information provided
includes:
• Tools and equipment required for overhaul
• Replacement parts information
• Cleanliness and careful handling
• Cleaning and inspection
• Assembly procedures
• Transmission removal and installation
• Locating wear data
• Locating spring specifications
• Locating torque specifications for plugs, bolts,
and nuts
3–2. TOOLS AND EQUIPMENT
a. Improvised Equipment. A work table—700 kg
(1500 pound) capacity (Figure 3–1) may be improvised.
b. Special Tools. Special tools are illustrated in
Figure 3–2 and Figure 3–3 and are identified in
Table 3–1 and Table 3–2.
c. Mechanic’s Tools and Shop Equipment. The
following tools, in addition to the common tools
ordinarily required, should be available.
Common hand tools, metric where required
• Metric wrench set (sockets, box-end wrenches,
and Allen wrenches)
• Snapring (retaining ring) pliers
• Micrometer (metric preferred)
• Depth micrometer (metric preferred)
• Dial indicator set (metric preferred)
• Metric headless guide bolts set
• M16 eye bolt
• M10 eye bolt
• Suitable hoist—900 kg (2000 lb) capacity
• A 20 N·m (150 lb inch) torque wrench
• A 500 N·m (350 lb ft) torque wrench
• Clean, lint-free shop cloths (do not use waste
cloths)
• A press for disassembly and assembly of
spring-loaded clutches and interference-fit parts
• Containers for parts
• Supply of wood blocks
• Petrolatum
• Container of mineral spirits for cleaning parts
WARNING!
Use appropriate safety equipment such as safety
glasses, safety shoes, and gloves.
CAUTION;
Caustic cleaning compounds will damage some
transmission parts. Use only mineral spirits to
clean transmission parts.

120 cm
(48 in.)
200 cm
(78 in.) OIL DRAIN STEEL TOP

TROUGH
60 cm 16-GAUGE SHEET STEEL
(24 in.) 35 mm (11Ú2 in.) DEEP
35 mm (11Ú2 in.) WIDE
OIL DRAIN
(BOTH SIDES) 5x15 cm
(2x6 in. BOARD)
FOR TOP FRAME
10x10 cm AND LEG BRACKETS
(4x4 in. LEGS)
V00660.02

Figure 3–1. Work Table

Copyright © 2005 General Motors Corp. 3–1

 4000 PRODUCT FAMILIES SERVICE MANUAL—ALLISON 4 th GENERATION

1 5
2 3 4

11
7 9 10
8

14
12 13 15 16

17
18 19 21 22
20

23

26
24 25 27 30

31
28
29

NOTE: Objects are not shown to scale V06922.02.00

Figure 3–2. 4000 Product Family Special Tools

3–2 Copyright © 2005 General Motors Corp.

 GENERAL OVERHAUL INFORMATION
Table 3–1. 4000 Product Family Special Tools*

Kent-Moore Figure 3–2 Reference

Tool No.** Item No. Description Paragraph
J 3940 1 Bearing Race Remover 5–14c,e; 5–16a,c
J 8092 2 Drive Handle 2–17b; 5–3b; 5–5e; 5–6b,c; 5–7b;
5–10b; 5–11b; 5–14g; 5–16e
J 24171-A 3 Seal Remover 2–17a; 5–5b; 5–6a; 5–14c; 5–16a
J 26417-A 29 Pressure Gauge Set 2–15b
J 29109 4 Overhaul Stand 4–2a; 6–2a
J 33163 5 Valve Body Parts Tray Set (includes 5–18a
J 33163-1 and J 33163-2)
J 33884 NA Pressure Switch Test Block NA
J 35923-2 19 C1 Spring Compressor (use with J 37030-3) 5–7a,b
J 35924 7 Main-Pressure Spring Remover/Installer 5–18e,h
J 35926 24 Transmission Holding Bracket 4–2a; 6–2a
J 37030-1 17 C2 Spring Compressor (use with J 37030-3) 5–7a,b
J 37030-2 18 C5 Spring Compressor (use with J 37030-3) 5–14e,f; 5–16c,d; 5–17c
J 37030-3 20 C1, C2, and C5 Spring Compressor Tool Base 5–7a,b; 5–14e,f; 5–15f; 5–16c,d
J 37031-A 22 Output Seal Installer 6–2q,s
J 37032 9 Input Seal Installer 5–5e; 5–6c
J 37033 10 Output Bearing Cup Installer (use with J 37034) 5–14f,h; 5–15g,h
J 37034 15 Output Bearing Installer/Drive Sleeve 5–5e; 5–6b,c; 5–14f,g,h; 5–15g,h,i,j;
5–16d,e,f; 5–17d,e,f
J 37035 11 Spanner Nut Torque Tool Set 5–14c,h; 5–15c,j; 5–16a,f; 5–17a,f;
6–2q,r,s,t
J 37036 12 Turbine Shaft Bushing/Output Bushing/P2 5–7b; 5–11b; 5–14g; 5–16e
Carrier Bushing Installer
J 37038 21 P1 Carrier Bushing and Ground Sleeve Bearing, 5–5e; 5–6b, c; 5–10b
Pump Body Bushing, and Bearing Retainer
Bushing Installer
J 37040 13 Rotating Clutch Bushing Installer 5–7b
J 37041 14 Front Support Sleeve and PTO Bearing Installer 5–5d; 5–6b
J 38548 27 Torque Converter End Play Gauge 5–3b; 6–2v
J 38564 25 Torque Converter Bolt Tool 4–2g
J 39534 26 Wear Plate Rivet Installer NA
J 39949 8 Torque Converter Cover Bushing Installer 5–3b
J 39954 16 Charging Pump Bushing Installer 5–6c
J 41445 23 Transmission Holding Bracket 4–2a; 6–2a
J 41462 6 Main-Pressure Relief Spring Compressor 5–6a,b
J 42048 28 Retarder Flow Valve Spring Compressor 5–14c,h; 5–15c,j
J 46150 30 Slinger Installer 6–2z
J 47942 31 Valve Body Spring Compressor 5–18c,j
* We believe this source and its tools to be reliable. These tools may be available from other manufacturers. General
Motors does not endorse, indicate any preference for, or assume any responsibility for the products or tools from
these firms, or for any such items that may be available from other sources.
** Kent-Moore Tool Division, 29784 Little Mack, Roseville, Michigan 48066

Copyright © 2005 General Motors Corp. 3–3

 4000 PRODUCT FAMILIES SERVICE MANUAL—ALLISON 4 th GENERATION

1
2 3 4

5 6
7 8

10
9 23

11

14
24
16 17
15

25

12
18 19
20

13

22
21

NOTE: Objects are not shown to scale V06923.02.00

Figure 3–3. 4700 and 4800 Model Special Tools

3–4 Copyright © 2005 General Motors Corp.

 GENERAL OVERHAUL INFORMATION
Table 3–2. 4700 and 4800 Model Special Tools*

Figure 3–3
Kent-Moore Item Reference
Tool No.** Number Description Paragraph
J 3940 1 Bearing Race Remover 5–15d,f; 5–17c
J 8092 2 Drive Handle 2–17b; 5–15i; 5–17e
J 24171-A 3 Seal Remover 2–17a; 5–15c; 5–17a
J 35923-4 11 Spring Compressor Tool Base 5–13d,e; 5–17d
J 35926-A 13 Transmission Lifting Bracket (modified to lift 4–2a; 6–2a
4700 and 4800 models)
J 35926-UPD NA Modification Template (used to modify J 35926 to NA
become J 35926-A)
J 37030-2 10 C5 Spring Compressor 5–15f,g; 5–17c
J 37030-3 11 C1, C2, and C5 Spring Compressor Tool Base 5–15f,g; 5–17c
J 37032 4 Input Seal Installer NA
J 37033 5 Output Bearing Cup Installer 5–16d; 5–17d
J 37034 9 Output Bearing Installer/Drive Sleeve 5–13d,e,f; 5–15g,h,i,j;
5–17d,e,f; 6–2r,t
J 37035 6 Spanner Nut Torque Tool Set 5–15c,j; 5–17a,f; 6–2r,s,t
J 37036 8 Turbine Shaft Bushing/Output Bushing/P2 Carrier 5–15i; 5–17e
Bushing Installer
J 41445 12 Transmission Holding Bracket 4–2a; 6–2a
J 42048 23 Retarder Flow Valve Spring Compressor 5–15c,j
J 43020 15 P3 Planetary Lifting Ring 4–2n; 6–2k
J 43023 16 P4 Planetary Bushing Installer 5–13f
J 43024 -A 17 Output Shaft Seal Installer 2–17b; 6–2r,t
J 43025 18 C5 Return Spring 5–13d,e; 5–17d
J 43046 19 Torque Wrench Adapter 4–2m; 6–2l
J 43047 20 Bearing Installer/Remover 5–13d,e
J 43202 21 Output Shaft Bearing Installer 5–15i; 5–17e
J 43278 7 Output Shaft Holding Tool 5–14h; 5–15j; 5–16f;
5–17a,f; 6–2r,t
J 43922 22 Measuring Blocks And Straight Edge 6–2m,n
J 43975 14 4700 and 4800 Model Tool Kit (Includes the following NA
special tools: J 43020, J 43023, J 43024, J 43025,
J 43046, J 43047, J 43202, J 43278, and J 43922)
J 46150 24 Slinger Installer 6–2z
J 47942 25 Valve Body Spring Compressor 5–18c,j
* We believe this source and its tools to be reliable. These tools may be available from other manufacturers. General
Motors does not endorse, indicate any preference for, or assume any responsibility for the products or tools from these
firms, or for any such items that may be available from other sources.
** Kent-Moore Tool Division, 29784 Little Mack, Roseville, Michigan 48066

Copyright © 2005 General Motors Corp. 3–5

 4000 PRODUCT FAMILIES SERVICE MANUAL—ALLISON 4 th GENERATION
3–3. REPLACEMENT PARTS
a. Ordering Information. Refer to the current issue
of 4000 Product Family Parts Catalog PC2456EN for
parts information. Do not order replacement parts
using the reference numbers in this service manual.
b. Parts Normally Replaced at Overhaul. The
following parts are normally replaced at each
transmission overhaul:
• Gaskets
• Lockstrips
• Washers or retaining rings damaged by
removal or abnormal wear
• Oil seals and piston sealrings
• Spiral retaining ring 4 (Foldout 8)
• Suction filter 5 (Foldout 11)
WARNING!
Do not burn discarded Teflon® seals; toxic gases
are produced by burning Teflon.
3–4. CAREFUL HANDLING
Handle parts and subassemblies carefully to prevent
nicking, scratching, and denting. Parts that fit together
closely and have a specific operating clearance can
bind if damaged. Parts that depend upon smooth
surfaces for sealing may leak if scratched. Control
valve body assembly parts are especially susceptible
to leaking if scratched (valves, when dry, must move
freely by their own weight). Handle these parts
carefully and protect them during removal, cleaning,
inspection, and installation. Keep control valve body
assembly parts in clean containers until installation.
3–5. CLEANING AND INSPECTION
a. Dirt Causes Malfunction. All parts must be
clean to permit effective inspection. Do not allow dirt
or foreign material to enter the transmission during
assembly. Even minute particles can cause close-fit
parts, such as valves, to malfunction.
3–6 Copyright © 2005 General Motors Corp.
b. Cleaning Transmission, Parts
CAUTION:
Seal all openings and the breather before steam
cleaning the transmission. The material on
friction-faced clutch plates, the bonding agent,
and clutch housing machined surfaces can be
damaged by water, steam cleaning, or
unapproved solvents and detergents. Use only
mineral spirits to clean friction-faced clutch
plates and clutch housings.
1. Clean all metallic transmission parts, except
bearings and friction-faced clutch plates, by
steam cleaning or with mineral spirits. Do not
use caustic soda solution for steam cleaning. If
steam cleaning, do not allow steam or water to
enter the transmission. Clean friction-faced
clutch plates and bearings with mineral spirits
only.
2. Dry all parts, except bearing assemblies, with
compressed air. To prevent rust, lubricate
steam-cleaned parts as soon as they are dry.
3. Clean fluid passages by working a piece of soft
wire through the passages and flushing them
with mineral spirits. Dry the passages with
compressed air.
4. Examine parts, especially fluid passages, after
cleaning to make certain they are entirely
clean. Re-clean parts if necessary.
5. Removal of minor defects with such items as
crocus cloth, honing stones, and scrapers
produces debris and residue. Cover adjacent
parts, ports, and cavities before removing
defects. Thoroughly reclean the affected areas
after rework.
c. Cleaning Bearings
WARNING!
Never dry bearings by spinning them with
compressed air. A spinning bearing can
disintegrate, allowing balls or rollers to become
lethal flying projectiles. Also, spinning a bearing
without lubrication can damage the bearing.
1. Bearings that have been in service should be
thoroughly cleaned in mineral spirits.
 GENERAL OVERHAUL INFORMATION
2. Soak particularly dirty bearings or ones filled
with hardened grease in mineral spirits before
trying to clean them.
3. Before inspection, lubricate bearings with
transmission fluid.
d. Inspecting Bearings
CAUTION:
If excessive metal contamination has occurred,
replacement of all bearings is recommended.
1. Inspect bearings for rough rotation. Replace a
bearing if its rotation is still rough after
cleaning and lubrication.
2. Inspect bearings for scored, pitted, scratched,
cracked, or chipped races, and for excessive
roller or ball wear. Replace the bearing if any
of these defects are found.
3. Inspect a defective bearing’s bore and mating
shaft for grooved, burred, or galled conditions
that indicate the bearing has been turning in the
bore or on the shaft. If shaft or bore damage
cannot be repaired with crocus cloth, replace
the defective part.
4. When removing a bearing, do not apply
pressure across the balls. This can cause
brinelling and bearing failure.
5. If a bearing must be removed or installed
without the proper tool, press only on the
race which is adjacent to the mounting
surface.
e. Keeping Bearings Clean. Ball or roller bearing
failures are usually caused by dirt or grit in the
bearing. Keep bearings clean during removal and
installation. Observe the following rules to be sure
maximum bearing life:
• Do not unwrap new bearings until they are to
be installed.
• Do not remove the grease in which new
bearings are packed until they are to be
installed.
• Do not lay bearings on a dirty bench. Place
bearings on clean paper, or lint-free cloth.
Copyright © 2005 General Motors Corp.
• If a bearing is not installed immediately, wrap
or cover the lubricated bearing with clean
paper or lint-free cloth to keep out dust.
f. Inspecting Cast Parts and Machined Surfaces
1. Inspect bores for wear, scratches, grooves, and
dirt. Remove scratches and burrs with crocus
cloth. Clean the part. Replace parts that are
deeply scratched or grooved.
2. Inspect all fluid passages for obstructions. If an
obstruction is found, remove it with
compressed air, or by working a soft wire back
and forth through the passage and flushing it
with mineral spirits.
3. Inspect mounting faces for nicks, burrs,
scratches, and foreign matter. Remove any
defects with crocus cloth or a soft stone. Clean
the part. If scratches are deep, replace the
defective part.
4. Inspect threaded openings for damaged
threads. Chase damaged threads with a
correctly sized tap. Clean the part.
5. Inspect the ribs inside the main housing for
reaction plate wear grooves in the side of the
ribs. Replace housings that have wear grooves
beyond wear limits. (Refer to Wear Limits,
Table 7–1 in Section 7.)
6. Replace housings or other cast parts that are
cracked.
7. Inspect all machined surfaces for damage that
could cause fluid leakage or other malfunction.
Rework or replace defective parts.
8. Inspect the oil tracks of the control module and
main housing for porosity, broken lands,
cracks, dirt, and land surface imperfections.
These imperfections will cause severe fluid
leakage leading to transmission failure.
g. Inspecting Bushings and Thrust Washers
1. Inspect bushings for scores, burrs, sharp edges,
and evidence of overheating. Remove scores
with crocus cloth. Remove burrs and sharp
edges with a scraper or knife blade. Before
reinstalling, carefully check bushings for signs
of distress. Clean the part.
3–7
 4000 PRODUCT FAMILIES SERVICE MANUAL—ALLISON 4 th GENERATION
CAUTION:
When removing a defective bushing, do not
damage the bushing bore.
2. Replace bushings that are out-of-round, deeply
scored, or excessively worn. Inspect parts
mated to bushings to be sure they are not
damaged or worn beyond use.
3. Inspect thrust washers for distortion, scores,
burrs, and wear. Replace a thrust washer if
defective or worn.
h. Inspecting Sealrings and Gaskets
1. Inspect piston sealrings and lip-type seals for
nicks, cuts, tears, splits, and pattern damage. A
damaged seal can indicate rough or sharp
edges in piston grooves or on a mating surface
that could damage a new seal.
2. Inspect piston sealring grooves for nicks, burrs,
dents, or displaced metal that could damage
the new seal. Remove raised metal, sharp
edges, burrs, or nicks with a soft stone and
crocus cloth. Thoroughly clean all residue
from the piston before assembly.
3. Replace all composition gaskets.
4. Inspect hook-type sealrings for wear, broken
hooks, and distortion. Install a new hook-type
sealring if the old ring shows any wear on its
outside diameter, or if there is excessive side
wear. Install a new sealring if there is wear on
the sealring outside diameter mating surface.
5. Inspect clutch housing sealing surfaces for
nicks, burrs, dents, or displaced metal that
could interfere with mating parts or damage
the piston seal. Remove raised metal, sharp
edges, burrs, or nicks with a soft stone and
crocus cloth. Thoroughly clean all residue
from the housing before assembly.
6. Measure butt-joint sealring end gap by
inserting the sealring into its respective sealing
bore. Use a feeler gauge to measure end gap.
Discard sealrings that do not meet
specifications. Refer to Table 7–1, Wear Limits
Data, in Section 7.
3–8 Copyright © 2005 General Motors Corp.
i. Inspecting Gears
1. Inspect gears for scuffed, nicked, burred, or
broken teeth. If a defect cannot be removed
with a soft stone, replace the gear.
2. Inspect gear teeth for wear that has changed
the original tooth shape. If this condition is
found, replace the gear.
3. Inspect the thrust face of gears for scores,
scratches, and burrs. Remove such defects with
a soft stone. If scratches and scores cannot be
removed with a soft stone, replace the gear.
Thoroughly remove all residue from surface.
4. Inspect gears for load pattern and signs of
distress. Any sign of distress indicates that a
gear failure during operation is possible.
Reusing distressed gears is an individual
customer decision based upon experience.
Backlash cannot be used to establish critical
gear wear. Backlash tolerances are of such
nature that a gear usually pits, scuffs, scores, or
galls long before gear wear becomes critical.
j. Inspecting Splined Parts
1. Inspect splined parts for stripped, twisted,
chipped, or burred splines. Remove burrs with
a soft stone. Replace the part if other defects
are found. Spline wear is not considered
harmful except where it affects the fit of the
splined parts. Thoroughly remove all residue
from surface.
2. Spline wear is determined by measuring and
comparing the unworn and worn areas of the
spline. This can also be checked by comparing
feeler gauge thickness to the depth of the worn
area. Replace parts having excessive spline
wear. Refer to Table 7–1, Wear Limits Data, in
Section 7.
3. Backlash cannot be used to establish critical
spline wear. Accurate backlash measurement
requires the mating parts to be concentrically
located.
k. Inspecting Threaded Parts. Inspect threaded
parts for burred or damaged threads. Remove burrs
with a soft stone or fine file. Replace damaged parts.
Thoroughly remove all residue from surface.
 GENERAL OVERHAUL INFORMATION
l. Inspecting Retaining Rings. Inspect all retaining
rings for nicks, distortion, or excessive wear. Replace
the retaining ring if any of these defects are found. The
retaining ring must snap tightly into its groove to
function properly.
m. Inspecting Springs. Inspect springs for signs of
cracking, overheating, permanent set, or wear due to
rubbing adjacent parts. Replace the spring if any of
these defects are found. Refer to Table 7–2, Spring
Data, in Section 7.
n. Inspecting Clutch Plates (Figure 3–4)
1. Inspect friction-faced clutch plates for burrs,
embedded metal particles, severely pitted
faces, loose faces, excessive wear, cone,
cracks, distortion, shallow oil groove depth, or
damaged spline teeth. Remove burrs using a
soft stone. Replace plates which have any
defects. Remove all residue from part.
2. Inspect steel plates for burrs, scoring,
excessive wear, excessive cone, distortion,
embedded metal, galling, cracks, breaks, or
damaged tangs. Remove burrs and minor
surface irregularities using a soft stone.
Replace plates which have any non-repairable
defects. Remove all residue from part.
3. The amount of clutch plate cone is determined
by measuring the distance between the inside
diameter of the plate and a level surface
(Figure 3–4). Discard plates having excessive
cone. Refer to Table 7–1, Wear Limits Data, in
Section 7.
4. Determine oil groove depth with a depth
micrometer or by measuring the smooth
surface (total) thickness of the plate, measuring
the thickness of the steel part of the plate at the
oil groove, and subtracting this measurement
from the total thickness. Replace plates not
having the minimum oil groove depth. Refer to
Table 7–1, Wear Limits Data, in Section 7.
LEVEL SURFACE
CLUTCH PLATE
MEASURE HERE FOR CONE
V00493.01
Figure 3–4. Method Of Measuring Clutch Plate Cone
Copyright © 2005 General Motors Corp.
o. Inspecting Swaged And Interference-Fit Parts.
If there is evidence of looseness, replace the assembly.
p. Inspecting Sealing Surfaces
1. Inspect surfaces in contact with hook-type and
butt-joint sealrings for step wear, nicks,
scratches, and scoring. Use a soft stone or
crocus cloth to remove only the raised metal
portion of these defects. Polishing the area to
remove a defect is neither necessary nor
desirable. If the defects are too severe to
correct, replace the defective part. Remove all
residue from part.
2. Inspect surfaces in contact with spring-loaded,
lip-type oil seals for nicks, scratches,
roughness, or other surface irregularities.
Inspect for embedded particles, step wear, and
dirt on flanges or other components exposed to
external contamination. Remove the defects
and restore the finish. Replace the part if scores
or scratches permit fluid leakage. Remove all
residue from part.
3–6. ASSEMBLY PROCEDURES
a. Parts Lubrication. During final assembly,
lubricate all moving parts with transmission fluid. The
fluid will help protect friction surfaces and ferrous
metals until the unit is in service.
b. Grease Used for Assembly. During assembly use
oil-soluble grease with a low melting point
(petrolatum) to temporarily retain parts, butt-joint
sealrings, scarf-cut sealrings, and hook-type sealrings.
c. Sealing Compounds and Nonsoluble Greases.
Do not use gasket-type sealing compounds, fibrous
greases, or nonsoluble vegetable-base cooking
compounds inside the transmission or where they
could be flushed into the transmission hydraulic
system.
d. Clutches and Pistons
1. Soak each friction-faced clutch plate (two-
minute minimum) in transmission fluid before
final assembly.
2. Apply a generous amount of transmission fluid
to the piston cavity before final assembly.
3. Assemble clutch plates so that the cone of each
plate faces the same direction.
3–9
 4000 PRODUCT FAMILIES SERVICE MANUAL—ALLISON 4 th GENERATION
e. Threaded Plugs and Hydraulic Fittings
CAUTION:
• Do not use Teflon®
tape on threaded parts
where slivers can enter the transmission and
cause a malfunction.
• Improperly installed plugs or fittings can
cause leakage and cracked housings.
Threaded plugs in 4000 Product Family transmissions
are the straight-thread, O-ring type. Be sure that the
O-ring is in like-new condition and tighten all plugs to
the torque value specified in the assembly procedure or
in the exploded views.
f. Coated Threaded Fasteners. Control module
bolts are manufactured with a band of sealant on the
threads. Coated bolts may be reused, however repeated
removal and installation may reduce the effectiveness
of the coating. If fluid leaks are detected around the
bolts, replace the coated bolts. Do not attempt to
re-apply a sealing compound. The coated bolts sizes
are M10 x 1.5 x 55 mm and M10 x 1.5 x 100 mm.
g. Lip-Type Oil Seals
1. When replacing lip-type seals, make sure the
spring-loaded lip is toward the fluid to be
sealed (toward the inside of the unit). Coat the
inside of the seal with high temperature grease
(MIL-G-3545A or equivalent) to protect the
seal during shaft installation and to provide
lubrication during initial operation.
2. The circumference of some seals is precoated
with a dry sealant. The sealant is usually
colored for easy identification. Precoated seals
do not require any additional sealant before
installation.
3. Before installation, apply a non-hardening
sealant to the circumference of seals not
precoated with a dry sealant.
3–10 Copyright © 2005 General Motors Corp.
h. Butt-Joint Sealrings
CAUTION:
If humidity is allowed to penetrate and expand a
butt-joint sealring, the sealring can be damaged
during installation. A damaged sealring will
permit transmission fluid to leak from the clutch
piston cavity and cause clutch slippage. Do not
open the sealed package until you are ready to
install the sealring.
1. Butt-joint sealrings require special handling
during assembly. The sealrings contain
materials that absorb moisture from the
atmosphere causing the sealring to expand.
Check sealring end clearance before
installation to make sure the sealring has not
expanded.
2. Remove the sealring from its package and
place the sealring in its operational position
inside the bore that it will be sealing.
3. Use a feeler gauge to check the end clearance
of the sealring. The end clearance must not be
less than the specifications. Refer to the
respective rebuild Steps in Section 5.
4. If the end clearance is less than specifications,
bake the sealring in an oven at 93–149°C
(200–300°F) for 24 hours or get a new
sealring. Repeat Steps (2) and (3).
5. Pack the sealring and its groove with a liberal
amount of oil-soluble grease.
6. Roll the sealring to about half its free diameter
and hold it for about 10 seconds. Being careful
not to spread the sealring more than necessary,
slide it onto the hub. Place one end of the
sealring into the groove and gradually work the
seal into the groove.
i. Bearings
1. When removing a bearing, do not apply
pressure across the balls. This can cause
brinelling and bearing failure.
 GENERAL OVERHAUL INFORMATION
2. If a bearing must be removed or installed
without an installation sleeve, drive or press
only on the race which is adjacent to the
mounting surface. If a press is not available,
carefully seat the bearing with a drift and a
hammer, driving against the supported race.
j. Bushings. Whenever a new bushing is being
installed, NEVER allow the pressing tool to bottom
against a needle thrust bearing. ALWAYS make sure
that the pressing tool bottoms against the part that the
bushing is being pressed into.
k. Electrical Components. For inspection and
repair of electrical components, refer to the 3000 and
4000 Product Families Troubleshooting Manual
TS3989EN.
3–7. REMOVING TRANSMISSION
FROM VEHICLE (Figure 3–5)
a. Drain Fluid
WARNING!
Avoid contact with the hot fluid or the hot sump
when draining transmission fluid. Direct contact
with the hot fluid or the hot sump may result in
bodily injury.
1. Drain the transmission fluid before removing
the transmission from the vehicle. The
transmission fluid should be warm to promote
complete drainage.
2. Remove the drain plug from the control
module. Examine the drained fluid for evidence
of contamination (see Paragraph 2–11).
Reinstall the drain plug. If the drain plug
threads are damaged, see Paragraph 2–12 for
corrective action.
3. Remove transmission fill tube if it interferes
with transmission removal.
WARNING!
DO NOT disconnect the hydraulic fluid line
between the accumulator and the retarder until
air and hydraulic pressure have been bled from
the line.
Copyright © 2005 General Motors Corp.
NOTE
A significant amount of fluid may drain from a
hydraulic hose when it is disconnected from the
transmission.
4. Disconnect all hydraulic hoses from the
transmission. If a retarder is installed,
disconnect the accumulator line from the
retarder housing. Remove the hoses from the
vehicle if they interfere with the transmission
removal. Plug all openings to keep dirt from
entering the hydraulic system.
5. If an integral cooler is used, drain coolant from
the cooler and disconnect coolant hoses.
Remove the hoses from the vehicle if they
interfere with transmission removal. Plug all
openings to keep dirt from entering the cooling
system.
b. Disconnecting Controls
1. Disconnect or completely remove controls. If
controls are not removed from the
transmission, position them so that they do not
interfere with transmission removal.
2. Loosen bolt in 20-way transmission
feedthrough harness connector.
3. Disconnect the transmission external harness
from the 20-way transmission feedthrough
harness connector. Also disconnect the external
harness from the engine, output, and turbine
speed sensors (Figure 3–5). Place a cover on
the transmission electrical connector to keep
out dirt. Also be sure to disconnect the
transmission feedthrough harness from the
harness bracket.
4. If PTO(s) are used, disconnect the PTO(s)
harness.
5. Disconnect the transmission external harness
from the retarder temperature sensor and the
retarder control valve body.
c. Uncoupling Transmission From Vehicle and
Engine Driveline
1. Disconnect the vehicle drive shaft from the
transmission output flange or yoke. Position
the disconnected shaft to avoid interference
with removing the transmission.
3–11
 4000 PRODUCT FAMILIES SERVICE MANUAL—ALLISON 4 th GENERATION

REAR OUTPUT
FRONT COOLER COOLER SPEED
PORTS (OPTIONAL) PORTS SENSOR

FRONT REAR (WITHOUT RETARDER)

PTO CONTROLS
OUTPUT SPEED SENSOR AND LINES

RETARDER
ACCUMULATOR LINE TEMPERATURE
(RETARDER ONLY) SENSOR

REAR COOLER PORTS TURBINE

SPEED SENSOR ENGINE SPEED SENSOR
RETARDER “K” SOLENOID CONNECTOR
REAR (WITH RETARDER) RIGHT SIDE V07323.01.00

Figure 3–5. Disconnection Locations

2. Transmissions with PTOs require uncoupling 3–8. WEAR LIMITS

one of the following:
• PTO from transmission
Refer to Table 7–1, Wear Limits Data, in Section 7, for
information covering part fits, clearances, and wear
• PTO drive shaft from the PTO
limits.
3. If the transmission supports the rear of the
engine, place a jack or other support under the
engine.
3–9. SPRING SPECIFICATIONS
4. Securely support the transmission with a hoist,
jack, or other suitable removal equipment. Refer to Table 7–2, Spring Data, in Section 7, for
spring identification and specifications.
5. Remove all bolts, nuts, washers, spacers, and
supports that attach the transmission to the
vehicle and the engine.
3–10. TORQUE SPECIFICATIONS
d. Removing the Transmission
1. Move the transmission away from the engine Assembly procedures in Sections 5 and 6 specify
approximately 106 mm (4.17 inch) until it is the torque requirements for all plugs, bolts, and
completely clear of the engine. Remove the nuts. Torque values are also presented with the
adapter ring and/or gasket (if used). foldout illustrations in the back of this manual.
Torque values specified are for dry assembly, except
2. Raise or lower the transmission as necessary to when otherwise noted. Wash and dry bolts and
remove it from the vehicle. washers before assembly.

3–12 Copyright © 2005 General Motors Corp.

 SECTION 4—TRANSMISSION DISASSEMBLY
4–1. SCOPE a. Mounting Transmission on Repair Stand

a. Section. This section covers disassembly of 4000
Product Family transmissions. The disassembly se-
quence is continuous and includes all models.
b. Procedures. When a procedure does not apply to
your specific model, go to the next applicable
procedure.
c. Illustrations. Illustrations will not always show
your model, but when an operation is identical for all
models, the correct procedure is shown.
d. General Information. Refer to Sections 3 and 7
for general information as follows:
1. Mount holding bracket J 35926 or J 35926-A
(4700 and 4800 models), with holding bracket
J 41445 attached, onto the main housing
module.
2. Attach a hoist, making sure lifting attachments
are placed so that the transmission is balanced,
and raise the transmission to the mounting face
of the overhaul stand.
3. Secure the transmission holding fixture to
overhaul stand J 29109.
b. Removal of Power Takeoff (Figure 4–1)

Paragraph Title NOTE:

3–2 Tools and Equipment
Each PTO has eight mounting bolts, two studs, and
3–3 Replacement Parts
a gasket. Removal instructions are for a
3–4 Careful Handling transmission with a single left-side or top mounted
3–5 Cleaning and Inspection PTO. If your transmission has more than one PTO
3–7 Removing Transmission From Vehicle or the PTO is mounted in a different location, use
7–1 Wear Limits Data the same procedure to remove the PTO(s).
7–2 Spring Data

e. Foldouts. Refer to Foldouts 4 through 12 for 1. Remove eight PTO mounting bolts 1.
exploded views. Carefully remove PTO assembly 2, and
gasket 3.
4–2. DISASSEMBLY OF 2. Inspect two PTO studs 4 for damage and
TRANSMISSION remove if necessary.

c. Removal of External Parts

WARNING! (Figures 4–2 and 4–3)
PREVENT PERSONAL INJURY
1. Inspect transmission breather 20 for damage or
Use proper tools and lifting equipment when
installing or removing a transmission from the an obstruction. Remove if necessary for
repair stand. replacement or cleaning.
Transmission dry weights are as follows:
4000 Product Family (except 4700 and 4800 NOTE:
models) If your transmission is PTO equipped and you have
• Base Transmission — 377 kg (831 lb) not removed the PTO(s), return to Paragraph 4–2b.
• With PTO Provision — 405 kg (893 lb)
• With Retarder — 411 kg (906 lb) 2. Remove screw 5 retaining oil fill tube bracket 6
• With PTO and Retarder — 439 kg (968 lb) to the main housing module. Remove
4000 Product Family (4700 and 4800 models) bracket 6, fill tube 8, seal 9, and dipstick 7.
• Base Transmission — 493 kg (1087 lb)
3. Remove six bolts 12 retaining remote cooler
• With PTO Provision — 521 kg (1149 lb) manifold 11 to the main housing module.
• With Retarder — 527 kg (1162 lb) Remove remote cooler manifold 11 and
• With PTO and Retarder — 555 kg (1224 lb) gasket 10.

Copyright © 2005 General Motors Corp. 4–1

 4000 PRODUCT FAMILIES SERVICE MANUAL—ALLISON 4 th GENERATION

1 2
4
3

3
1

4
V06836

Figure 4–1. PTO Removal

20 ENGINE
2
SPEED TURBINE 1
SENSOR SPEED 4 7
SENSOR 3 5
6

9
OUTPUT 15
SPEED
SENSOR

13

16
17
18
19
10
11
12

14

V06837.03.00

Figure 4–2. Removal of Externally Mounted Parts

4–2 Copyright © 2005 General Motors Corp.

 TRANSMISSION DISASSEMBLY
7. Remove bolt 4, retainer 3, speed sensor 2, and
O-ring 1 from the converter housing module
(engine speed sensor), main housing module
(turbine speed sensor), and rear cover or
retarder (output speed sensor). Refer to Figure
4–3 for sensor locations.

d. Removal of Integral Oil Cooler (Figure 4–4)

1. Remove two bolts 11 and seventeen bolts 12.
Remove cover 13, gasket 14, and two
O-rings 10.
ENGINE 2. Remove plate assembly 9 and four O-rings 8.
SPEED SENSOR
3. Remove nine bolts 7 and nine washers 6.
Remove cooler housing 3 and gasket 1.
TURBINE
SPEED SENSOR
e. Removing Integral Retarder Sump Oil Cooler
OUTPUT
SPEED SENSOR
(Foldout 12,C)
V09786.00.00

1. If used and not already removed, remove the

Figure 4–3. Speed Sensors retarder accumulator hose from the fitting on
4. Remove bolt 19. cooler manifold 16.

5. Remove flange 15 or yoke 14. Remove
O-ring 17, retainer plug 18, and O-ring 16.
6. Inspect journal sealing area for minimum
allowed diameter of 85.0 mm (3.346 inch).
2. If not already removed, remove inlet and outlet
water hoses from hose adapter 2 on the cooler
manifold 16.
3. Remove six bolts 5.

5
4
3
1
11
8
4 2 9
5
6 7 10
8
19
18 17
11 19
18 17 10

16 11
15

12

14
13 11 V06843

Figure 4–4. Integral Oil Cooler

Copyright © 2005 General Motors Corp. 4–3

 4000 PRODUCT FAMILIES SERVICE MANUAL—ALLISON 4 th GENERATION

WARNING!
To help avoid personal injury, securely support
the cooler before removing the bolts retaining the
cooler to the manifold. The cooler weighs 30 kg
(64 lbs); use care when handling the cooler.

4. Support cooler 7 to prevent it from falling from

manifold 16.
5. Remove sixteen M10 x 1.5 x 60 bolts 1.
6. Remove inlet and outlet water hose adapters 2
from cooler manifold 16. Remove two
gaskets 3.
2
7. Remove cooler assembly 7.
8. Remove two gaskets 6 from the cooler.
9. Rotate the transmission so that the retarder is
facing up.
10. Remove seven M10 x 1.5 x 187.5 bolts 9. 1

11. Remove M10 x 1.5 x 50 bolt 8.

12. Remove three M12 x 1.75 x 195 bolts 10.
13. Remove cooler manifold 16.
14. Remove gasket 4.
f. Removal of Control Valve Module
(Figure 4–5)
WARNING!
Get help when lifting the control module.
Assistance from a hoist or another person may be
required. The control module weighs
approximately 25 kg (55 lb).
1. Remove forty-three bolts 3 and 4 retaining
control module 1 to the main housing module,
including the bolts retaining the filter covers.
2. Loosen control module 1 by applying pressure
at the reinforced tabs or use jack bolts, inserted
into the control module bolt holes that bottom
against the main housing module.
3. Remove covers and filters if a handhold is
needed to remove the control module.
4. Remove control module assembly 1 and
gasket 2.
3 4
V09785.00.00
Figure 4–5. Control Module Removal
g. Removal of Torque Converter Module
(Figure 4–6)
1. Remove any brackets installed to prevent
torque converter movement.
2. Keep the torque converter cover from turning
by using a heel bar, two bolts, and a
screwdriver (Figure 4–6, View C).
3. Remove threaded plug 2 and O-ring 1 using a
3⁄4 inch Allen wrench (Figure 4–6, View A).
4. Attempting to loosen bolt 3 may cause the
turbine and turbine shaft to rotate. Hold the
turbine and turbine shaft stationary by using
one of the methods listed below:
• If the control module is removed, insert a
screwdriver into the vanes on the rotating
clutch module (Figure 4–6, View B).
• If the control module is in place, apply the
lockup clutch by applying restricted air
pressure through the lockup pressure tap

4–4 Copyright © 2005 General Motors Corp.

 TRANSMISSION DISASSEMBLY
located on the main housing (Figure 4–6,
View D). Insert a heel bar into a torque
converter housing bolt hole. Insert two bolts
into the flexplate adapter bolt holes. Then
place a screwdriver at an angle to prevent
converter rotation (Figure 4–6, View C).
8. Place two wooden blocks on the workbench,
5. Using converter bolt tool J 38564, remove
bolt 3.
6. Remove selective shim 4 located under bolt 3
(Figure 4–6, View A).
7. Attach a sling to the flexplate adapter by
positioning the adapter connections an equal
distance from each other. Using a chain
hoist, carefully lift torque converter
module 5 out of the converter housing
(Figure 4–6, View A).
spaced to support the torque converter module
and high enough for the converter hub to clear
the workbench. Lower the converter module,
converter hub down, onto the blocks.

CUPPED END DOWN RESTRICT MOVEMENT

5 USE HOIST AND SLING
2 1
3 4

J 38564

VIEW A

VIEW B

LOCKUP
PRESSURE
TAP

VIEW C VIEW D VL06840.01.00

Figure 4–6. Torque Converter Module Removal

Copyright © 2005 General Motors Corp. 4–5

 4000 PRODUCT FAMILIES SERVICE MANUAL—ALLISON 4 th GENERATION

h. Removal of Converter Housing Module

(Figure 4–7)
NOTE:
Seven converter housing retaining bolts 3 are
removed from inside converter housing 1. Use
mechanical fingers or a similar tool to remove these
bolts.
1. Remove twenty-five bolts 3 that retain
converter housing 1 to main housing module 4.
2. Using the same sling used for removing the
converter module, lift straight up on converter
housing module 1 to remove it.
3. Remove main housing gasket 2 from converter
housing 1 or from main housing module 4.
NOTE:
Proceed to Paragraph 4–2 sub-paragraph shown
below by output module configuration and model.
• i—Retarder (except 4700 and 4800 models)
• j—Retarder (4700 and 4800 models)
• k—Rear Cover (except 4700 and 4800 models)
• l—Rear Cover (4700 and 4800 models)
i. Removal of Retarder Module (Except 4700
and 4800 Models) (Figure 4–8)
1. Remove twelve bolts 2, three bolts 3, two
bolts 4, four bolts 5, and four bolts 6 that
secure retarder module 1 to main housing
module 8. If used, remove the rear support
bracket.

WARNING!
Get help when lifting the retarder module.
1 Assistance from a hoist or another person may be
3 required. The retarder module weighs
approximately 34 kg (75 lb).

2. Thread an M14 eye bolt into the retarder

2
4 output shaft and lift retarder module 1 from
main housing module 8.
V07335
3. Remove retarder gasket 7 from main housing
Figure 4–7. Converter Housing Module Removal module 8 or from retarder module 1.

2 2
2 2
2 2

2 2
1
2 2 2

8 4 2
4 2
5
7 6 5 5 5
3
3 OR
4 6 6 6
6 5 3 3
V06844

Figure 4–8. Removal of Retarder Module (Except 4700 and 4800 Models)

4–6 Copyright © 2005 General Motors Corp.

 TRANSMISSION DISASSEMBLY

1
4 4
4 4
2 4 4

4 4
3 4

4 4
5
7 4
7 4
8
9 8 8 8
6 6 OR
9 9 9 6 6
7 8
9
V06845

Figure 4–9. Removal of Retarder Module (4700 and 4800 Models)

j. Removal of Retarder and Output Shaft Module
(4700 and 4800 Models) (Figure 4–9)
1. Remove twelve bolts 4, three bolts 6, two
bolts 7, four bolts 8, and four bolts 9 that
secure retarder module 5 to main housing
module 1. If used, remove the rear support
bracket.
2. If used, remove the rear support bracket.
3. Thread an M10 or M14 eye bolt into the output
shaft and lift upward to remove rear cover
module 3.
4. Remove rear cover gasket 2 from main housing
module 1 or from rear cover module 3.

WARNING!
Get help when lifting the retarder module.
Assistance from a hoist or another person may be
required. The retarder module weighs
approximately 34 kg (75 lb).

2. Thread an M14 eye bolt into the retarder

output shaft and lift retarder module 5 from
main housing module 1.
3. Remove retarder gasket 3 from main housing
module 1 or from retarder module 5. 1
2
4
k. Removal of Rear Cover Module (Except 4700 5
and 4800 Models) (Figure 4–10) 3
V06846

1. Remove nineteen bolts 5 and washer 4, if

present. Figure 4–10. Rear Cover Module Removal

Copyright © 2005 General Motors Corp. 4–7

 4000 PRODUCT FAMILIES SERVICE MANUAL—ALLISON 4 th GENERATION

l. Removal of Rear Cover and Output Shaft m. Removal of C6 Adapter Housing Module
Module (4700 and 4800 Models) (4700 and 4800 Models) (Figure 4–13)
(Figure 4–11 and Figure 4–12)
1. Remove fourteen bolts 4 (Figure 4–12). Remove 1. Remove fourteen bolts 3 that secure the C6
five bolts 5. adapter housing module 4 to main housing
2. If used, remove the rear support bracket. module 1 using special tool J 43046.
3. Thread an M14 eye bolt into output shaft 7
(Figure 4–11) and lift upward to remove rear WARNING!
cover module 6.
Get help when lifting the C6 adapter housing
4. Remove rear cover gasket 3 from C6 adapter module. Assistance from a hoist or another
housing module 2 or from rear cover module 6. person may be required. The C6 adapter housing
module weighs approximately 68 kg (150 lb).
1

2 2. Attach a sling to the C6 adapter housing

module 4 with the legs of the sling equally
3 4 spaced on the module. Using a chain hoist,
carefully lift the C6 adapter housing module 4
6 from the transmission.
7
3. Remove and discard C6 adapter housing
gasket 2.

5 4. Remove and discard eleven tolerance rings 5.

V05580

Figure 4–11. Removal of Rear Cover and Output 1

Shaft Module
J 43046
2
BOLT, M12 x 1.75 x 45
(14) MARKED 4
4 4 3
4 4
4
4 4

4 4

4 4

4 4

BOLT, 4 5 5 4
METRIC HEAVY 5 5
(5) MARKED 5 5
5
V05374

V07494
Figure 4–13. Removal of C6 Adapter Housing Module
Figure 4–12. Rear Cover and Output Shaft Module Bolts (4700 and 4800 Models)

4–8 Copyright © 2005 General Motors Corp.

 TRANSMISSION DISASSEMBLY
n. Removal of P3 Planetary Module
(4700 and 4800 Models) (Figure 4–14)
1. Remove selective shim 5.
2. Remove shim locating ring 4.
3. Remove P4 shaft flange 3.
4. Attach special tool J 43020 to P3 planetary 2.
Attach chain hoist and lift from transmission.
o. Removal of Main Shaft Module (Figure 4–15).
Remove main shaft module assembly 1 from the
transmission.
1 2.41 mm (0.095 inch). Maximum allowable
p. Removal of P2 Module, C5 Clutch Plates,
and P1 Module (Figures 4–16 and 4–17)
1. Lift P2 planetary module 1 from the main
housing module (Figure 4–17).
2. Lift C5 clutch pack from the main housing
module—eight friction plates 3 and nine steel
reaction plates 2 (Figure 4–16).
3. Measure the thickness and cone of each
friction plate 3. Minimum thickness is
3.48 mm (0.137 inch). Maximum allowable
cone is 0.25 mm (0.010 inch).
4. Measure thickness and cone of each steel
reaction plate 2. Minimum thickness is
cone is 0.25 mm (0.010 inch).

5. Lift P1 planetary module 1 from the

2 transmission (Figure 4–17).

3
4

5
1 C5
J 43020
2
3
V05375

Figure 4–14. Removal of P3 Planetary Module

E02516.01

Figure 4–16. P2 Module and C5 Clutch Plates

WIDE RATIO MODELS

1

1 2
CLOSE RATIO MODELS 3
V01737.00.06

E01271.01

Figure 4–15. Removal of Main Shaft Module Figure 4–17. P1 Module

Copyright © 2005 General Motors Corp. 4–9

 4000 PRODUCT FAMILIES SERVICE MANUAL—ALLISON 4 th GENERATION
q. Removal of Front Support/Charging Pump
Module and Rotating Clutch Module
(Figures 4–18 and 4–19)
1. Remove seven bolts 1 and seven bolts 2 that
retain front support and charging pump
module 3 to the main housing module
(Figure 4–18).
2. Lift front support and charging pump module 3
over the turbine shaft and away from the main
housing module.
2
3 r. Removal of C3/C4 Clutch Assembly From
1
V01272
Figure 4–18. Removal of Front Support/Charging
Pump Module
E01273.01
Figure 4–19. Removal of Rotating Clutch Module
4–10 Copyright © 2005 General Motors Corp.
CAUTION:
• Always remove the turbine speed sensor be-
fore removing the rotating clutch module to
avoid possible damage to the turbine speed
sensor.
• When you remove rotating clutch module 1,
carefully place it on the workbench and pre-
vent it from rolling off the bench.
3. Using a hoist and an M16 eye bolt, lift turbine
shaft and rotating clutch module 1 (Figure 4–19)
from the main housing module and place it on
the workbench.
Main Housing Module (Figure 4–20)
CAUTION:
Make sure the main housing module is
horizontal when removing the C3/C4 clutch
assembly.
1. Remove fourteen bolts 3 retaining C3/C4
clutch assembly 1 in main housing module 2.
2. Remove the C3/C4 clutch assembly by sliding
it out of the input end of the main housing.
3. Remove the main housing from the repair
stand for cleaning.
4. Inspect the main housing C5 clutch plate
splines. Maximum wear allowed is 1.15 mm
(0.045 inch).
1 3
2 E01274.01
Figure 4–20. Removal of C3/C4 Clutch Module
 SECTION 5—MODULE REBUILD
5–1. SCOPE 7. Remove turbine hub assembly 17 from torque
converter cover assembly 6.
a. Section. This section describes the disassembly 8. Remove stator assembly 20.
and assembly of the modules removed in Section 4.
9. If replacement is necessary, remove thrust
b. Procedures. During rebuild procedures, refer to bearing race 32 from torque converter pump
the exploded views (Foldouts 4 through 12) in the assembly 33.
back of this manual.
10. Remove thrust bearing assembly 18 from the
turbine. Remove turbine hub sealring 16. Place
turbine hub sealring 16 into its mating bore.
5–2. GENERAL INFORMATION Measure the ID of the sealring at the maximum
FOR MODULE REBUILD distance from the hook. Replace the sealring if
Refer to Sections 3 and 7 for general overhaul the maximum ID of 61.77 mm (2.432 inch) is
information as follows: exceeded. Inspect and measure the OD of the
turbine hub 17. Minimum OD wear is
Paragraph Description 66.69 mm (2.626 inch).
3–2 Tools, Equipment 11. Remove pump thrust bearing assembly 30,
3–3 Replacement Parts race 29, and selective shim 28.
3–4 Careful Handling 12. Remove retaining ring 21.
3–5 Cleaning and Inspection 13. Remove star plate 19.
3–6 Assembly Procedures
14. Remove stator thrust plate assembly 22 and
7–1 Wear Limits Data
measure its thickness. Minimum thickness
7–2 Spring Data allowed is 9.45 mm (0.372 inch).
15. Remove stator thrust washer 23.
5–3. TORQUE CONVERTER MODULE 16. Remove and inspect stator race 24, thirteen
springs 25, and rollers 26.
a. Disassembly (Foldout 4,B)
17. From torque converter cover assembly 6, re-
1. Before disassembling the torque converter, move forty-four bolts 14 retaining lockup
note balance marks or mark a line across the clutch backplate 13 to torque converter cover
converter cover to the pump assembly with a assembly 7.
scribe. Aligning these marks will make sure
the torque converter is correctly assembled and 18. Remove lockup clutch backplate 13. Measure
reduce balance problems. the thickness of the backplate wear surface.
Minimum thickness allowed is 11.79 mm
2. Place torque converter module 4 on a flat (0.464 inch). Measure for distortion of the
surface—pump drive tangs downward. lockup clutch backplate. Maximum distortion
3. Remove thirty-six nuts 5 from the OD of allowed is 0.15 mm (0.006 inch).
torque converter cover 7. 19. Remove lockup clutch damper assembly 12
4. If replacement is necessary, remove damaged from torque converter cover assembly 6. Mea-
T-head bolt(s) 34 from the OD of torque sure the thickness of the lockup clutch. Mini-
converter pump assembly 33. mum thickness allowed is 8.51 mm
(0.335 inch). Measure for distortion of the
5. Carefully remove torque converter cover
lockup clutch. Maximum allowable distortion is
assembly 6 from pump assembly 33. Avoid
0.51 mm (0.020 inch). Measure spline wear be-
damage to their sealing surfaces.
tween the turbine hub and the lockup clutch
6. Remove O-ring 31 used between the cover damper. Maximum allowable wear is 0.38 mm
assembly and pump assembly. (0.015 inch) on either spline.

Copyright © 2005 General Motors Corp. 5–1

 4000 PRODUCT FAMILY SERVICE MANUAL
20. Remove lockup clutch piston assembly 10. Re-
move inner sealring 9 and outer sealring 11
from the lockup piston assembly. Measure the
thickness of the lockup piston assembly. Mini-
mum thickness allowed is 6.53 mm
(0.257 inch).
21. Inspect the ID of cover bushing 8. Maximum
ID of the bushing allowed is 66.91 mm
(2.634 inch). Remove the bushing if
replacement is necessary.
22. Inspect converter pump hub 33. Minimum OD
is 88.99 mm (3.504 inch).
23. Remove thrust bearing assembly 15.
b. Assembly (Foldout 4,B and Figure 5–1)
1. Install stator race 24 into stator and cam
assembly 27.
2. Install thirteen springs 25 and stator rollers 26
into stator and cam assembly 27. Be sure
springs and rollers are installed as shown in
Figure 5–1. Use oil-soluble grease to help hold
the springs and rollers in place.
3. Install thrust washer 23 and thrust plate
assembly 22 onto stator and cam assembly 27.
Install star plate 19.
4. Install retaining ring 21.
5. Do not install selective shim 28 at this time.
Install thrust bearing race 29 and bearing
assembly 30.
CAUTION:
When installing thrust bearings, make sure that
the locating lip on either the inner or outer thrust
bearing race is not preventing the race from
contacting the thrust surface of the mating part.
Failure to do this leads to premature thrust
bearing failure and incorrect shim selection to
maintain proper internal part clearance.
6. Install thrust bearing assembly 18.
7. If removed, press a new bushing 8 into cover 7
bushing bore using J 39949 bushing installer
and J 8092 drive handle.
8. Install new sealring 16 onto turbine hub and
insert turbine assembly 17 into the new
bushing and inspect for freedom of rotation.
5–2 Copyright © 2005 General Motors Corp.
SPRING (End of spring Roller to be installed in
may be up or down) small end of cam pocket
STATOR CAM
V01360.03.00
Figure 5–1. Stator Roller/Spring Installation
9. Install thrust bearing assembly 15 in converter
cover 7.
10. Install lockup piston sealring 9 on the hub of
converter cover 7 and lockup piston sealring 11
on the OD of lockup piston assembly 10. In-
stall the lockup clutch piston.
11. Install lockup clutch damper assembly 12 into
cover 7.
12. Install lockup clutch backplate 13.
13. Install forty-four bolts 14. Tighten the bolts to
24–29 N·m (18–21 lb ft).
14. Install the turbine hub sealring 16 onto turbine
assembly 17. Install the turbine hub
assembly 17 into torque converter cover as-
sembly 6 aligning balance mark on the turbine
with the balance mark on the lockup clutch
damper.
15. Install stator assembly 20.
16. If removed, install thirty-six T-head bolts 34
into the flange of converter pump assembly 33.
If removed, install pump thrust bearing race 32
into torque converter pump assembly 33.
17. Install O-ring 31 onto converter cover assem-
bly 6. With balance marks or scribe mark
aligned, place converter pump assembly 33
over the top of converter cover assembly 6.
18. Install four nuts 5, evenly spaced, onto four
T-head bolts 34. Tighten the nuts to 30–35 N·m
(22–26 lb ft).
19. Using a depth micrometer, measure from the
top of the drive tang surface to the thrust sur-
face of the turbine hub. This is dimension A
(Figure 5–2).
 MODULE REBUILD

DRIVE TANG SURFACE SHIM (30) LOCATION DRIVE TANG SURFACE

THRUST
SURFACE
OF THRUST DIM. B
TURBINE DIM. A SURFACE
HUB OF
TURBINE
HUB

J 38548

E02517.01

Figure 5–2. Torque Converter Selective Shim

20. Turn the converter on its side and insert tool
J 38548, with bolt removed, into the converter
plug bore. Turn the torque converter so that it
rests on tool J 38548. Repeat the same mea-
surement as in Step (19). This is dimension B.
21. Subtract dimension B from dimension A to get
dimension C (A–B=C).
22. Dimension C must be 0.08–0.36 mm (0.003–
0.014 inch). If dimension C is correct, proceed
with Step (28).
23. If dimension C is not correct, then a shim is
needed. Select the proper shim from Table 5–1
and proceed with Step (24).
NOTE:
24. Disassemble the converter and reassemble us-
ing selected shim.
25. Install four nuts 5, evenly spaced, onto four
T-head bolts 34. Tighten the nuts to 30–35 N·m
(22–26 lb ft).
26. Perform the measurement again. Dimension C
must be 0.08–0.36 mm (0.003–0.014 inch). If
dimension C is correct, proceed with Step (28).
27. If dimension C is not correct, then a shim
change is needed. Disassemble the converter
and reassemble without shim 28, and go back
to Step (18).
28. Install the remaining thirty-two nuts 5 onto T-head
bolts 34. Tighten all the nuts to 30–35 N·m
(22–26 lb ft).
• For models without PTO provision, proceed
with Paragraph 5–4.
• For models with PTO provision, skip Para-
graph 5–4 and proceed with Paragraph 5–5.

Table 5–1. Torque Converter Selective Shims

Dimension C Use P/N Shim Thickness

0.08–0.36 mm (0.003–0.014 inch) — —

0.36–0.58 mm (0.014–0.023 inch) 29503879 0.23–0.27 mm (0.009–0.011 inch)
0.58–0.81 mm (0.023–0.032 inch) 29503880 0.46–0.48 mm (0.018–0.019 inch)
0.81–0.99 mm (0.032–0.039 inch) 29503881 0.69–0.711 mm (0.027–0.028 inch)

Copyright © 2005 General Motors Corp. 5–3

 4000 PRODUCT FAMILY SERVICE MANUAL
5–4. TORQUE CONVERTER 2. Remove breather assembly 20.
HOUSING MODULE 3. If present, remove ten bolts 24 or 27, PTO
(Models Without PTO Provision) cover 25 or 28, and gasket 26 or 29.
a. Disassembly (Foldout 5,A) 4. Remove eleven bolts 2 holding bearing
retainer assembly 3 and PTO gear assembly 10
1. If not previously removed, remove bolt 7, into converter housing 19.
speed sensor retainer 6, and engine speed 5. Remove bearing retainer assembly 3 and PTO
sensor assembly 4. Measure engine speed gear assembly 10. If necessary, use jack bolts
sensor resistance (speed sensor resistance to loosen the bearing retainer assembly.
varies by temperature).
b. Disassembly of Bearing Retainer
Resistance (Ohms) Temperature (°C) Temperature (°F) (Foldout 5,B)
250 –40 –40
1. Remove sealrings 8 and 9 from bearing
340 20 68 retainer 7. Remove oil seal assembly 4 using
450 110 230 tool J 24171-A.
2. Inspect bushing 6 for damage or wear.
Maximum allowable bushing ID is 89.19 mm
CAUTION:
(3.511 inch). Remove the bushing if damaged or
Use the correct wrench size to avoid crushing the worn.
vent assembly.
c. Disassembly of PTO Gear Assembly
2. Remove breather assembly 2. (Foldout 5,B)
b. Assembly (Foldout 5,A) 1. Remove oil pump drive hub 13 from PTO
1. Install engine speed sensor assembly 4, speed gear 12.
sensor retainer 6, and bolt 7. Tighten the bolt to 2. Inspect oil pump drive hub for excessive wear
24–29 N·m (18–21 lb ft). on drive tangs. Maximum allowable tang wear
is 0.31 mm (0.012 inch).
CAUTION: 3. Remove sealring 14 from PTO gear 12. If
Use the correct wrench size to avoid crushing the damaged, press two bearings 11 from PTO
vent assembly. gear 12.

2. Install breather assembly 2. Torque breather d. Assembly of PTO Gear Assembly

assembly to 12–16 N·m (9–12 lb ft). (Foldout 5,B)
3. Skip to Paragraph 5–6. 1. Press two bearings 11 onto the PTO gear using
tool J 37041.
5–5. TORQUE CONVERTER
HOUSING MODULE CAUTION:
(Models With PTO Provision) Oil pump drive hub 13 can be incorrectly
a. Disassembly (Foldout 5,B) installed backwards—position the oil pump
drive hub tangs toward the oil pump.
1. If not previously removed, remove bolt 18,
speed sensor retainer 17, and engine speed
2. Install oil pump drive hub 13 into PTO gear 12,
sensor assembly 15. The engine speed sensor
aligned with hub tangs toward the oil pump.
must have a resistance of 300 ± 30 Ohms.
3. Insert sealring 14 into the sealing bore of pump
housing 10 (Foldout 6,A) and measure end gap
CAUTION:
with feeler gauges. Sealring end gap must be
Use the correct wrench size to avoid crushing the 1.18–1.66 mm (0.047–0.065 inch). Refer to
vent assembly. Paragraph 3–6h.

5–4 Copyright © 2005 General Motors Corp.

 MODULE REBUILD
4. Remove sealring 14 (Foldout 5,B) from the
seal bore and install the sealring onto PTO
gear 12.
e. Assembly of Bearing Retainer Assembly
(Foldout 5,B)
1. If removed, install bushing 6 using a press, and
tools J 37038 and J 8092.
5–6.
2. Install sealring 9 onto bearing retainer 7. Install
oil seal 4 using a press, and tools J 37032 and
J 37034.
3. Insert sealring 8 into the sealing bore in PTO
gear 12 and measure the end gap using feeler
gauges. Sealring end gap must be 1.18–1.66 mm
(0.047–0.065 inch). Refer to Paragraph 3–6h.
4. Remove sealring 8 from sealing bore and
install the sealring onto bearing retainer 7.
f. Assembly (Foldout 5,B)
1. Using a mallet, lightly tap PTO gear
assembly 10 into converter housing 19 until
the gear assembly is seated.
2. Use guide bolts to install bearing retainer
assembly 3, rocking the retainer while
installing it.
3. Install eleven bolts 2 to hold bearing retainer
assembly 3 and PTO gear assembly 10 to
housing 19. Tighten the bolts to 51–61 N·m
(38–45 lb ft).
4. If used, install PTO covers 25 or 28 and
gaskets 26 or 29 using ten bolts 24 or 27 in
the cover. Tighten the bolts to 51–61 N·m
(38–45 lb ft).
5. Install engine speed sensor assembly 15 and
engine speed sensor retaining bolt 18. Tighten
the bolt to 24–29 N·m (18–21 lb ft).
Copyright © 2005 General Motors Corp.
CAUTION:
Use the correct wrench size to avoid crushing the
breather.
6. Install breather 20. Tighten the breather to
12–16 N·m (9–12 lb ft).
FRONT SUPPORT AND OIL
PUMP MODULE
a. Disassembly (Foldout 6,A)
1. Remove three sealrings 25 from the hub of
front support 20.
2. Remove eight bolts 6 retaining pump housing
assembly 7 or 10 (PTO unit) to front support
assembly 15.
3. Remove pump housing assembly 7 or 10 and
gear set 11.
4. On models without PTO, remove O-ring 4 and
oil seal assembly 5 using tool J 24171-A.
5. Measure gear-cavity depth of pump housing 9
or 10. Maximum depth allowed is 19.04 mm
(0.750 inch) (Figure 5–3).
6. Measure gear-cavity diameter of pump
housing 9 or 10. Maximum ID allowed is
150.25 mm (5.915 inch) (Figure 5–4).
7. For models without PTO provision, inspect
bushing 8 inside pump housing 9 for wear or
damage. Measure the ID of the pump bushing.
Maximum ID allowed is 89.19 mm
(3.511 inch).
8. If worn or damaged, remove bushing 8 from
pump housing 9.
9. Install gear set 11 into pump housing 9.
Measure pump gear side clearance of both
gears. Maximum allowable clearance is
0.10 mm (0.004 inch) (Figure 5–5).
5–5
 4000 PRODUCT FAMILY SERVICE MANUAL

PUMP
HOUSING

DRIVE
GEAR
PUMP
HOUSING MAX SIDE DRIVEN GEAR
MAX DEPTH OF CLEARANCE
GEAR CAVITY 0.10 mm (0.004 in.) V02518
19.04 mm (0.75 in.) V01899.01

Figure 5–5. Measuring Gear Side Clearance

Figure 5–3. Measuring Gear-Cavity Depth of the Pump Housing
of the Pump Housing

PUMP
HOUSING

MAX GEAR TOOTH

MAX ID OF
TIP CLEARANCE
GEAR CAVITY
0.15 mm (0.006 in.)
150.25 mm (5.915 in.)
V02519
V01277.01

Figure 5–6. Measuring Gear Tooth Tip Clearance

Figure 5–4. Measuring Gear-Cavity Diameter
of the Pump Housing

10. Measure gear tooth tip clearance. Maximum

allowable clearance is 0.15 mm (0.006 inch)
(Figure 5–6).

11. Measure driven gear to pump housing clear-

ance. Maximum clearance allowed is 0.30 mm
(0.012 inch) (Figure 5–7).

12. Inspect bushing 12 that is inside the inner

(drive) gear of gear set 11. Measure the ID of PUMP HOUSING MAX CLEARANCE BETWEEN
bushing 12. The maximum allowable ID is DRIVEN GEAR OD AND PUMP
66.93 mm (2.635 inch). DRIVEN GEAR HOUSING 0.30 mm (0.012 in.)
V02520

13. If bushing 12 is damaged or worn, remove the Figure 5–7. Measuring Driven Gear Clearance
bushing. to the Pump Housing

5–6 Copyright © 2005 General Motors Corp.

 MODULE REBUILD
14. Remove fourteen bolts 14 retaining the wear
plate 13 to front support 20. Remove wear
plate 13.
15. If damaged, remove roller bearing 26 from
front support 20 using a drift and hammer.
16. Measure the OD of front support sleeve 21.
Minimum diameter is 119.81 mm (4.717 inch).
Also inspect for wear. If worn or damaged, re-
move front support sleeve 21 from front sup-
port 20.
17. If damaged, remove dowel pins 19 from front
support 20.
18. If worn or damaged, remove ground sleeve 16
or 17 by pressing ground sleeve from front
support 20.
19. Compress spring 22, using tool J 41462, until
load is removed from dowel pin 24. Remove
dowel pin 24 and carefully release the load on
spring 22 by rotating the handle on tool
J 41462 in the counter-clockwise direction.
When spring 22 has reached its free length, re-
move tool J 41462. Remove spring 22 and ball
23 from the front support 20.
20. Inspect for damage in the ball seat area of front
support 20. Measure tension of spring 22 and
compare to value in Table 7–2, Spring Data, in
Section 7.
b. Assembly of Front Support
(Foldout 6,A and Figure 5–8)
1. Replace front support 20 if damage to the ball
seat or other area was found.
2. Replace spring 22 if spring load did not meet
load specifications.
3. Install ball 23 and spring 22 into front
support 20. Compress spring 22 using tool
J 41462 until dowel pin 24 can be inserted to
retain spring 22. Remove tool J 41462.
Copyright © 2005 General Motors Corp.
4. If removed, install ground sleeve 16 or 17.
Place front support 20 on press bed. The
machined flat at the base of the ground sleeve
must align with the arrow “↑” cast on the front
support (Figure 5–8, View C). Press ground
sleeve 16 or 17 into front support 20 to
shoulder. Total runout of spline OD may not
exceed 0.13 mm (0.005 inch).
5. If removed, install dowel pins 19. Press the
pins to a height of 14.5 mm (0.57 inch) from
the surface of front support 20.
6. If removed, align the lubrication hole in
sleeve 21 with the relief valve bore (bottom of
front support), and install front support sleeve
21 using a press and tools J 37041 and J 37034.
Refer to Figure 5–8, View B.
7. Install wear plate 13. Secure with fourteen
bolts 14. Tighten the bolts to 51–61 N·m
(38–45 lb ft).
8. Install bearing 26 using a press, and tools
J 37038 and J 8092. Press bearing 26 flush to
0.25 mm (0.010 inch) below the surface.
c. Assembly of Pump Housing (Foldout 6,A)
NOTE:
Steps (1), (2), and (3) below apply only to
transmissions without PTO provision.
1. If removed, install bushing 8 into pump
housing 9 using a press, and tools J 37038 and
J 8092.
2. Install oil seal 5 using a press, and tools
J 37032 and J 37034.
3. Install O-ring 4.
4. If removed, install bushing 12 into drive
(inner) gear of gear set 11. Align the staking in
the pre-staked bushing with the slots in the
inside gear of gear set 11. Use tool J 39954.
5. Lubricate pump gear set 11 and install the gear
set in pump housing 9 or 10.
5–7
 4000 PRODUCT FAMILY SERVICE MANUAL

FRONT
FRONT SUPPORT (20) TOP
DOWEL PINS E
(19 )
DOWEL PIN
14.5 mm
GROUND SLEEVE (0.57 in.)

INSTALL REMOVE

SPLINE OD T.I.R.
0.30 mm
(0.012 in.)

E
RELIEF VALVE
SECTION E-E BORE
BOTTOM
VIEW A
VIEW B
To install, align flat on
ground sleeve with arrow
on front support.

GROUND SLEEVE (16 OR 17)

20

VIEW C V01344.00.04

Figure 5–8. Ground Sleeve Removal and Installation

6. Retain the pump housing to the front support with 5–7. ROTATING CLUTCH MODULE
eight bolts 6. Tighten the bolts to 51–61 N·m
(38–45 lb ft). a. Disassembly (Foldout 6,B)

7. Measure the end gap of three rotating
sealrings 25 before installation. Insert the
sealrings into the rotating clutch hub bore
and measure end gap with a feeler gauge.
Sealring end gap must be 1.00–1.44 mm
(0.040–0.056 inch). Refer to Paragraph 3–6h.
8. Install three rotating sealrings 25 on front
support 20 hub.
1. Remove internal retaining ring 43.
2. Remove P1 sun gear assembly 41.
3. Inspect thrust bearing 42 for wear. Replace the
bearing if it is worn.
4. Remove C2 internal retaining ring 40.
5. Remove C2 clutch backplate 39.

5–8 Copyright © 2005 General Motors Corp.

 MODULE REBUILD
6. Measure the wear surface thickness of C2
clutch backplate 39. Minimum thickness
allowed is 7.90 mm (0.311 inch). Measure
flatness of the backplate. Maximum allowable
distortion is 0.15 mm (0.006 inch).
7. Remove C2 clutch pack—seven friction plates
38 and seven steel reaction plates 37.
8. Measure the thickness of each friction plate 38.
Minimum thickness allowed is 2.92 mm
(0.115 inch). Measure the oil groove depth and
cone of each friction plate. Minimum groove
depth allowed is 0.20 mm (0.008 inch).
Maximum cone allowed is 0.25 mm (0.010 inch).
9. Measure the thickness and cone of each steel
reaction plate 37. Minimum thickness allowed
is 2.41 mm (0.095 inch). Maximum cone
allowable is 0.25 mm (0.010 inch).
10. Remove C2 drive hub 36, including two thrust
bearings 35. Inspect the splines of the C2 drive
hub. Maximum spline wear allowed is
0.38 mm (0.015 inch).
11. Remove C1 drive hub 34. Inspect the splines of
the C1 drive hub. Maximum allowable spline
wear is 0.38 mm (0.015 inch).
12. Remove C1 external retaining ring 33 and
C1 clutch pack—one backplate 32, seven fric-
tion plates 30 and six steel reaction plates 31,
and one apply plate 29.
13. Measure the thickness of each friction plate 30.
Minimum allowable thickness is 2.92 mm
(0.115 inch). Measure the oil groove depth and
cone of each friction plate. Minimum groove
Copyright © 2005 General Motors Corp.
depth allowable is 0.20 mm (0.008 inch). Max-
imum cone allowed is 0.25 mm (0.010 inch).
14. Measure the thickness of each steel reaction
plate 31. Minimum allowable thickness is
2.41 mm (0.095 inch). Maximum cone allow-
able is 0.25 mm (0.010 inch).
15. Measure the wear surface thickness and cone
of C1 clutch apply plate 29 and backplate 32.
Minimum thickness allowed is 5.90 mm
(0.232 inch) and 9.90 mm (0.390 inch), respec-
tively. Measure flatness of the C1 clutch apply
plate and backplate. Maximum allowable dis-
tortion is 0.15 mm (0.006 inch).
16. Remove thrust bearing 14 from rotating clutch
hub assembly 11.
17. Remove retaining ring 15 and turbine shaft as-
sembly 3 or 6.
18. Inspect bushing 5 inside the end of turbine
shaft 4 or 7. Measure the ID of the turbine shaft
bushing. Maximum ID allowed is 36.14 mm
(1.423 inch).
19. Remove three rotating sealrings 8.
20. Remove O-ring 2 from turbine shaft
assembly 3 or 6.
21. Place rotating clutch on tool base J 37030-3 so
rotating drum is supported by tool tangs (Fig-
ure 5–9, View C). Install J 35923-2 (Figure 5–
9, View A), including the bearing, washer and
handle. Tighten tool, compressing C1 balance
piston 26 and C1 return spring assembly 25,
and remove the balance piston retaining
ring 28.
5–9
 4000 PRODUCT FAMILY SERVICE MANUAL
J 37030-3
HANDLE
FLAT WASHER
BEARING J 35923-2
VIEW A
VIEW D
Figure 5–9. Rotating Clutch Disassembly/Assembly
WARNING!
Carefully release spring force. Piston springs are
highly compressed. Personal injury can occur if
the spring force is not controlled.
22. Release spring force by rotating handle in
counterclockwise direction. Remove handle,
flat washer, bearing, and J 35923-2 tool.
23. Remove balance piston 26, sealring 27, and
C1 spring assembly 25.
24. Install tools J 37030-3, J 37030-1, J 35923-2
(Figure 5–9, View B), bearing, washer, and
handle. Tighten tool and remove internal re-
taining ring 22. Remove tools after relieving
spring force.
5–10 Copyright © 2005 General Motors Corp.
J 37030-3
HANDLE
FLAT WASHER
BEARING J 35923-2
VIEW B
J 37030-3
VIEW C
ALIGNMENT SLOTS V06847.02.00
25. Remove C2 spring assembly 20.
26. Lift rotating clutch drum 9 free of rotating
clutch hub 13 and C1/C2 pistons 24 and 19. In-
spect the clutch splines of the rotating drum.
Maximum spline wear allowed is 0.38 mm
(0.015 inch).
27. Remove C1/C2 pistons 24 and 19 and
sealrings 18 and 23 from hub assembly 11
rocking the piston from side to side.
28. Inspect the ID of rotating clutch hub
bushing 12. Maximum allowable ID of the
bushing is 120.27 mm (4.735 inch). Remove
the bushing from hub assembly 11 if replace-
ment is necessary. Avoid damaging the bush-
ing bore.
 MODULE REBUILD
29. Remove piston sealrings 16 and 17 from
hub 13.
30. Separate C1 piston 24 and sealring 23 from C2
piston 19 and sealring 18 by tapping lightly on
the C1 piston.
b. Assembly Foldout 6,B)
1. If removed during disassembly, install
bushing 12 into drive hub assembly 11 using
tools J 37040 and J 8092.
2. Install piston sealring 16 on hub assembly 13
and piston sealring 18 into C2 piston 19. Install
piston sealring 17 on rotating clutch hub
assembly 13 and piston sealring 23 onto C1
piston 24.
3. With a mallet, lightly tap C2 piston 19 (with
sealring 18) onto hub assembly 11.
4. Align notch on C1 piston with any lubrication
orifice on the rotating drive hub. With a mallet,
lightly tap C1 piston 24 (with sealring 23) onto
the center of C2 piston 19 and over rotating
clutch hub assembly 13.
5. Install rotating clutch drum 9 over hub
assembly 11 and C1/C2 pistons 24 and 19.
6. Install C2 spring assembly 20. Align the spring
assembly with the rotating clutch hub 36 tangs
and the splines on the C2 piston 19. The C2
spring assembly must make contact with the
bottom of the slots in the C2 piston. If the spring
assembly does not reach the bottom, remove the
C2 spring assembly and re-index it in the next
spline on the rotating drum 9. Repeat this
process until the C2 spring assembly is in the
proper position.
7. Install C2 spring plate 21. Index the spring
plate with the drive hub tangs and the splines
on the C2 piston.
8. Place the rotating clutch on tool base J 37030-3
so that the rotating drum is supported by tool
tangs. Install tool J 37030-1 (Figure 5–9, View
B), J 35923-2, that includes the bearing,
washer, and handle. Tighten tool to compress
C2 spring assembly 20, and install retaining
ring 22. Remove tools.
9. Install sealring 27 onto balance piston 26.
Copyright © 2005 General Motors Corp.
10. Install C1 spring assembly 25. Aligning mark
on balance piston with slot on the C1 clutch
piston, install balance piston 26 onto the C1
piston.
11. Install tool J 35923-2 (Figure 5–9, View A),
that includes the bearing, washer, and handle.
Tighten tool to compress C1 spring assembly
and install retaining ring 28 into the hub of the
rotating clutch assembly. Remove tool.
12. If removed, install bushing 5 into turbine shaft
assembly 3 or 6 using tools J 37036 and
J 8092.
13. Install O-ring 2 onto the forward end of the tur-
bine shaft.
14. Install each rotating sealring 8 into the
ground sleeve bore and measure the end gap.
Sealring end gap must be 0.65–1.01 mm
(0.026–0.039 inch). Refer to Paragraph 3–6h.
Install three rotating sealrings 8, with correct
end gap, onto the rear of the turbine shaft.
15. Install turbine shaft assembly 3 or 6. Retain the
turbine shaft with retaining ring 15.
CAUTION:
Be sure that thrust bearings are assembled to
function correctly. Make sure that the locating
lip on either the inner or outer thrust bearing
race is not preventing the race from contacting
the thrust surface of the mating part. Failure to
do this leads to premature thrust bearing failure
and incorrect shim selection to maintain proper
internal part clearance.
16. Install thrust bearing 14 onto the rotating
clutch hub assembly 13.
17. Install C1 clutch pack (Figure 5–10)—one
clutch apply plate 29, seven friction plates 30,
six steel reaction plates 31, and one
backplate 32. Install clutch plates alternately,
starting with a friction plate 30. Install C1 re-
taining ring 33.
18. Install C1 drive hub 34. Be sure that the drive
hub passes over the external splines of all
seven plates 30.
19. Install a thrust bearing 35 on each side of C2
drive hub 36, and install this assembly over C1
drive hub 34.
5–11
 4000 PRODUCT FAMILY SERVICE MANUAL
20. Install C2 clutch plates—seven friction
plates 38 and seven steel reaction plates 37. In-
stall clutch plates alternately, starting with a
steel reaction plate 37.
21. Install C2 backplate 39. Install C2 retaining
ring 40.
22. If removed, install thrust bearing 42 on sun
gear assembly 41.
23. Install P1 sun-gear drive hub 41. Install retain-
ing ring 43.
5–8. C3/C4 AND MAIN HOUSING
MODULE
a. Disassembly (Foldout 7)
NOTE:
When replacing a nameplate, keep the original
identification plate. Stamp the information from the
original identification plate onto the replacement
identification plate.
1. Replace a damaged nameplate—remove
retaining rivet 24 and nameplate 23.
2. Inspect the inner C5 clutch plate splines of
main housing 31. Maximum allowable spline
wear is 1.15 mm (0.045 inch).
3. Remove fourteen bolts 2 retaining the C3
backplate assembly 3 and C3 clutch housing
BACKPLATE
Figure 5–10. C1 Apply Plate and Backplate
5–12 Copyright © 2005 General Motors Corp.
assembly 11. Remove C3 backplate
assembly 3.
4. Inspect four thrust plates 5 and clutch
backplate 4. Minimum allowable thrust plate 5
thickness at the contact surface is 2.82 mm
(0.111 inch). Maximum allowable distortion of
backplate 4 is 0.15 mm (0.006 inch).
Maximum allowable step wear of backplate 4
is 0.13 mm (0.005 inch).
5. Remove P1 ring gear 6. Inspect the clutch
splines of the P1 ring gear. Maximum
allowable spline wear is 0.38 mm (0.015 inch).
6. Remove the C3 clutch pack—five friction
plates 7 and five steel reaction plates 8.
7. Measure the thickness and cone of each
friction plate 7. Minimum thickness is
3.485 mm (0.137 inch). Maximum allowable
cone is 0.25 mm (0.010 inch).
8. Measure the thickness and cone of each steel
reaction plate 8. Minimum allowable thickness
is 3.25 mm (0.128 inch). Maximum allowable
cone is 0.25 mm (0.010 inch).
9. Remove piston return plate assembly 9.
10. Inspect plate 9. Minimum allowable thickness
of plate 9 is 4.91 mm (0.193 inch). Replace if
damaged.
11. Remove C3 housing assembly 11.
CLUTCH APPLY PLATE
V05566.00.01
 MODULE REBUILD
12. Inspect six thrust plates 12 in C3 housing 13.
Minimum allowable thrust plate 12 thickness
at the contact surface is 2.82 mm (0.111 inch).
Maximum allowable distortion of backplate 4
is 0.15 mm (0.006 inch). Maximum stepwear
of 0.13 mm (0.005 inch) is allowed. If replace-
ment is necessary, remove the thrust plates. In-
spect splines in C3 clutch housing 13.
Maximum spline wear allowed is 1.15 mm
(0.045 inch).
13. Remove C4 clutch pack—six steel reaction
plates 14 and five friction plates 15.
14. Measure the thickness and cone of each fric-
tion plate 15. Minimum allowable thickness is
3.485 mm (0.137 inch). Maximum allowable
cone is 0.25 mm (0.010 inch).
15. Measure the thickness and cone of each steel
reaction plate 14. Minimum allowable
thickness is 3.25 mm (0.128 inch). Maximum
allowable cone is 0.25 mm (0.010 inch).
16. Remove piston return plate assembly 16. In-
spect plate 16. Minimum allowable thickness
of plate 23 is 4.91 mm (0.193 inch)
17. Remove piston 17 from C4 housing 18. Inspect
splines in C4 clutch housing 18. Maximum
spline wear allowed is 1.15 mm (0.045 inch).
b. Assembly (Foldout 7)
1. Install piston 17 into C4 housing 18.
2. Install piston return plate assembly 16.
3. Install C4 clutch pack. Starting with a friction
plate—alternately install five friction plates 15
and six steel reaction plates 14.
4. To assemble the C3 housing (if thrust plates
were removed), install six thrust plates 12 into
C3 clutch housing 13. The thrust plate must be
Copyright © 2005 General Motors Corp.
tightly attached to the housing; no movement
is allowed.
5. Install C3 clutch piston 10 into C3 clutch-
housing assembly 13.
6. Install C3 clutch housing assembly 11 with
clutch piston 10 on top of the assembled C4
clutch housing assembly. Make sure index
notches on the clutch housings are aligned.
7. Install piston return plate 9.
8. Install P1 ring gear 6.
9. Install the C3 clutch pack. Starting with a
friction plate, alternately install five friction
plates 7 and five steel reaction plates 8.
10. To assemble the C3 backplate (if thrust plates
were removed), install six thrust plates 5 into
C3 backplate 4. The thrust plate must be
tightly attached to the housing; no movement
is allowed.
11. Install C3 backplate assembly 3. Align the
notch on the C3 backplate with the notches on
the C3 and C4 housings.
12. Install fourteen retaining bolts 2 into the C3/C4
clutch assembly. Tighten the bolts to 51–61 N·m
(38–45 lb ft).
13. If removed, install nameplate 23 and screw 24.
5–9. MAIN SHAFT MODULE
a. Disassembly (Foldout 8)
1. Remove external spiral retaining ring 4.
2. Remove P2 sun gear 5.
3. Remove bearing spacer 6.
4. Remove thrust bearing 2.
5–13
 4000 PRODUCT FAMILY SERVICE MANUAL
5. Remove selective shim 1. On 4700 and 4800
models, remove non-selective shim 1.
6. On close ratio transmissions, remove P3 sun
gear 7 from main shaft 8.
7. For all models, inspect main shaft 7 or 8 for
wear, damage, and evidence of chipped or
cracked splines or gear teeth. Measure the
journals as illustrated in Figure 5–11.
Maximum main shaft spline wear is
0.38 mm (0.015 inch).
b. Assembly (Except 4700 and 4800 Models)
(Foldout 8)
NOTE:
Do not install thrust bearing 2 or selective shim 1
until final transmission assembly. Measurement for
selective shim 1 is performed during final buildup.
1. On close ratio transmissions, install P3 sun
gear 7 onto main shaft 8.
2. Install bearing spacer 6.
3. Install P2 sun gear 5.
4. Install external spiral retaining ring 4
c. Assembly (4700 and 4800 Models) (Foldout 8)
1. Install P3 sun gear 7 onto main shaft 8.
2. Install bearing spacer 6.
3. Install P2 sun gear 5.
4. Install external spiral retaining ring 4.
5. Install non-selective shim 1.
6. Install thrust bearing 2.
35.92 mm
(1.414 in.)
52.98 mm
(2.085 in.)
35.92 mm
(1.414 in.)
V02524
Figure 5–11. Measurement of Main Shaft Journals
5–14 Copyright © 2005 General Motors Corp.
5–10. P1 PLANETARY MODULE
a. Disassembly (Foldout 9,A)
1. Remove internal retaining ring 2 from P2 ring
gear 15.
2. Remove P2 ring gear 15.
3. Measure P1 planetary carrier assembly 3 pinion
end play. Pinion end play must not exceed
0.94 mm (0.037 inch). Measure all six pinion
gears.
4. Remove retaining ring 4. Remove indexing
ring 5.
5. Remove six pinion spindles 6 from P1
carrier 8.
6. Slide pinion gear 11, thrust washers 10 and 13,
and two bearing assemblies 12 from the side of
P1 planetary carrier 8. Repeat the procedure
with the five remaining pinion gears.
7. Measure the thickness and any step wear for all
thrust washers 10 and 13. Minimum thrust
washer thickness allowed is 1.40 mm
(0.055 inch). Maximum allowable step wear is
0.12 mm (0.005 inch).
8. Remove thrust bearing assembly 14 from P1
planetary carrier 8.
9. Inspect bushing 9 inside P1 planetary carrier 8
for wear or damage. Maximum ID allowed is
89.32 mm (3.516 inch). If worn, remove
bushing 9.
10. Determine if there is spline wear between
P1 planetary carrier 8 and P2 planetary ring
gear 15. Maximum allowable spline wear is
0.38 mm (0.015 inch).
b. Assembly (Foldout 9,A)
1. If replacement is necessary, press a new
bushing 9 into P1 carrier 8 using a press,
installer J 37038, and drive handle J 8092.
Press bushing 9 flush to 0.40 mm (0.016 inch)
below the surface.
2. Install two bearing assemblies 12 into the
center of pinion gear 11. Install thrust
washers 10 and 13 inside P1 planetary
carrier 8, align thrust washer tangs with the
 MODULE REBUILD
slots in the planetary, and retain them with oil-
soluble grease.
3. Slide the pinion gear and bearing assemblies
into the side of the P1 planetary carrier
between the thrust washers.
4. Repeat the procedure for the five remaining
pinion gears.
5. Install six spindles 6 so the lower step is
positioned for proper installation of indexing
ring 5.
6. Install indexing ring 5 and retaining ring 4.
7. If components were replaced, measure pinion
end play. Pinion end play must not exceed
0.94 mm (0.037 inch). Measure all six pinion
gears.
8. Install P2 ring gear 15 over P1 planetary
carrier assembly 3.
9. Install internal retaining ring 2 into P2 ring
gear 15, connecting P1 planetary carrier
assembly 3 and the P2 planetary ring gear.
CAUTION:
Be sure that thrust bearings are assembled to
function correctly. Make sure that the locating
lip on either the inner or outer thrust bearing
race is not preventing the race from contacting
the thrust surface of the mating part. Failure to
do this leads to premature thrust bearing failure
and incorrect shim selection to maintain proper
internal part clearance.
10. Install thrust bearing assembly 14 on P1 plane-
tary carrier assembly 3.
5–11. P2 PLANETARY MODULE
a. Disassembly (Foldout 9,B)
1. Remove retaining ring 2.
2. Remove P3 ring gear 15. Remove and inspect
thrust bearing assembly 14.
3. Measure P2 planetary carrier pinion end play.
Pinion end play must not exceed 0.94 mm
(0.037 inch). Measure all four pinion gears.
Copyright © 2005 General Motors Corp.
4. Remove internal retaining ring 4. Remove
indexing ring 5. Remove four pinion
spindles 13 from P2 carrier 7.
5. Slide a pinion gear 11, thrust washers 9 and 12,
and two roller bearings 10 from the side of P2
planetary carrier 7. Repeat the procedure with
the three remaining pinion gears.
6. Measure the thickness and any step wear for all
thrust washers 9 and 12. Minimum allowable
thickness of the thrust washers is 1.40 mm
(0.055 inch). Maximum allowable step wear is
0.12 mm (0.005 inch).
7. Inspect bushing 8 inside P2 planetary carrier 7
for wear or damage. Maximum ID of the
bushing is 53.23 mm (2.096 inch). Remove
bushing 8 if it is worn or damaged.
8. Determine whether there is spline wear
between P2 planetary carrier 7 and P3
planetary ring gear 15. Maximum wear
allowed is 0.38 mm (0.015 inch).
b. Assembly (Foldout 9,B and Figure 5–12)
1. If replacement is necessary, press a new
bushing 8 into P2 carrier 7 using a press,
installer J 37036, and driver J 8092.
2. Install two roller bearings 10 into the center of
pinion gear 11. Install thrust washers 9 and 12
in P2 planetary carrier 7, align thrust washer
tangs with slots in the planetary, and retain
them with oil-soluble grease. Slide the pinion
gear and two bearing sets, into the side of the
P2 planetary carrier between the thrust
washers. Repeat the procedure with the three
remaining pinion gears.
CAUTION:
If the wear on the indexing ring is minor, flip it
over to get a fresh reaction point for the spindle.
Replace the indexing ring if both corners of the
indexing ring are worn. Failure to take corrective
action may allow the spindle to rotate which may
reduce or shut off lubrication to the pinion
bearings and thrust washers.
3. Install four spindles 13 so the lower step is
positioned for proper installation of indexing
ring 5.
4. Install indexing ring 5 and internal retaining
ring 4.
5–15
 4000 PRODUCT FAMILY SERVICE MANUAL

DIMENSION A

VIEW A VIEW B

V06848

Figure 5–12. Planetary Spindle and Indexing Ring

5. If components were replaced, measure pinion
end play. Pinion end play must not exceed
0.94 mm (0.037 inch). Measure all four pinion
gears. Install thrust bearing 14.
6. Install thrust bearing 14.
7. Install P3 ring gear 15 over P2 carrier
assembly 3.
8. Install retaining ring 2 into P3 ring gear 15 so
that the P2 carrier and P3 ring gear are linked.
NOTE:
• For 4000 Product Family models with retarder
b. Assembly (Foldout 9,C)
(except 4700 and 4800 models) proceed to Para-
graph 5–14.
• For 4000 Product Family models without
retarder (except 4700 and 4800 models) skip
Paragraph 5–14 and 5–15 and proceed to
Paragraph 5–16.
5–12. P3 PLANETARY MODULE
(4700 and 4800 Models)
2. Remove internal retaining ring 2. Remove
indexing ring 3. Remove four planetary
spindles 7.
3. Slide pinion gear 9, thrust washers 8, and two
bearing assemblies 10 from the side of P3
planetary carrier 4. Repeat the procedure for
three remaining pinion gears.
4. Measure the thickness and any step wear for
eight thrust washers 8. Minimum allowable
thickness of the thrust washers is 1.40 mm
(0.055 inch). Maximum step wear allowed is
0.12 mm (0.005 inch).
1. Install two roller bearing assemblies 10 into the
center of pinion gear 9. Install thrust washers 8
in P3 planetary carrier 4, align the thrust washer
tangs with the slots in the carrier, and retain
them with oil-soluble grease. Slide the pinion
gear and bearings into the side of the P3
planetary carrier between the thrust washers.
Repeat the procedure with the three remaining
pinion gears.

a. Disassembly (Foldout 9,C) 2. Install four planetary spindles 7 so the lower

1. Measure pinion end play of P3 carrier
assembly 1. Pinion end play must not exceed
0.94 mm (0.037 inch). Measure the three
remaining pinion gears 9.
step is positioned for proper installation of
indexing ring 3.
3. Install indexing ring 3. Install internal retaining
ring 2.

5–16 Copyright © 2005 General Motors Corp.

 MODULE REBUILD
4. If components were replaced, measure pinion
end play. Pinion end play must not exceed
0.94 mm (0.037 inch). Measure all four pinion
gears 9.
NOTE:
Do not install shim locating ring 6 or selective
shim 12 until final transmission assembly.
Measurement for selective shim is performed during
final buildup.
5–13. C6 ADAPTER HOUSING MODULE
(4700 and 4800 Models)
(Foldout 9,C)
a. Disassembly of Ring Gear and Hub Assembly
1. Remove P4 ring gear and hub assembly 45.
2. Remove retaining ring 48 from P4 ring gear and
hub assembly 45 and separate P4 ring gear 46
and P4 ring gear hub 47.
3. Remove thrust bearing 44.
b. Disassembly
1. Remove C6 backplate 29.
2. Thread three M8 eye bolts into the three tapped
holes of P4 planetary carrier assembly 32.
3. Attach hoist and remove P4 planetary carrier
assembly 32 from C6 adapter housing 22.
c. Disassembly of P4 Planetary Carrier Assembly
1. Remove internal retaining ring 33 from C6
clutch drum hub 43.
2. Turn over P4 carrier assembly and remove
clutch drum hub 43.
3. Remove internal retaining ring 34 and indexing
ring 35 from P4 carrier assembly 32.
4. Remove six spindles 39 from P4 carrier 37.
5. Measure pinion end play. Pinion end play must
not exceed 0.94 mm (0.037 inch). Measure the
five remaining pinion gears.
6. Remove six P4 pinion gears 41 from P4 carrier
assembly 32.
Copyright © 2005 General Motors Corp.
7. Remove twelve thrust washers 40 and twelve
caged needle bearings 42 from the pinion gears.
8. Measure the thickness and any step wear for
twelve thrust washers 40. Minimum allowable
thickness of the thrust washers is 1.40 mm
(0.055 inch). Maximum step wear allowed is
0.12 mm (0.005 inch).
9. Inspect bushing 38 in carrier 37 for wear or
damage. Maximum allowable bushing ID is
113.33 mm (4.462 inch). Remove bushing 38 if
it is worn or damaged.
d. Disassembly of Remaining C6 Parts
1. Lift C6 clutch pack from C6 adapter housing
assembly—eight friction plates 28 and nine
reaction plates 27.
2. Measure the thickness and cone of each friction
plate 28. Minimum thickness is 3.68 mm
(0.145 inch). Maximum allowable cone is
0.25 mm (0.010 inch).
3. Measure thickness and cone of each steel
reaction plate 27. Minimum thickness is
3.24 mm (0.128 inch). Maximum allowable
cone is 0.25 mm (0.010 inch).
4. Remove thrust bearing 31.
5. Remove P4 sun gear 30.
6. Place special tool J 43025 onto return spring
assembly 17 (Figure 5–13).
J 35923
J 43025
V05581
Figure 5–13. Compressing Spring and
Retainer Assembly
5–17
 4000 PRODUCT FAMILY SERVICE MANUAL
7. Compress return spring assembly 17 using
J 35923-4 tool base, washer, bearing, handle, NOTE:
and piston spring compressor J 43025 Ball bearing assembly 26 is properly seated when it is
(Figure 5–14). Remove external retaining against the shoulder at the bottom of the bearing
ring 16 and slowly release the spring force. bore and is 1.57–3.35 mm (0.062–0.132 inch) below
8. Remove piston return spring assembly 17. the machined face of the adapter housing at the top
of the bearing bore.
9. Remove C5 piston 18 from C6 adapter housing
module 14. 4. Press ball bearing assembly 26 into C6 adapter
10. Remove internal sealring 20 from C5 housing assembly 21 until it is properly seated.
piston 18. Remove external sealring 19 from
C5 piston 18.
11. Place C6 adapter housing module 21 on press J 37034
stand. Place special tool J 43047 and J 37034
onto ball bearing 26 (Figure 5–15). Support
ball bearing from falling with a block of wood. J 43047

12. Using press, remove ball bearing 26.

13. Inspect ball bearing assembly 26. Refer to Para-

graph 3–5d and 3–5e.
e. Assembly
1. Turn C6 adapter housing assembly 21 over and
place on press stand.
2. Place ball bearing 26 in C6 adapter housing
assembly 21. V05583

3. Place special tool J 43047 and J 37034 on ball Figure 5–15. Removal of Ball Bearing From
bearing assembly 26 (Figure 5–16). C6 Adapter Housing

J 35923-4

J 37034

J 43047

V05582 V05584

Figure 5–14. Bottom View of C6 Adapter Figure 5–16. Installation of Ball Bearing
Housing and J 35923-4 Into C6 Adapter Housing

5–18 Copyright © 2005 General Motors Corp.

 MODULE REBUILD
5. Install piston ID lip-type sealring 20 onto C5
piston 18. Install external sealring 19 onto C5
piston 18.
6. Align the tang on the back of the C5 clutch
piston 18 with the notch in the C6 adapter
housing 22 before installing C5 clutch piston
18. Install C5 clutch piston 18 into C6 adapter
housing module 14. Use a rubber mallet to seat
the piston.
7. Place spring return assembly 17 in C6 adapter
housing assembly 21. Use alignment notch to
guide installation.
WARNING!
Piston springs are highly compressed. Be
extremely careful during installation. Personal
injury can occur if the spring force is not
controlled.
8. Place retaining ring 16 in C6 adapter housing
assembly 21.
9. Compress spring and retainer assembly 17
using J 35923-4 tool base, washer, bearing,
handle, and piston spring compressor J 43025.
Install retaining ring 16 and slowly release the
spring force (Figures 5–17 and 5–18).
J 35923
J 43025
V05581
Figure 5–17. Compressing Spring and
Retainer Assembly
Copyright © 2005 General Motors Corp.
f. Assembly of P4 Planetary Carrier Assembly
1. Install two caged needle bearings 42 into the
center of pinion gear 41. Install thrust washers
40 in P4 planetary carrier 37. Align thrust
washer tangs with slots in carrier 37 and retain
them with oil-soluble grease. Slide pinion gear
41 and two bearings 42 into the side of P4
planetary carrier 37 between thrust washers 40.
Repeat the procedure for the five remaining
pinion gears.
2. Install six spindles 39 so the lower step is
positioned for proper installation of indexing
ring 35.
3. Install indexing ring 35 and internal retaining
ring 34.
4. If components were replaced, measure pinion
end play. Pinion end play must not exceed
0.94 mm (0.037 inch). Measure all six pinion
gears. Install thrust bearing 44.
5. Install P4 planetary carrier assembly 32 into
the C6 clutch drum hub 43.
6. Support P4 planetary carrier hub 43 slightly off
of the work table so P4 planetary carrier
assembly 32 can fall through. Install retaining
ring 33 into C6 clutch hub 43
J 35923-4
V05582
Figure 5–18. Bottom View of C6 Adapter Housing
and J 35923-4
5–19
 4000 PRODUCT FAMILY SERVICE MANUAL
7. Thread three M10 eye bolts into the P4
planetary carrier assembly 32.
8. If replacing, install P4 carrier bushing 38 in P4
carrier 37 using special tool J 43023 and
J 37034 (Figure 5–19).
9. Install thrust bearing 31 on P4 sun gear 30.
10. With thrust bearing 31 facing up, place the
thrust bearing and P4 sun gear inside P4 plane-
tary carrier assembly 32. While holding onto
P4 sun gear 30, carefully install both P4 sun
gear 30 and P4 carrier assembly 32 into C6
adapter housing 22 using a sling and hoist.
NOTE:
Do not install ring gear and hub assembly 45 in the
C6 adapter housing assembly 21 until final
transmission assembly. Measurement for selective
shim is performed during final buildup.
g. Assembly of C6 Clutch
1. Install the C6 clutch pack in the C6 adapter
housing—nine reaction plates 27 and eight
friction plates 28, stacked alternately, starting
with a steel reaction plate 27. Stack all plates
so plate cone faces the same direction.
Reaction plates 27 mesh with the C6 adapter
housing 22 and friction plates 28 mesh with C6
clutch hub 43.
2. Install C6 backplate 29.
J 37034
J 43023
V05587
Figure 5–19. Installation of P4 Planetary Bushing
5–20 Copyright © 2005 General Motors Corp.
NOTE:
• For 4700 and 4800 models with a retarder,
proceed to Paragraph 5–15.
• For 4700 and 4800 models without a retarder,
proceed to Paragraph 5–17.
5–14. RETARDER AND P3 PLANETARY
MODULE
a. Disassembly of Retarder Valve Body
(Foldout 10,C)
1. Remove nine bolts 93 and three bolts 89
retaining retarder control body assembly 65 to
retarder housing 41 and remove control body
assembly 65.
2. Remove pressure tap plug 92 and discard
O-ring 91.
3. Remove separator plate 63.
4. Remove plug 81, O-ring 80, spring 78, and
regulator valve 77 from retarder valve body 75.
Discard O-ring 80.
5. Remove plug 83, O-ring 84, spring 85, and
relay valve 86 from retarder valve body 75.
Discard O-ring 84.
6. Remove retaining pin 76 from the back side of
the retarder valve body 75.
7. Remove solenoid and connector assembly 71
from retarder valve body 75.
8. Remove and discard O-ring seal 73 and O-
ring 74.
9. Measure the resistance of retarder solenoid 72.
Resistance must be 4–8 Ohms.
10. If replacement is necessary refer to the Allison
4th Generation Troubleshooting Guide,
TS3989EN.
b. Disassembly of Temperature Sensor
(Foldout 10,C)
1. Remove temperature sensor retainer bolt 48
and temperature sensor retainer 47. Carefully
remove temperature sensor assembly 45 from
retarder housing 41.
2. Determine retarder temperature sensor
resistance measured with an ohmmeter. Refer
to Figure 5–20.
 MODULE REBUILD

1,000,000

100,000
SENSOR RESISTANCE (‰)

10,000

1,000

100

10

1
— 40 14 68 122 176 230 284 338 392

— 40 —10 20 50 80 110 140 170 200

TEMPERATURE
V04641.01

Figure 5–20. Temperature Sensor Chart

c. Disassembly of Retarder Housing

(Foldout 10,C) NOTE:
Output seal 60 must be removed before retainer
CAUTION: locknut 59 can be removed.
Be sure to remove speed sensor 53. Failure to
remove the speed sensor will result in equipment
damage. 5. If not removed, remove output oil seal
assembly 60 using seal removal tool
1. Remove output speed sensor bolt 56, sensor
J 24171-A.
retainer 55, and output speed sensor
assembly 53 from the retarder housing. Remove
O-ring 54 and discard. Measure output speed 6. Remove bearing retaining locknut 59 using
sensor resistance (speed sensor resistance special tool J 37035. Remove Belleville
varies by temperature). washer 58.

Resistance Temperature Temperature 7. Support retarder housing 41 so that P3

(Ohms) (°C) (°F) planetary carrier assembly 3 can be removed
250 –40 –40 from the retarder housing. Place special tool
340 20 68 J 37035 over the output shaft splines and
450 110 230 against the threaded shoulder of the P3
planetary carrier. Press on J 37035 with a
2. Remove tachograph plug 39 and brass
hydraulic press or drive on J 37035 with a
washer 40.
mallet until the P3 planetary carrier is
3. Remove retaining ring 50 and valve plug 49. separated from the retarder housing.
4. Use J 42048 to compress vlave plug 33.
Remove retaining ring 32 and tool J 42048. 8. Remove three bolts 52 to allow removal of
Remove valve plug 33, O-ring 34, spring 35, retarder stator assembly 18 from retarder
and retarder valve 36. Remove spring pin 37 housing 41. Remove retarder housing
only if damaged. gasket 28.

Copyright © 2005 General Motors Corp. 5–21

 4000 PRODUCT FAMILY SERVICE MANUAL
9. Remove rotor assembly 29. Remove
sealrings 27 and 30 from rotor
assembly 29. Inspect splines inside rotor 29.
Maximum spline wear allowed is 0.38 mm
(0.015 inch).
10. If replacement is required, remove cone and
roller bearing assembly 57 from retarder hous-
ing 41. If necessary to replace, remove bearing
cup 51 using bearing tool J 3940.
NOTE:
11. Remove one bolt 99, three bolts 101, jumper
manifold 98, or remote side manifold 100, and
gasket 97 from rear of retarder housing 41.
12. Remove bolt 96, jumper manifold 95 or remote
side manifold 97, and gasket 94 from the rear
of retarder housing 41.
13. Remove nine bolts 44, cover 43, and gasket 42
from the bottom of retarder housing 41.
d. Disassembly of P3 Planetary
Carrier Assembly (Foldout 10,C)
WARNING!
Place the P3 planetary assembly on its side to
avoid possible injury while disassembling the
planetary.
1. Remove retaining ring 11 and thrust washer 10
from P3 planetary carrier assembly 3.
NOTE:
• For 4500 models (wide ratio) transmissions,
skip to Step (3).
• For close ratio models, proceed with Step (2).
2. On a close ratio transmission, remove output
shaft assembly 4. Inspect the splines on output
shaft assembly 4. Maximum spline wear
allowed is 0.38 mm (0.015 inch).
3. If replacement is necessary, remove cone and
roller bearing assembly 17.
4. Measure pinion end play. Pinion end play must
not exceed 0.94 mm (0.037 inch). Measure the
three remaining pinion gears.
5. Remove retaining ring 7. Remove P3 indexing
ring 8. Remove four P3 planetary spindles 12.
6. Slide P3 pinion gear 14, P3 thrust washers 13
and 16, and two bearing assemblies 15 from
5–22 Copyright © 2005 General Motors Corp.
the side of P3 planetary carrier 9. Repeat the
procedure with three remaining pinion gears.
7. Measure the thickness and any step wear for
eight P3 thrust washers 13 and 16. Minimum
allowable thickness of the thrust washers is
1.40 mm (0.055 inch). Maximum step wear
allowed is 0.12 mm (0.005 inch).
• For 4500 models (wide ratio) transmissions,
proceed with Step (8).
• For close ratio models, skip Step (8) and pro-
ceed with Step (9).
8. On wide ratio transmissions, remove output
shaft assembly 4. Inspect the splines on output
shaft assembly 4. Maximum spline wear
allowed is 0.38 mm (0.015 inch).
9. Inspect bushing 5 inside the end of output
shaft 6 for wear or damage. Measure the ID of
the output shaft bushing. Maximum allowable
ID is 36.14 mm (1.423 inch).
e. Disassembly of Retarder Stator Assembly
(Foldout 10,C)
1. Remove O-ring 26 from retarder stator
assembly 18.
WARNING!
Piston springs are highly compressed. Be
extremely careful during removal and
installation. Personal injury can occur if the
spring force is not controlled.
2. Remove C5 clutch piston 21 from retarder
stator 25 by compressing spring and retainer
assembly 20 using J 37030-3 tool base, washer,
bearing, handle, and piston spring compressor
J 37030-2. Remove retaining ring 19 and
slowly release the spring force.
3. Remove C5 piston outer sealring 22 from
C5 clutch piston 21.
4. Remove C5 piston inner sealring 23 from
C5 clutch piston 21.
5. If replacement is necessary, remove bearing
cup 24 using bearing tool J 3940.
 MODULE REBUILD
f. Assembly of Retarder Stator
(Foldout 10,C)
1. If removed, install bearing cup 24 using
bearing tool J 37033 and drive sleeve J 37034.
2. Install C5 piston inner sealring 23 onto C5
clutch piston 21.
3. Install C5 piston outer sealring 22 onto C5
clutch piston 21.
4. Align the tang notch on the back of the C5
clutch piston with the tang on retarder stator
25. Install C5 clutch piston 21 into retarder
stator 25.
5. Install spring and retainer assembly 20, align
the tab in the spring and retainer assembly with
the notch in retarder stator 25.
WARNING!
Piston springs are highly compressed. Be
extremely careful during installation. Personal
injury can occur if the spring force is not
controlled.
6. Compress spring and retainer assembly 20
using J 37030-3 tool base, washer, bearing,
handle, and piston spring compressor
J 37030-2. Install external retaining ring 19
and slowly release the spring force.
7. Install O-ring 26 on retarder stator 25.
g. Assembly of P3 Planetary Carrier Assembly
(Foldout 10,C)
1. If removed, install cone and roller bearing
assembly 17. Use drive sleeve J 37034 and
press the bearing against the shoulder on P3
carrier 3.
2. If removed, install bushing 5 inside the end of
output shaft 6 using installer J 37036, drive
handle J 8092, and a press.
3. Install output shaft assembly 4 into P3
planetary carrier 9.
4. Install thrust washer 10 and retaining ring 11
into P3 planetary carrier.
Copyright © 2005 General Motors Corp.
5. Install two roller bearing assemblies 15 into
the center of pinion gear 14.
6. Install thrust washers 13 and 16 in P3 planetary
carrier 9, align the thrust washer tangs with the
slots in the carrier, and retain them with oil-
soluble grease. Slide the pinion gear and
bearings into the side of the P3 planetary
carrier between the thrust washers. Repeat the
procedure with the three remaining pinion
gears.
7. Install four planetary spindles 12 so the lower
step is positioned for proper installation of
indexing ring 8.
8. Install indexing ring 8. Install internal retaining
ring 7.
9. If components were replaced, measure pinion
end play. Pinion end play must not exceed
0.94 mm (0.037 inch). Measure all four pinion
gears.
h. Assembly of Retarder Housing Assembly
(Foldout 10,C)
1. If removed, install bearing cup 51 using
bearing tool J 37033 and drive sleeve J 37034.
2. Install new gasket 42, cover 43, and nine
bolts 44. Tighten bolts to 24–29 N·m (18–
21 lb ft).
3. Install remote side manifold 100 or jumper
manifold 98 and new gasket 97 to retarder
housing 41 using bolt 99. Tighten bolts to
51–61 N·m (38–45 lb ft).
4. Place P3 carrier assembly 3 on the work table
(output shaft up) and place stator assembly 18
over the output shaft.
5. Install sealrings 27 and 30 onto rotor 29. Install
the rotor assembly over the output shaft.
6. Install two M8 guide bolts into retarder
stator 25. Install gasket 28 onto the guide
bolts. Place retarder housing 41 over the
output shaft and guide bolts, aligning the
holes of the housing with the holes of the
stator assembly. Remove the guide bolts as
you install three bolts 52. Tighten bolts 52 to
12–15 N·m (9–11 lb ft).
5–23
 4000 PRODUCT FAMILY SERVICE MANUAL
7. If removed, install cone and roller bearing
assembly 57 using installer J 37034. Press
cone and roller bearing assembly 57 into
retarder housing 41 while rotating the retarder
housing.
NOTE:
When installing the Belleville washer, be sure that
the concave side of the washer at the inside diameter
contacts the inner race of the bearing and that the
anti-rotation tang engages the drilled hole in the P3
carrier. Tilt the Belleville washer, tang toward the
bearing, to engage the tang into the hole.
8. Install Belleville washer 58.
CAUTION:
Over-tightening bearing retainer locknut 59 will
damage cone and roller bearing assemblies 17
and 57 and cups 24 and 51.
9. Lubricate output shaft threads and install
locknut 59 so that the Verspel® buttons are in
contact with the Belleville washer 58. Replace
current locknut if it does not exhibit 3 N·m
(7.5 lb ft) of running torque.
10. Using special tools J 37035 and J 43278, with
the torque wrench and breaker bar positioned
as shown in Figure 5–21, rotate the torque
wrench clockwise to tighten bearing retainer
locknut 59 to 185–200 N·m (137–147 lb ft).
Locknut torque values are for bench assembly
only. If the output module is mounted on the
transmission, tighten the bearing retainer
locknut to 74–88 N·m (55–64 lb ft).
11. Support retarder housing 41 so that the turning
torque of the P3 carrier assembly 3 can be
measured after installation of bearing retainer
locknut 59. Use tool J 37035 to measure turn-
ing torque. Maximum turning torque is 3 N·m
(27 lb inch).
5–24 Copyright © 2005 General Motors Corp.
NOTE:
Delay installing output oil seal assembly 60.
12. Install valve plug 49 and retaining ring 50.
13. If removed, install spring pin 37 into retarder
valve 36 and insert into valve bore. Install
spring 35, O-ring 34, plug 33, and retaining
ring 32. Use J 42048 to compress plug 33 and
install retaining ring 32.
14. Install output speed sensor assembly 53, with
new O-ring 54, and output speed sensor bolt 56.
Tighten the bolt to 24–29 N·m (18–21 lb ft).
15. Carefully install temperature sensor assembly 45
into retarder housing 41. Install temperature
sensor retainer 47 and retainer bolt 48. Tighten
the bolt to 24–29 N·m (18–21 lb ft).
16. Install brass washer 40 onto tachograph
plug 39. Install plug 39 into retarder housing 41.
Tighten the plug to 60–67 N·m (45–49 lb ft).
i. Assembly of the Retarder Valve Body
(Foldout 10,C)
1. Install new O-ring 74 and seal 73 on retarder
solenoid 72.
2. Insert solenoid and connector assembly 71 into
retarder valve body 75.
3. Install relay valve 86, valve spring 85,
O-ring 84, and plug 83 into retarder control
body 75.
4. Install regulator valve 77, valve spring 78,
O-ring 80, and plug 81 into retarder control
body 75.
5. Install exhaust backfill valve 70, spring 69,
O-ring 68, and plug 67 into retarder control
body 75.
 MODULE REBUILD

6. Install guide pin 76 into the retarder control b. Disassembly of Temperature Sensor
body 75. (Foldout 10,D)
7. Install retarder control valve cover gasket 87 1. Remove temperature sensor retainer bolt 38
and retarder control valve cover 88 on and temperature sensor retainer 37. Carefully
frontside and separator plate 63 on backside of remove temperature sensor assembly 35 from
retarder control valve body 75. retarder housing 31.
8. Install O-ring 91 and pressure tap plug 92.
Tighten the plug to 10–13 N·m (7–10 lb ft). 2. Measure retarder temperature sensor resistance
measured with an ohmmeter. Refer to
9. Install retarder control body assembly 65, nine Figure 5–20.
bolts 93, and three bolts 89 that retain it to re-
tarder housing 41. Tighten bolts to 24–29 N·m c. Disassembly of Retarder Housing
(18–21 lb ft). (Foldout 10,D)
10. Skip to Paragraph 5–18.
CAUTION:
5–15. RETARDER AND OUTPUT
Be sure to remove speed sensor 46. Failure to
SHAFT MODULE (4700 and 4800 remove the speed sensor will result in equipment
Models Equipped With Retarder) damage.
a. Disassembly of Retarder Valve Body
(Foldout 10,D) 1. Remove output speed sensor bolt 49, sensor
retainer 48, and output speed sensor
1. Remove three bolts 78 and nine bolts 82
assembly 46 from the retarder housing. Remove
retaining retarder control body assembly 54 to
O-ring 47 and discard. Measure output speed
retarder housing 31 and remove control body
sensor resistance (speed sensor resistance
assembly 54.
varies by temperature).
2. Remove pressure tap plug 81 and discard
O-ring 80. Resistance Temperature Temperature
(Ohms) (°C) (°F)
3. Remove separator plate 52.
250 –40 –40
4. Remove plug 70, O-ring 69, spring 67, and
valve 66 from retarder valve body 64. Discard 340 20 68
O-ring 69. 450 110 230
5. Remove plug 72, O-ring 73, spring 74, and
valve 75 from retarder valve body 64. Discard 2. Remove tachograph plug 29 and brass
O-ring 73. washer 30.

6. Remove retaining pin 65 from the back side of 3. Remove retaining ring 40 and plug 39.
the retarder valve body 64.
4. Use J 42048 to compress plug 23. Remove
7. Remove solenoid and connector assembly 60 retaining ring 22 and tool J 42048. Remove
from retarder valve body 64. plug 23, O-ring 24, spring 25, and retarder
8. Remove and discard O-ring seal 62 and valve 26. Remove spring pin 27 only if
O-ring 63. damaged.

9. Measure the resistance of retarder solenoid 61.

Resistance must be 4–8 Ohms. NOTE:
10. If replacement is necessary refer to the Allison Output seal 45 must be removed before retainer
4th Generation Troubleshooting Manual, locknut 44 can be removed.
TS3989EN.

Copyright © 2005 General Motors Corp. 5–25

 4000 PRODUCT FAMILY SERVICE MANUAL
5. If not removed, remove output oil seal
assembly 45 using seal removal tool
J 24171-A.
6. Remove locknut 44 using special tool J 37035.
Remove Belleville washer 43 (Foldout 10,D).
7. Support retarder housing 31 so that output
shaft 3 can be removed from retarder housing
31. Place special tool J 37035-3 over the
output shaft splines. Press on output shaft
assembly 3 with a press until output shaft
assembly 3 is separated from retarder
housing 31.
d. Completion of Retarder Housing Disassembly
(Foldout 10,D)
1. Remove three bolts 20 to allow removal of
retarder stator assembly 7 from retarder
housing 31. Remove and discard retarder
housing gasket 17.
2. Remove rotor assembly 18. Remove rotating
sealrings 16 and 19 from rotor assembly 18.
Inspect splines inside rotor 18. Maximum
spline wear allowed is 0.38 mm (0.015 inch).
3. If replacement is required, remove cone and
roller bearing assembly 42 from the retarder
housing. If replacement is necessary, remove
bearing cup 41 using bearing tool J 3940.
4. Remove bolt 85 and three bolts 87, jumper
manifold 84 or remote side manifold 86, and
gasket 83 from the rear of retarder housing 31.
5. Remove nine bolts 34, cover 33, and gasket 32
from the bottom of retarder housing 31.
e. Disassembly of Output Shaft Assembly
(Foldout 10,D)
1. Inspect the splines on output shaft assembly 3.
Maximum spline wear allowed is 0.38 mm
(0.015 inch).
2. If replacement is necessary, remove cone and
roller bearing assembly 6.
5–26 Copyright © 2005 General Motors Corp.
3. If replacement is necessary, remove output
shaft bushing 4. Maximum bushing ID allowed
is 36.14 mm (1.423 in.).
f. Disassembly of Retarder Stator Assembly
(Foldout 10,D)
1. Remove O-ring 15 from retarder stator
assembly 7.
WARNING!
Piston springs are highly compressed. Be
extremely careful during removal and
installation. Personal injury can occur if the
spring force is not controlled.
2. Remove C5 clutch piston 10 from retarder
stator housing 14 by compressing piston return
spring and retainer assembly 9 using J 37030-3
tool base, washer, bearing, handle, and piston
spring compressor J 37030-2. Remove
retaining ring 8 and slowly release the spring
force.
3. Remove external sealring 11 from C5 clutch
piston 10.
4. Remove internal lip-type sealring 12 from C5
clutch piston 10.
5. If replacement is necessary, remove roller
bearing cup 13 using bearing tool J 3940.
g. Assembly of Retarder Stator (Foldout 10,D)
1. If removed, install bearing cup 13 using
bearing tool J 37033 and drive sleeve J 37034.
2. Install internal lip-type sealring 12 onto C5
clutch piston 10. Install external sealring 11
onto C5 clutch piston 10.
3. Align the tang notch on the back of the C5
clutch piston with the tang on the retarder
stator before installing C5 clutch piston 10 into
retarder stator 14. Install C5 clutch piston 10
into retarder stator 14.
 MODULE REBUILD
4. Install spring and retainer assembly 9, aligning
the tab in the spring and retainer assembly with
the notch in retarder stator 14.
WARNING!
Piston springs are highly compressed. Be
extremely careful during installation. Personal
injury can occur if the spring force is not
controlled.
5. Compress piston return spring and retainer
assembly 9 using J 37030-3 tool base, washer,
bearing, handle, and piston spring compressor
J 37030-2. Install external retaining ring 8 and
slowly release the spring force.
6. Install O-ring 15 on retarder stator housing 14.
h. Assembly of Retarder Housing (Foldout 10,D)
1. If removed, install bearing cup 41 using
bearing tool J 37033 and drive sleeve J 37034.
2. Install rotating sealrings 16 and 19 onto rotor
assembly 18. Install the rotor assembly 18 onto
the retarder housing 31.
3. Install two M8 guide bolts into retarder
stator housing 14. Install gasket 17 onto the
guide bolts. Place stator assembly 7, using the
guide bolts, aligning the holes of the retarder
housing 31 with the holes of the stator
assembly 7. Remove the guide bolts as you
install three bolts 20. Tighten bolts 20 to
12–15 N·m (9–11 lb ft).
i. Assembly of Output Shaft Assembly
(Foldout 10,D)
1. If removed, install bushing 4 inside the end of
output shaft 5 using installer J 37036, drive
handle J 8092, and a press.
2. If removed, install cone and roller bearing
assembly 6. Use special tools J 43202 with
J 37034 and press the bearing onto output
shaft 5 (Figure 5–23).
3. Support output shaft assembly 3. Place retarder
housing 31 over output shaft assembly 3.
Copyright © 2005 General Motors Corp.
j. Completion of Retarder Housing Assembly
(Foldout 10,D)
1. If removed, install cone and roller bearing
assembly 42 using installer J 37034. Press
cone and roller bearing assembly 42 into
retarder housing 31 while rotating retarder
housing 31.
NOTE:
When installing the Belleville washer, make sure
that the concave side of the washer at the inside
diameter contacts the inner race of the bearing and
that the anti-rotation tang engages the drilled hole
in the P3 carrier. Tilt the Belleville washer, tang
toward the bearing, to engage the tang into the hole.
2. Install Belleville washer 43 (Foldout 10,D).
CAUTION:
Over-tightening bearing retainer locknut 44 will
damage roller bearings 6 and 42 and bearing
cups 13 and 41. If the torque wrench and breaker
bar positions in Figure 5–24 are reversed, the
bearing retainer locknut will be overtorqued. Be
sure wrenches are positioned ONLY as shown in
Figure 5–24.
3. If using current locknut 44, lubricate the output
shaft threads and install locknut 44 so that the
Vespel® buttons are in contact with Belleville
washer 43 (Foldout 10,D). Replace current
bearing retainer locknut if it does not exhibit
5 N·m (44 lb inch) of running torque.
4. Using special tools J 37035 and J 43278, with
the torque wrench and breaker bar positioned
as shown in Figure 5–24, rotate the torque
wrench clockwise to tighten bearing retainer
locknut 44 to 185–200 N·m (137–147 lb ft).
Locknut torque values are for bench assembly
only. If the output module is mounted on the
transmission, tighten the bearing retainer
locknut to 74–88 N·m (55–64 lb ft).
5. Support retarder housing 31 so that the turning
torque of the output shaft can be measured
after installation of bearing retainer locknut 44
5–27
 4000 PRODUCT FAMILY SERVICE MANUAL
(Figure 5–24). Use tool J 43278 to measure
turning torque. Maximum turning torque is
3 N·m (27 lb in.) (Figure 5–21).
NOTE:
Delay installing output oil seal assembly 45 until
final assembly.
6. Install plug 39 and retaining ring 40.
7. If removed, install spring pin 27 into retarder
valve 26 and insert into valve bore. Install
spring 25, O-ring 24, and plug 23. Use J 42048
to compress plug 23 and install retaining
ring 22.
8. Install output speed sensor assembly 46, with
new O-ring 47, and output speed sensor bolt 49.
Tighten the bolt to 24–29 N·m (18–21 lb ft).
9. Carefully install temperature sensor assembly 35
into retarder housing 31. Install temperature
sensor retainer 37 and retainer bolt 38. Tighten
the bolt to 24–29 N·m (18–21 lb ft).
10. If removed, install brass washer 30 onto ta-
chograph plug 29. Install plug 29 into retarder
housing 31. Tighten plug 29 to 60–67 N·m
(45–49 lb ft).
5–16. REAR COVER MODULE
J 43278
Resistance (Ohms) Temperature (°C) Temperature (°F)
V05592
Figure 5–21. Output Shaft Turning Torque
Measurement—Retarder Equipped
5–28 Copyright © 2005 General Motors Corp.
k. Assembly of the Retarder Valve Body
(Foldout 10,D)
1. Install new O-ring 63 and O-ring seal 62 onto
retarder solenoid 61.
2. Insert solenoid and connector assembly 60 into
retarder valve body 64.
3. Install relay valve 75, valve spring 74, O-ring 73,
and plug 72 into retarder control body 64.
4. Install regulator valve 66, valve spring 67,
O-ring 69, and plug 70 into retarder control
body 64.
5. Install exhaust backfill valve 59, spring 58,
O-ring 57, and plug 56 into retarder control
body 64.
6. Install guide pin 65 into the retarder control
body 64.
7. Install retarder control valve cover gasket 76
and retarder control valve cover 77 on
frontside and separator plate 52 on backside of
retarder control valve body 64.
8. Install O-ring 80 and pressure tap plug 81.
Tighten the plug to 10–13 N·m (7–10 lb ft).
9. Install retarder control body assembly 54, nine
bolts 82, and three bolts 78 that retain it to re-
tarder housing 31. Tighten bolts to 60–67 N·m
(45–49 lb ft).
10. Skip to Paragraph 5–18.
(Models Equipped With Rear Cover,
Except 4700 and 4800 Models)
a. Disassembly (Foldout 10,A)
1. Remove retaining bolt 35 and output speed
sensor assembly 32. Measure output speed
sensor resistance (speed sensor resistance
varies by temperature).
250 –40 –40
340 20 68
450 110 230
 MODULE REBUILD
2. If used, remove the tachograph sensor. If
present, remove plug 29 and washer or
O-ring 28.
3. If not previously removed, remove output
seal assembly 40 using seal removal tool
J 24171-A.
2. On a close ratio transmission, remove output
shaft assembly 6. Inspect the splines on output
shaft assembly 6. Maximum spline wear
allowed is 0.38 mm (0.015 inch).
3. If replacement is necessary, remove cone and
roller bearing assembly 19.

NOTE:
4. Measure pinion end play. Pinion end play
Output seal 40 must be removed before retainer
should not exceed 0.94 mm (0.037 inch).
locknut 39 can be removed.
Measure the three remaining pinion gears.

4. Remove bearing retainer locknut 39 using

5. Remove retaining ring 9. Remove indexing
special tool J 37035.
ring 10. Remove four planetary spindles 14.
5. Remove Belleville washer 38.

6. Support rear cover assembly 27 so that P3 6. Slide pinion gear 16, thrust washers 15 and 18,
planetary carrier assembly 5 can be removed. and two bearing assemblies 17 from the side of
Place special tool J 37035 over output shaft P3 planetary carrier 11. Repeat the procedure
splines and against the threaded shoulder of the with three remaining pinion gears.
P3 planetary carrier. Press on special tool
J 37035 with a hydraulic press or drive on 7. Measure the thickness and any step wear of
J 37035 with a mallet until the P3 planetary eight washers 15 and 18. Minimum allowable
carrier assembly is separated from the rear thickness of the thrust washers is 1.40 mm
cover assembly. (0.055 inch). Maximum step wear allowed is
7. If replacement is required, remove cone and 0.12 mm (0.005 inch).
roller bearing 37 from rear cover assembly 27.
If necessary to replace, remove bearing cup 36
using bearing tool J 3940.
NOTE:
b. Disassembly of P3 Planetary Carrier
• For 4500 models (wide ratio) transmissions,
Assembly (Foldout 10,A)
proceed with Step (8).
• For all other models, skip Step (8) and proceed
WARNING!
with Step (9).
Place the P3 planetary assembly on its side to
avoid possible hand injury during disassembly.

1. Remove external retaining ring 13 and thrust
washer 12 from P3 planetary carrier
assembly 5.
NOTE:
• For 4500 (wide ratio) model transmissions,
skip to Step (3).
• For all other models, proceed with Step (2).
8. On 4500 model transmissions, remove output
shaft assembly 6. Inspect the splines on output
shaft assembly 6. Maximum spline wear
allowed is 0.38 mm (0.015 inch).
9. Inspect bushing 7 inside the end of output
shaft 8 for wear or damage. Measure the ID of
the output shaft bushing. Maximum allowable
ID is 36.14 mm (1.423 inch).

Copyright © 2005 General Motors Corp. 5–29

 4000 PRODUCT FAMILY SERVICE MANUAL
c. Completion of Rear Cover Disassembly
(Foldout 10,A)
WARNING!
Piston springs are highly compressed. Be
extremely careful during removal and
installation. Personal injury can occur if the
spring force is not controlled.
1. Remove C5 clutch piston 23 from rear cover
assembly 27 by compressing spring and
retainer assembly 22 using J 37030-3 tool
base, washer, bearing, handle, and piston
spring compressor J 37030-2. Remove
retaining ring 21 and slowly release the spring
force.
2. Remove piston sealring 24 from C5 clutch
piston 23.
3. Remove internal sealring 25 from C5 clutch
piston 23.
4. If replacement is necessary, remove bearing
cup 26 using bearing tool J 3940.
5. If replacement is necessary, remove dowel
pins 31.
d. Beginning Rear Cover Assembly
(Foldout 10,A)
1. If removed, install bearing cup 26 using
bearing tool J 37033, and bearing cup 36 using
bearing tool J 37033 and drive sleeve J 37034.
2. If removed, install dowel pins 31.
3. Install internal sealring 25 onto C5 clutch
piston 23. Install piston sealring 24 onto C5
clutch piston 23.
4. Align the tang notch on the back of the C5
clutch piston with the tang in the rear cover
before installing C5 clutch piston 23 into the
rear cover. Install C5 clutch piston 23 into rear
cover assembly 27.
5. Install spring and retainer assembly 22,
aligning the tab in the spring and retainer
5–30 Copyright © 2005 General Motors Corp.
assembly with the notch in rear cover
assembly 27.
WARNING!
Piston springs are highly compressed. Be
extremely careful during installation. Personal
injury can occur if the spring force is not
controlled.
6. Compress spring and retainer assembly 22
using J 37030-3 tool base, washer, bearing,
handle, and piston spring compressor
J 37030-2. Install external retaining ring 21
and slowly release the spring force.
e. Assembly of P3 Planetary Carrier Assembly
(Foldout 10,A)
1. If removed, install cone and roller bearing
assembly 19. Use driver sleeve J 37034 and
press the bearing against the shoulder on the
P3 carrier.
2. If removed, press bushing 7 inside the end of
output shaft 8 using installer J 37036, drive
handle J 8092, and a press.
3. Install output shaft assembly 6 into P3
planetary carrier 11.
4. Install thrust washer 12 and external retaining
ring 13.
5. Install two roller bearing assemblies 17 into
the center of pinion gear 16. Install thrust
washers 15 and 18 in P3 planetary carrier 11.
Align the thrust washer tangs with the slots in
the carrier and retain them with oil-soluble
grease. Slide pinion gear 16 and bearings into
the side of the P3 planetary carrier between the
thrust washers. Repeat the procedure with the
three remaining pinion gears.
CAUTION:
If the wear on the indexing ring is minor, flip it
over to get a fresh reaction point for the spindle.
Replace the indexing ring if both corners of the
indexing ring are worn. Failure to take corrective
action may allow the spindle to rotate which may
reduce or shut off lubrication to the pinion
bearings and thrust washers.
 MODULE REBUILD
NOTE:
Replacement indexing rings should look like the
example in Figure 5–12. The ring is stamped with
HD5. Replacement spindles should look like the
example in Figure 5–12. The spindle has a 2
stamped on the rear end.
6. Install four pinion spindles 14 so the lower step
is positioned for proper installation of indexing
ring 10.
7. Install indexing ring 10. Install internal
retaining ring 9.
8. If components were replaced, measure pinion
end play. Pinion end play must not exceed
0.94 mm (0.037 inch). Measure all four pinion
gears.
f. Completion of Rear Cover Assembly
(Foldout 10,A)
1. Place P3 carrier assembly 5 on the work table
(with the output shaft up) and place rear cover
assembly 27 over the output shaft.
2. If removed, install cone and roller bearing
assembly 37 into rear cover assembly 27 using
drive sleeve J 37034.
NOTE:
When installing the Belleville washer, make sure
that the concave side of the washer at the inside
diameter contacts the inner race of the bearing and
that the anti-rotation tang engages the drilled hole
in the P3 carrier. Tilt the Belleville washer, tang
toward the bearing, to engage the tang into the hole.
3. Install Belleville washer 38.
CAUTION:
Over-tightening bearing retainer locknut 39 will
damage cone and roller bearing assemblies 19
and 37 and cups 26 and 36.
4. Lubricate the output shaft threads and install
locknut 39 so that the Vespel® buttons are in
Copyright © 2005 General Motors Corp.
contact with Belleville washer 38. Replace
current bearing retainer locknut if it does not
exhibit 5 N·m (44 lb in.) of running torque.
5. Using special tools J 37035 and J 43278, with
the torque wrench and breaker bar positioned as
shown in Figure 5–22, rotate the torque wrench
clockwise to tighten current bearing retainer
locknut 39 to 182–200 N·m (137–147 lb ft).
Locknut torque values are for bench assembly
only. If the output module is mounted on the
transmission, tighten the bearing retainer
locknut to 74–88 N·m (55–64 lb ft).
6. Support rear cover assembly 4 so that turning
torque of P3 carrier assembly 5 can be
measured after installation of bearing retainer
locknut 39 (Figure 5–22). Use tool J 37035 to
measure turning torque. Maximum turning
torque is 3 N·m (27 lb in.).
7. Install output speed sensor assembly 32, with
new O-ring 33, and output speed sensor bolt 35.
Tighten bolt to 60–67 N·m (45–49 lb ft).
8. If a tachograph is used, install tachograph
sensor and tighten to manufacturer’s
specification. If a tachograph is used and the
sensor is not installed, install brass washer 28
onto tachograph plug 29. Install plug 29
into the rear cover. Tighten plug to 60–67 N·m
(45–49 lb ft).
J 37035-1
V00223.00.03
Figure 5–22. P3 Carrier Turning Torque
Measurement—Rear Cover Equipped
5–31
 4000 PRODUCT FAMILY SERVICE MANUAL
5–17. REAR COVER AND OUTPUT
SHAFT MODULE (4700 and 4800
Models Equipped With Rear Cover)
a. Disassembly (Foldouts 10,B and 10,C)
1. Remove retaining bolt 23 and output speed
sensor assembly 22 (Foldout 10,B). The output
speed sensor must have a resistance of 270–
330 Ohms.
2. If used, remove the tachograph sensor. If
present, remove plug 19 and washer 20.
3. If not previously removed, remove output
seal 29 using seal removal tool J 24171-A.
NOTE:
Output seal 29 must be removed before retainer
locknut 28 can be removed.
4. Remove bearing retainer locknut 28 using
special tool J 37035 and J 43278.
5. Remove Belleville washer 27.
6. Support rear cover assembly 17 so that output
shaft assembly 6 can be removed. Press on
output shaft assembly 6 until it is separated
from the rear cover assembly 17 (Figure 5–23).
V05598
Figure 5–23. Removal of Output Shaft Assembly
5–32 Copyright © 2005 General Motors Corp.
b. Disassembly of Output Shaft Assembly
(Foldout 10,B)
1. Inspect splines on the output shaft assembly.
Maximum spline wear allowed is 0.38 mm
(0.015 inch).
2. If replacement is required, remove bushing 7
from output shaft 8. If replacement is needed,
remove bearing 9. Maximum bushing 10
allowed is 36.14 mm (1.423 in.).
c. Completion of Rear Cover Disassembly
(Foldout 10,C)
WARNING!
Piston springs are highly compressed. Be
extremely careful during removal and
installation. Personal injury can occur if the
spring force is not controlled.
1. Remove C6 clutch piston 13 from rear
cover 18 by compressing C5 piston spring and
retainer assembly 12 using J 37030-3 tool
base, washer, bearing, handle, and piston
spring compressor J 37030-2. Remove
retaining ring 11 and slowly release the spring
force.
2. Remove external sealring 14 from C6 clutch
piston 13.
3. Remove internal sealring 15 from C6 clutch
piston 13.
4. If replacement is necessary, remove bearing
cup 16 using bearing tool J 3940.
d. Beginning Rear Cover Assembly
(Foldout 10,B)
1. If removed, install bearing cup 16 using
bearing tool J 37033, and bearing cup 21 using
bearing tool J 37033 and drive sleeve J 37034.
2. Install internal sealring 15 onto C6 clutch
piston 13. Install external sealring 14 onto C6
clutch piston 13.
3. Align the tang notch on the back of the C6
clutch piston with the tang in the rear cover
before installing C6 clutch piston 13 into rear
cover 18. Install C6 clutch piston 13 into rear
cover 18.
 MODULE REBUILD
4. Install C5 piston spring and retainer assembly
12, aligning the tab in the spring and retainer
assembly with the notch in rear cover 18.
WARNING!
Piston springs are highly compressed. Be
extremely careful during installation. Personal
injury can occur if the spring force is not
controlled.
5. Compress C5 piston spring and retainer
assembly 12 using J 35923-4 tool base, washer,
bearing, handle, and piston spring compressor
J 43025. Install retaining ring 11 and slowly
release the spring force. Remove the special
tools.
e. Assembly of Output Shaft Assembly
(Foldout 10,B)
1. If removed, install bushing 7 inside the end of
output shaft 8 using installer J 37036, drive
handle J 8092, and a press.
2. If removed, install cone and roller bearing
assembly 9. Use special tools J 43202 with
J 37034 and press the bearing onto output
shaft 8 (Figure 5–24).
f. Completion of Rear Cover Assembly
(Foldout 10,B)
1. Support output shaft assembly 6 and place rear
cover 18 over the output shaft assembly 6.
2. If removed, install cone and roller bearing
assembly 27 into rear cover 18 using drive
sleeve J 37034.
NOTE:
When installing the Belleville washer, be sure that
the concave side of the washer at the inside diameter
contacts the inner race of the bearing and that the
anti-rotation tang engages the drilled hole in the
output shaft. Tilt the Belleville washer, tang toward
the bearing, to engage the tang into the hole.
Copyright © 2005 General Motors Corp.
J 37034
J 43202
V05586
Figure 5–24. Installation of Cone and Roller Bearing
Onto Output Shaft
3. Install Belleville washer 28.
4. Lubricate the output shaft threads and install
locknut 28 so that the Vespel® buttons are in
contact with Belleville washer 27 (Foldout
10,J). Replace current bearing retainer locknut
if it does not exhibit 5 N·m (44 lb in.) of run-
ning torque.
CAUTION:
Over-tightening bearing retainer locknut 29 will
damage roller bearings 9 and 27 and bearing
cups 16 and 21. If the torque wrench and breaker
bar positions in Figure 5–25 are reversed, the
bearing retainer nut will be overtorqued. Be sure
wrenches are positioned ONLY as shown in
Figure 5–25.
5. Using special tools J 37035 and J 43278, with
the torque wrench and breaker bar positioned as
shown in Figure 5–25, rotate the torque wrench
clockwise to tighten current bearing retainer
locknut 28 to 185–200 N·m (137–147 lb ft).
Locknut torque values are for bench assembly
only. If the output module is mounted on the
transmission, tighten bearing retainer
locknut 28 to 74–88 N·m (55–64 lb ft).
5–33
 4000 PRODUCT FAMILY SERVICE MANUAL
6. Support rear cover assembly 17 so that turning
torque of output shaft assembly 6 can be
measured after installation of bearing retainer
locknut 28. Use tool J 43278 to measure
turning torque. Maximum turning torque is
3 N·m (27 lb inch) (Figure 5–25).
7. If removed, install tachograph sensor or
plug 19 and washer 20.
NOTE:
Delay installing output oil seal assembly 29.
8. Install output speed sensor assembly 22, with
new O-ring 25, and output speed sensor bolt 23.
Tighten bolt to 24–29 N·m (18–21 lb ft).
J 43278
J 37035
V05589.00.01
Figure 5–25. Bearing Retainer Locknut
Torque—Rear Cover Equipped
5–34 Copyright © 2005 General Motors Corp.
5–18. CONTROL VALVE MODULE
(Foldout 11)
CAUTION:
• To help prevent transmission damage protect
control module parts during removal, clean-
ing, inspection, and installation. Keep them in
clean containers until they are installed.
• Control valve module assembly springs and
other parts can be mistakenly interchanged.
Tag each part with its item number as it is re-
moved and use Valve Tray Set J 33163 to sim-
plify correct valve body reassembly.
• Control valve module parts fit together
closely and have specific operating clearances.
They can bind if damaged. These parts de-
pend upon smooth sealing surfaces and may
leak if the sealing surface is scratched. Valves,
when dry, must move freely by their own
weight in their bores. Carefully handle all
such parts.
NOTE:
Refer to the latest revision of SIL 18-TR-98 for de-
tailed service information regarding suspected con-
tamination from water or Glycol. The presence of
water and/or ethylene glycol coolant in the trans-
mission fluid is detrimental to the internal compo-
nents. Contaminated fluid has a deteriorating effect
on transmission components.
a. Removal of Filters
1. If not previously removed, remove two filter
covers 146, two gaskets 147, two O-rings 148,
two O-rings 149, and two filters 150.
2. Remove three bolts 3 and face seal 6. Remove
suction filter 5 and gasket 7. Discard suction
filter 5 and gasket 7.
 MODULE REBUILD
b. Removal of Electrical Components c. Disassembly of the Solenoid Valve Body
and Sensors
1. Remove twelve bolts 57. Remove two bolts 48.
NOTE:
2. Remove bracket 56 with diagnostic pressure
Refer to Troubleshooting Manual TS3989EN switch 55. Inspect switch for glycol
(Allison 4th Generation Controls) for inspection and contamination (refer to latest revision of SIL
repair procedures. 18–TR-98). Maximum resistance of pressure
switch 55 must not exceed 2 Ohms. Minimum
1. If present remove two bolts 133 and oil level resistance of pressure switch (open) must be at
sensor assembly (OLS) 134. Clean the OLS least 20,000 Ohms. The switch should close
with a soft cloth. Refer to TS3989EN for between 159–255 kPa (23–37 psi).
sensor operation.
3. Remove bracket 47.
2. Disconnect all connectors. Release connectors
in the wire harness by pushing in the center tab 4. Remove three face seals 49.
with a small screw driver as shown in Figure
5–26. 5. Lift solenoid valve body 60 and separator
plate 93 from main valve body 115 being care-
3. Remove three bolts 46 from standoff
ful not to lose the four springs 50 and 53 and
assembly 13.
accumulators 51 and 52. Set the solenoid valve
4. Remove standoff assembly. body 60 on a flat work surface.

V09556.00.00

Figure 5–26. Disconnecting Connectors

Copyright © 2005 General Motors Corp. 5–35

 4000 PRODUCT FAMILY SERVICE MANUAL
6. Remove PCS2 72 with O-rings 73 and 74. Re-
move valve 75 and spring 76.
7. Remove PCS1 67 with O-rings 68 and 69. Re-
move valve 70 and spring 71.
8. Remove TCC solenoid 62, O-rings 63 and 64,
valve 65, and spring 66.
9. Insert tool J 47942 tool into slot to push in di-
agnostic valve 78 and release clip 77, remove
spring 79 and valve 78.
WARNING!
Valve springs are highly compressed. Be ex-
tremely careful during disassembly. Personal in-
jury can occur if the spring force is not
controlled.
10. Remove PCS3 80, two O-rings 81 and 82,
valve 83, and spring 84.
11. Remove PCS4 85, two O-rings 86 and 87,
valve 88, and spring 89.
12. Remove Main Mod solenoid 90 and two
O-rings 91 and 92.
13. Measure resistance of each solenoid by using
chart in Figure 5–20.
d. Disassembly of C6 Control Valve Body
NOTE:
C6 control valve body is only in 4700 and 4800 mod-
el transmissions.
1. Remove four bolts 154 remove C6 valve body
bracket 153, spring 152, accumulator 151, and
valve body 156.
2. Remove pin 158 for C6 Enable solenoid 160.
Remove nut 164 and plate 163, remove C6 en-
able solenoid 160, two O-rings 161 and 162,
valve 159, and spring 157.
3. Remove screw 171 and bracket 170. Remove
C6 Clutch solenoid 167, O-rings 168 and 169,
valve 166, and spring 165.
5–36 Copyright © 2005 General Motors Corp.
4. Inspect both valves and bores for nicks, wear,
and damage.
e. Disassembly of Main Valve Body
1. Remove two bolts 94 and main valve body as-
sembly 95.
2. Lift Main Control Valve body 115 and set on
flat work space.
3. Remove solenoid retention pin 111 from bot-
tom of control valve body.
4. Remove solenoid assembly 112 with O-rings
113 and 114. Measure resistance of the sole-
noid by using the chart in Figure 5–20.
5. Remove valve retention pin 96.
6. Remove stop 99, spring 98, and convertor flow
valve 97.
7. Remove valve retention pin 100.
8. Remove stop 103, spring 102, and lube regula-
tor valve 101.
WARNING!
Valve springs are highly compressed. Be ex-
tremely careful during disassembly. Personal in-
jury can occur if the spring force is not
controlled.
9. Install spring compressor J 35924 (Figure 5–27).
Compress spring 106, remove valve retention
pin 104, and carefully remove compressor
J 35924 after turning handle counterclockwise
to release spring force.
10. Remove stop 107, spring 106, and main regula-
tor valve 105.
11. Remove valve retention pin 111.
12. Remove clip 110, spring 109, and control main
valve 108.
13. Remove valve retention pin 120.
14. Remove stop 119, spring 118, and C2 latch
valve 117.
 MODULE REBUILD
h. Assembly of the Main Valve Body
Figure 5–27. Use of Tool to Release Main-Pressure
Valve Spring Force
15. Remove valve retention pin 124.
16. Remove stop 123, spring 122, and exhaust
back valve 121.
17. Remove valve retention pin 128.
18. Remove stop 127, spring 126, and C1 latch
valve 125.
19. Remove valve retention pin 132.
20. Remove stop 131, spring 130, and converter
regulator valve 129. Inspect stop 131 for bat-
tering. Replace the stop if it is battered.
21. Remove gasket 172, separator plate 136, and
channel plate gasket 137.
f. Disassembly of the Channel Plate
1. If damaged, remove two pins 139.
2. Remove drain plug 141 and O-ring 142.
3. Remove nine pressure tap plugs 145 with
O-ring 144.
4. Remove O-rings from all tap plugs 145.
g. Assembly of the Channel Plate
1. Install new O-rings on all tap plugs 45.
2. Install nine pressure tap plugs 145. Tighten plugs to
10–13 N·m (7–10 lb ft).
Copyright © 2005 General Motors Corp.
3. Install drain plug 141. Tighten plug to
25–32 N·m (18–24 lb ft).
4. If removed, install two pins 139.
5. Install gasket 137 and separator plate 136.
1. Install converter regulator valve 129,
spring 130, and stop 131.
2. Install valve retention pin 132.
3. Install C1 latching valve 125, spring 126, and
stop 127.
4. Install valve retention pin 128.
5. Install exhaust-back valve 121, spring 122, and
stop 123.
6. Install valve retention pin 124.
7. Install C2 latch valve 117, spring 118, and
stop 119.
8. Install valve retention pin 120.
9. Install control main valve 108, spring 109, and
clip 110.
10. Install O-rings 113 and 114 on solenoid 112
and install solenoid.
11. Install solenoid retention pin 116 through bot-
tom of main valve body assembly.
12. Install main regulator valve 105, spring 106,
and stop 107.
13. Install spring compressor J 35924 (Figure 5–27).
Compress spring 106, install valve retention
pin 104, and remove J 35924 after turning han-
dle counterclockwise until the tool clears
pin 104.
14. Install lube regulator valve 101, spring 102,
and stop 103.
15. Install valve retention pin 100.
16. Install converter flow valve 97, spring 98, and
stop 99.
17. Install valve retention pin 96.
18. Install main valve body assembly 95 onto sep-
erator plate 136, channel plate gasket 137, and
channel plate assembly 138.
19. Install solenoid separator plate 93 onto main
valve body assembly 115.
5–37
 4000 PRODUCT FAMILY SERVICE MANUAL
i. Assembly of C6 Control Valve Body
NOTE:
Apply transmission fluid to the control module bolts
as they are installed. This will provide lubrication
during the installation and tightening and prevent
thread seizure.
NOTE:
C6 control valve body is only available in 4700 and
4800 model transmissions.
1. Install spring 157, valve 159, two O-rings 161
and 162, C6 enable solenoid 160, solenoid pro-
tective plate 163, push-on nut 164, and sole-
noid retention pin 158 into C6 valve body 156.
2. Install spring 165, valve 166, two O-rings 168
and 169, solenoid 167, bracket 170 and secure
to C6 valve body 156 with screw 171.
3. Install accumulator plug 151 and spring 152 into
C6 valve body 156.
4. Position C6 control valve body assembly 155
onto separator plate 136, channel plate
assembly 137, and channel plate assembly 138.
5. Install bracket 153 and four bolts 154. Tighten
the bolts to 10–13 N·m (7–10 lb ft).
j. Assembly of the Solenoid Valve Body
1. Install Main Mod solenoid 90, two O-rings 91
and 92.
2. Install spring 89, valve 88, O-rings 86 and 87
and PCS4 85.
3. Install spring 84, valve 83, two O-rings 81 and
and 82, and PCS3 80.
4. Install diagnostic valve 78 and spring 79. Insert
tool J 47942 tool into slot to push in valve and
install clip 77.
5. Install spring 66, valve 65, and TCC
solenoid 62 with two O-rings 63 and 64.
6. Install spring 71, valve 70, and PCS1 67 with
two O-rings 68 and 69.
5–38 Copyright © 2005 General Motors Corp.
7. Install spring 76, valve 75, and PCS2 72 with
O-rings 73 and 74.
8. Install three face seals 49.
9. Install four accumulators 51 and 52 and
springs 50 and 53.
10. Install bracket 47.
11. Install bracket 56 with diagnostic pressure
switch 55. Inspect switch for glycol contamina-
tion, refer to the latest revision of SIL 18-TR-98.
Maximum resistance of pressure switch 55
must not exceed 2 Ohms. Minimum resistance
of pressure switch (open) must be at least
20,000 Ohms. The switch should close be-
tween 159–255 kPa (23–37 psi).
12. Position solenoid body assembly 59 onto sole-
noid separator plate 93, and control valve
body 115.
13. Install twelve bolts 57. Install two bolts 48.
Tighten bolts to 10–13 N·m (7–10 lb ft).
k. Installation of Electrical Components
and Sensors
1. Position wire harness assembly 8 onto control
valve module.
2. Install wire harness assembly 8. Secure
standoff assembly 13 with three bolts 46.
Connect all connectors. Tighten bolts 46 to 5–
8 N·m (4–6 lb in.).
3. Postion oil level sensor assembly 134, if
present onto control valve module.
4. If present install two bolts 133, two Ferrule
Vitton® 135, and oil level sensor assembly 134.
Tighten bolts to 10–13 N·m (7–10 lb ft).
l. Install Filters
1. Install suction filter 5, gasket 7, and face
seal 6. Install three bolts 3. Tighten bolts to
10–13 N·m (7–10 lb ft).
2. Install case gasket 172.
3. Install two filters 150, two O-rings 149
and 148, two gaskets 147, and two filter
covers 146.
 SECTION 6—TRANSMISSION ASSEMBLY
6–1. SCOPE 1. Install C3/C4 clutch assembly 1 through the
input end of main housing 2, aligning the bolt
a. Section. This section covers the assembly of 4000 holes in the clutch assembly with the holes in
Product Family transmissions. The assembly sequence the main housing.
is continuous and includes all models.
2. Install two bolts 3, 180 degrees from each
b. Procedures. When a procedure does not apply to other, to hold clutch assembly 1 in place.
your specific model, go to the next applicable
procedure. 3. Rotate the transmission housing using repair stand
controls and install remaining twelve bolts 3.
c. Illustrations. Illustrations will not always show Tighten all bolts to 51–61 N·m (38–45 lb ft).
your model, but when an operation is identical for all
models, the correct procedure is shown. b. Installation of Rotating Clutch Module
(Figure 6–2). Use repair stand controls to put main
d. General Information. Refer to Section 3 for
housing in the vertical position. Use a hoist and an
general information as follows:
M16 eye bolt to insert rotating clutch module 1 in the
front of the main housing.
Paragraph Description
3–2 Tools, Equipment
3–3 Replacement Parts
3–4 Careful Handling
3–6 Assembly Procedures
1 3
e. Foldouts. Refer to Foldouts 4 through 12 for
disassembled views and torque specifications.

NOTE:
All parts must be cleaned and lubricated before
assembly. 2 E01274.01

Figure 6–1. Main Housing and C3/C4 Clutch Installation

6–2. ASSEMBLY OF TRANSMISSION

a. Assembly of Main Housing Module

(Figure 6–1)

1
CAUTION:
Before beginning assembly, attach bracket
J 41445 and holding fixture J 35926 to the main
housing. Use a hoist to mount the fixture and
housing on repair stand J 29109.

CAUTION:
E01273.01
Be sure that main housing is horizontal when
installing the C3/C4 clutch module. Figure 6–2. Rotating Clutch Module Installation

Copyright © 2005 General Motors Corp. 6–1

 4000 PRODUCT FAMILIES SERVICE MANUAL—ALLISON 4 th GENERATION

c. Installation of Front Support/Charging f. Installation of C5 Clutch Pack (Figure 6–5)

Pump Module (Figure 6–3)
1. Lower front support and charging pump
NOTE:
module 3 over the top of the turbine shaft.
The correct combination of C5 friction clutch plates
2. Align bolt holes in front support 3 with the and P3 ring gear must be used. Refer to
threaded holes in the main housing. SIL 12-WT-03 to determine the correct P3 ring gear
and C5 friction clutch plates combination.
3. Install seven bolts 1 and seven bolts 2. Tighten
bolts to 51–61 N·m (38–45 lb ft).
Install the C5 clutch pack in the main housing—nine
4. Rotate the repair stand so the rear of the main steel reaction plates 2 and eight friction plates 3,
housing is facing upward. stacked alternately, starting with a steel reaction plate.
Stack all plates so plate cone faces the same direction.
d. Installation of P1 Planetary Module
Steel plates mesh with the main housing and reaction
(Figure 6–4)
plates mesh with the P3 ring gear.
1. Install P1 planetary module 1—consisting of
the P1 carrier and P2 ring gear. g. Installation of Main Shaft Module (Except
4700 and 4800 Models) (Figure 6–6). Install main
2. Mesh the P1 pinion gears with the P1 ring gear shaft 1 as assembled in Section 5, without selective
inside the C3/C4 clutch assembly. shim 2 and thrust bearing 3
e. Installation of P2 Planetary Module
(Figure 6–5)
1. Install P2 planetary module 1—consisting of
the P2 carrier and the P3 ring gear.

2. Mesh the P2 pinions with the P2 ring gear

1
during installation.

2
3

E01271.01

Figure 6–4. P1 Planetary Module Installation

1
1 C5

2
3

E02516.01
V01272

Figure 6–3. Front Support/Charging Figure 6–5. P2 Planetary Module and

Pump Module Installation C5 Clutch Installation

6–2 Copyright © 2005 General Motors Corp.

 TRANSMISSION ASSEMBLY
2. Measure dimension A, from top of the straight
edge to the selective shim thrust surface on the
main shaft bearing spacer.
3. Measure dimension B, thickness of straight
WIDE RATIO MODELS edge. Subtract dimension B from dimension
1 A—the remainder is dimension C.
4. Place the retarder or rear cover module output
end down (facing the bench top). Install an
uncompressed gasket on the retarder or rear
cover mounting surface and place a straight
1 2 edge across the P3 planetary carrier.
CLOSE RATIO MODELS 3
V01737.00.06 5. Measure dimension D, from top of the straight
edge to the gasket.
Figure 6–6. Main Shaft Module Installation
6. Measure dimension E from the top of the
straightedge to the thrust bearing contact
h. Installation of Main Shaft Module (4700 and surface on the P3 planetary carrier. Subtract
4800 Models). Install main shaft module as as- dimension E from dimension D—the
sembled in Section 5. remainder is dimension F.
7. Dimension G is the remainder of “C minus F”
i. Main Shaft Selective Shim Measurement
and determines the thickness of the selective
(Close Ratio Models) (Figure 6–7)
shim.
1. Place a straight edge across the retarder or rear 8. Install the proper thickness selective shim and
cover mounting surface of the main housing. the thrust bearing.

BEARING AND UNCOMPRESSED

STRAIGHT EDGE SHIM REMOVED GASKET IN PLACE STRAIGHT EDGE DIM. E

DIM. A DIM. B
DIM. F
DIM. C
DIM. D

RETARDER NON-
MAIN SHAFT MODULE MODEL RETARDER
MODEL
PROCEDURE: FORMULA (C)–(F)=G

DIM. G USE P/N SHIM ID DIM. G USE P/N SHIM ID

5.7135–6.033 mm 6.844–7.113 mm
29501117 1 NOTCH 0.270–0.280 in. 29501121 5 NOTCHES
0.231–0.237 in.
6.034–6.303 mm 7.114–7.383 mm
29501118 2 NOTCHES 29501122 6 NOTCHES
0.238–0.247 in. 0.281–0.290 in.
6.304–6.573 mm 7.384–7.484 mm
29501119 3 NOTCHES 29512774 0 NOTCHES
0.248–0.258 in. 0.291–0.295 in.
6.574–6.843 mm
29501120 4 NOTCHES
0.259–0.269 in. V03210.01.00

Figure 6–7. Main Shaft Selective Shim Measurement for 4000 Product Family—Close Ratio

Copyright © 2005 General Motors Corp. 6–3

 4000 PRODUCT FAMILIES SERVICE MANUAL—ALLISON 4 th GENERATION

j. Main Shaft Selective Shim Measurement
(Wide Ratio Models) (Figure 6–8)
1. Place a straight edge across the retarder or rear
cover mounting surface of the main housing.
2. Measure dimension A, from top of the straight
edge to the selective shim thrust surface on the
main shaft bearing spacer.
3. Measure dimension B, thickness of straight
edge. Subtract dimension B from dimension
A—the remainder is dimension C.
4. Place retarder or rear cover output end down
(facing the bench top). Install an
uncompressed gasket on the retarder or rear
cover mounting surface and place a straight
edge across the P3 planetary carrier.
5. Measure dimension D, from top of the straight
edge to the gasket.
6. Measure dimension E from the top of the
straightedge to the thrust bearing contact
surface on the P3 planetary carrier. Subtract
dimension E from dimension D—the
remainder is dimension F.
7. Dimension G is the remainder of “C minus F”
and determines the thickness of the selective
shim.
8. Install the proper thickness selective shim and
the thrust bearing.
CAUTION:
To help prevent premature thrust bearing
failure, make sure that the locating lip on either
the inner or outer thrust bearing race is not
preventing the race from contacting the thrust
surface of the mating part. Failure to do this
leads to premature thrust bearing failure and
incorrect shim selection to maintain proper
internal part clearance.

BEARING AND UNCOMPRESSED

STRAIGHT EDGE SHIM REMOVED GASKET IN PLACE STRAIGHT EDGE DIM. E

DIM. A DIM. B
DIM. F
DIM. C
DIM. D

RETARDER NON-
MAIN SHAFT MODULE MODEL RETARDER
MODEL
PROCEDURE: FORMULA (C)–(F)=G

DIM. G USE P/N SHIM ID DIM. G USE P/N SHIM ID

4.6177–4.843 mm 5.654–5.923 mm
0.180–0.190 in. 29503218 1 NOTCH 0.224–0.233 in. 29503222 5 NOTCHES
4.844–5.113 mm 5.924–6.193 mm
29503219 2 NOTCHES 29503223 6 NOTCHES
0.192–0.201 in. 0.234–0.244 in.
5.114–5.383 mm 6.194–6.380 mm
29503220 3 NOTCHES 29503224 7 NOTCHES
0.202–0.212 in. 0.245–0.254 in.
5.384–5.653 mm
29503221 4 NOTCHES
0.213–0.223 in.
V03211.01.00

Figure 6–8. Main Shaft Selective Shim Measurement for 4000 Product Family—Wide Ratio

6–4 Copyright © 2005 General Motors Corp.

 TRANSMISSION ASSEMBLY
k. Installation of P3 Planetary Module (4700 and
4800 Models With Retarder) (Figure 6–9)
1. Thread special tool J 43020 onto P3 Planetary
Module 2 and use chain hoist to install P3
Planetary Module 2 in Main Housing
Module 1.
2. Install P4 shaft flange 3.
NOTE:
Do not install shim locating ring or selective shim
until final transmission assembly. Measurement for
selective shim is performed during final buildup.
CAUTION:
Over-tightening bolt 3 will damage the bolt. Use
the torque formula in Figure 6–12 to find the
correct torque value to apply to bolt 3.
3. Install fourteen bolts 3 through C6 adapter
housing module 4 into main housing 1. Tighten
bolts in a star pattern using special tool J 43046
and torque wrench to produce 100–120 N·m
(74–88 lb ft) at the bolt (Figure 6–11). Use the
formula in Figure 6–12 to find the correct
torque wrench value that will apply to the
required torque bolt 3.
1

l. Installation of C6 Adapter Housing Module J 43046

(4700 and 4800 Models With Retarder) 2

(Figure 6–10) 3
4
1. Install new C6 adapter housing gasket 2.

WARNING!
Get help when lifting the C6 adapter housing
module. Assistance from a hoist or another
person may be required. The C6 adapter housing
module weighs approximately 68 kg (150 lb).
5
2. Thread two M12 bolts and attach a sling to the V05374
C6 adapter housing module 4 by positioning
Figure 6–10. Installation of C6 Adapter
the housing connections equal distance from
Housing Module
each other. Using a chain hoist, carefully lift
and install the C6 adapter housing 4 onto the
transmission.

J 43046
2

3
4

J 43020

V05375 V05590

Figure 6–11. Tightening C6 Adapter Housing

Figure 6–9. Installation of P3 Planetary Module to Main Housing Bolts

Copyright © 2005 General Motors Corp. 6–5

 4000 PRODUCT FAMILIES SERVICE MANUAL—ALLISON 4 th GENERATION

BOLT
(C6 adapter housing
to main housing)
A
TORQUE WRENCH
J 43046

Tw Ta
CLOCKWISE
ROTATION
L

C6 ADAPTER HOUSING

L TOP VIEW
Tw = Ta X
L+A
L = Effective length of torque wrench
A = Effective length of special tool
Tw = Torque applied at the wrench (adjusted torque value to be applied with wrench)
Ta = Torque applied at the bolt (ACTUAL torque value specified by service manual)
V05591

Figure 6–12. C6 Adapter Housing to Main Housing Bolt Torque Formula

m. P3 Planetary Selective Shim Measurement surface. Place the P4 ring gear hub over the
(4700 and 4800 Models With Retarder) output shaft. Place two measuring blocks
(Figure 6–13) included in special tool J 43922 on the front
1. Place a straight edge across the rear face of the face of retarder. Place the straight edge
C6 adapter housing with uncompressed included in J 43922 across the top of the
retarder housing gasket. measuring blocks included in J 43922.

2. Measure dimension A, from top of the straight
edge to the selective shim thrust surface on the
P3 carrier face.
3. Measure dimension B, thickness of straight
edge. Subtract dimension B from dimension
A—the remainder is dimension C
(measurement between rear face of adapter
housing with uncompressed gasket and P3
carrier face).
4. Remove retarder housing gasket.
6. Measure dimension D from top of the straight
edge to the face of the retarder.
7. Measure dimension E from the top of the
straight edge J 43922 to the face of the P4 ring
gear hub.
8. Subtract dimension E from dimension D—
remainder is dimension F (measurement
between front face of retarder and P4 ring gear
hub face)

5. Place the retarder module output end down 9. Dimension G is the remainder of “C minus F”
(facing the bench top) on supports, so the and determines the thickness of the selective
output shaft is not contacting the bench shim, dimension G.

6–6 Copyright © 2005 General Motors Corp.

 4000 PRODUCT FAMILIES SERVICE MANUAL—ALLISON 4 th GENERATION

n. P3 Planetary Selective Shim Measurement (measurement between rear face of adapter

(4700 and 4800 Models With Rear Cover)
(Figure 6–14)
1. Place a straight edge across the rear face of the
C6 adapter housing with uncompressed rear
cover gasket.
2. Measure dimension A, from top of the straight
edge to the selective shim thrust surface on the
P3 carrier face.
3. Measure dimension B, thickness of straight
edge. Subtract dimension B from dimension
A—the remainder is dimension C measuring blocks included in J 43922.
housing with uncompressed gasket and P3
carrier face).
4. Remove rear cover gasket.
5. Place the rear cover module output end down
(facing the bench top) on supports, so the
output shaft is not contacting the bench
surface. Place the P4 ring gear hub over the
output shaft. Place the two measuring blocks
included in special tool J 43922 on the front
face of rear cover. Place the straight edge
included in J 43922 across the top of the

STRAIGHT EDGE GASKET

DIM. B J 43922 INSTALLED
STRAIGHT EDGE MEASURING
J 43922 BLOCK (2), J 43922

DIM. A DIM. C
DIM. F DIM. E
DIM. D

No Gasket

SUPPORTS

C6 ADAPTER HOUSING MODULE RETARDER AND OUTPUT SHAFT MODULE

PROCEDURE: FORMULA C–F=G
DIM. G USE P/N SHIM ID
0.8830–1.1534 mm
29530516 0
0.0347–0.0454 in.
1.1535–1.4234 mm
29530517 1 NOTCH
0.0455–0.0560 in.
1.4235–1.6934 mm
29530518 2 NOTCHES
0.0561–0.0666 in.
1.6935–1.9634 mm
29530519 3 NOTCHES
0.0667–0.0772 in.
1.9635–2.2334 mm
29530520 4 NOTCHES
0.0773–0.0879 in.
2.2335–2.5034 mm
29530521 5 NOTCHES
0.0880–0.0985 in.
2.5035–2.7734 mm
29530522 6 NOTCHES
0.0986–0.1091 in.
2.7735–3.0434 mm
29530523 7 NOTCHES
0.1092–0.1198 in.
3.0435–3.3134 mm
29530524 8 NOTCHES
0.1199–0.1304 in.

V05380.00.03

Figure 6–13. P3 Planetary Shim Measurement (4700 and 4800 Models With Retarder)

Copyright © 2005 General Motors Corp. 6–7

 4000 PRODUCT FAMILIES SERVICE MANUAL—ALLISON 4 th GENERATION

STRAIGHT EDGE GASKET

DIM. B J 43922 INSTALLED
STRAIGHT EDGE MEASURING
J 43922 BLOCK (2), J 43922

DIM. A DIM. C
DIM. F DIM. E
DIM. D

No Gasket

SUPPORTS

C6 ADAPTER HOUSING MODULE REAR COVER AND OUTPUT SHAFT MODULE

PROCEDURE: FORMULA C–F=G
DIM. G USE P/N SHIM ID
0.8830–1.1534 mm
29530516 0
0.0347–0.0454 in.
1.1535–1.4234 mm
29530517 1 NOTCH
0.0455–0.0560 in.
1.4235–1.6934 mm
29530518 2 NOTCHES
0.0561–0.0666 in.
1.6935–1.9634 mm
29530519 3 NOTCHES
0.0667–0.0772 in.
1.9635–2.2334 mm
29530520 4 NOTCHES
0.0773–0.0879 in.
2.2335–2.5034 mm
29530521 5 NOTCHES
0.0880–0.0985 in.
2.5035–2.7734 mm
29530522 6 NOTCHES
0.0986–0.1091 in.
2.7735–3.0434 mm
29530523 7 NOTCHES
0.1092–0.1198 in.
3.0435–3.3134 mm
29530524 8 NOTCHES
0.1199–0.1304 in.

V05612.00.03

Figure 6–14. P3 Planetary Shim Measurement (4700 and 4800 Models With Rear Cover)

6. Measure dimension D from top of the straight o. Installation of Remainder of P3 Planetary

edge to the face of the rear cover.
7. Measure dimension E from the top of the
straight edge J 43922 to the face of the P4 ring
gear hub.
8. Subtract dimension E from dimension D—
remainder is dimension F (measurement
between front face of rear cover and P4 ring
gear hub face).
9. Dimension G is the remainder of “C minus F”
and determines the thickness of the selective
shim dimension G.
Module and C6 Adapter Housing Module
(4700 and 4800 Models) (Foldout 9,C)
1. Install shim locating ring 6.
2. Install the proper selective shim 12 from
previous step m or n.
3. Install retaining ring 48 into P4 ring gear 46 to
complete hub assembly 45.
4. Install ring gear and hub 45.

6–8 Copyright © 2005 General Motors Corp.

 TRANSMISSION ASSEMBLY
p. Installation of Tolerance Rings Module
(4700 and 4800 Models With Retarder)
1. Insert eleven tolerance rings 49 (Foldout 9,C)
in counterbores flush to slightly below rear
mounting surface at locations shown in
Figure 6–15.
q. Installation of Retarder Module
(Models Equipped With Retarder,
Except 4700 and 4800 Models) (Figure 6–15)
1. Install guide bolts to ease retarder module 1
installation and keep gasket 7 in place.
2. Install retarder gasket 7 over the guide bolts
and against the main housing module 8.
WARNING!
Get help when lifting the retarder module.
Assistance from a hoist or another person may be
required. The retarder module weighs
approximately 34 kg (75 lb).
3. Thread an M14 eye bolt into the retarder out-
put shaft and lift retarder module 1 onto main
housing module 8. If used, install the rear sup-
port bracket.
4. Install twelve bolts 2, three bolts 3, two bolts 4,
four bolts 5, and four bolts 6 that secure re-
tarder module 1 to main housing module 8.
Tighten bolts 2, 4, and 5 to 100–120 N·m (74–
88 lb ft). Tighten bolts 3 and 6 to 51–61 N·m
(38–45 lb ft).
5. Retighten bearing retainer locknut 59
(Foldout 10,E) using tool J 37035 to 74–88 N·m
(55–64 lb ft).
6. Install output shaft oil seal assembly 60, using
tool J 37031.

2 2
2 2
2 2

2 2
1
2 2 2

8 4 2
4 2
5
7 6 5 5 5
3
3 OR
4 6 6 6
6 5 3 3
V06844

Figure 6–15. Retarder Module Installation

Copyright © 2005 General Motors Corp. 6–9

 4000 PRODUCT FAMILIES SERVICE MANUAL—ALLISON 4 th GENERATION

r. Installation of Retarder and Output Shaft

Module (4700 and 4800 Models With
Retarder)
1. Thread an M10 eye bolt into the output shaft
assembly 3 (Foldout 10,D).
2. Install new retarder stator housing gasket 1.
NOTE:
DO NOT reuse a tang once it has been bent. Use a
new locknut retainer 43 (Foldout 10,A).
8. Install output shaft oil seal 45 (Foldout 10,A)
using special tools J 43024 and J 37034, and
rubber mallet (Figure 6–16).

3. Install guide bolts to ease retarder and output

shaft module 5 installation, and keep the gasket
in place (Figure 6–17).

4. Install twelve bolts 4, two bolts 7, and four

J 37034
bolts 8 (Figure 6–17). Tighten bolts to 100–120
N·m (74–88 lb ft).
J 43024

5. Install four bolts 9 and three bolts 6 (Figure

6–17). Tighten bolts to 51–61 N·m (38–45 lb ft).

6. Lift with hoist, and install retarder and output

shaft module onto C6 adapter housing
module 2.

7. Use special tool J 43278 and J 37035 and tighten V05594

bearing retainer locknut 39 to 74–88 N·m Figure 6–16. Installation of Output Shaft Oil Seal
(55–64 lb ft) (Foldout 10,A). (4700 and 4800 Models With Retarder)

1
4 4
4 4
2 4 4

4 4
3 4

4 4
5
7 4
7 4
8
9 8 8 8
6 6 OR
9 9 9 6 6
7 8
9
V06845

Figure 6–17. Installation of Retarder and Output Shaft Module (4700 and 4800 Models)

6–10 Copyright © 2005 General Motors Corp.

 TRANSMISSION ASSEMBLY
s. Installation of Rear Cover Module
(Except 4700 and 4800 Models) (Figure 6–18)
1. Install guide bolts to ease rear cover 2
installation and keep gasket 1 in place.
2. Install a NEW rear cover gasket 1 on main
housing 4.
3. Place rear cover module 2 on main housing 4
using a hoist and sling as a lifting fixture.
Install rear support bracket 3 (Foldout 10,B), if
used.
4. Install nineteen bolts 3 (Figure 6–18).
Tighten bolts to 100–120 N·m (74–88 lb ft).
5. Retighten the spanner nut using tool J 37035 to
74–88 N·m (55–64 lb ft).
CAUTION:
Do not reuse a tang once it has been bent. Install
a new locknut retainer 38 (Foldout 10,A).
6. Install output shaft oil seal 5 (Figure 6–18)
using tool J 37031.
4
1
3
2 5 V06867
Figure 6–18. Rear Cover Module Installation
Copyright © 2005 General Motors Corp.
t. Installation of Rear Cover Module
(4700 and 4800 Models) (Figure 6–19)
1. Install guide bolts to ease rear cover 6
installation and keep gasket 3 in place.
2. Install a NEW rear cover gasket 3 on C6
adapter housing 2.
3. Place rear cover module 6 on adapter
housing 2 using a hoist and sling as a lifting
fixture. Install rear support bracket, if used.
4. Install fourteen bolts 4 and install five bolts 5
(Figure 6–20). Tighten bolts to 100–120 N·m
(74–88 lb ft).
5. Retighten bearing retainer locknut using tool
J 37035 and J 43278. Tool J 43278 holds the
bearing retainer locknut while tool J 37035
turns the shaft counterclockwise to retighten
the bearing retainer locknut. Tighten the
locknut to 74–88 N·m (55–64 lb ft).
CAUTION:
Do not reuse a tang once it has been bent. Install
a new locknut retainer 28 (Foldout 10,D).
6. Install output shaft oil seal 29 (Foldout 10,B)
using tool J 43024 and J 37034 and rubber
mallet (Figure 6–22).
6–11
 4000 PRODUCT FAMILIES SERVICE MANUAL—ALLISON 4 th GENERATION

2 J 43278
J 37035
3 4

5
V05589.00.01

V05580

Figure 6–21. Tightening Bearing Retainer

Figure 6–19. Installation of Rear Cover and Output Locknut—Rear Cover Equipped
Shaft Module

BOLT, M12 x 1.75 x 45

(14) MARKED 4
4 4
4 4
4 4 J 37034

4 4
J 43024
4 4

4 4

BOLT, 4 5 5 4
METRIC HEAVY 5 5
(5) MARKED 5 5

V07494 V05595

Figure 6–20. Rear Cover and Output Shaft Figure 6–22. Installation of Output Shaft Oil Seal
Module Bolts (4700 and 4800 Models With Rear Cover)

6–12 Copyright © 2005 General Motors Corp.

 TRANSMISSION ASSEMBLY
u. Installation of Converter Housing Module
(Figure 6–23)
1. Install guide bolts to ease converter housing 1
installation and keep gasket 2 in place.
2. Position the transmission input end up. Install a
NEW converter housing gasket 2 on main
housing module 4.
3. Lower converter housing 1 onto main
housing 4. If the transmission is PTO
equipped, rotate the PTO drive gear to align the
gear tangs with the charging pump.
4. Install seven bolts 3 into the inside of converter
housing 1. Use mechanical fingers, or a similar
tool, when installing these bolts.
5. Remove the two guide bolts and install the
remaining bolts 3. Tighten all bolts 3 to 51–61 N·m
(38–45 lb ft).
1 rotating clutch module (Figure 6–24,
3
2
4 and use a heel bar, screwdriver, and bolts.
V06868
Figure 6–23. Converter Housing Module Installation
Copyright © 2005 General Motors Corp.
v. Installation of Torque Converter Module
(Figure 6–24)
1. The torque converter is installed over the
turbine shaft which rotates inside the stator
shaft or ground sleeve. The splines on the
ground sleeve engage the converter stator. The
splines on the turbine shaft engage the
converter turbine. The end of the turbine shaft
is threaded and machined to accept the
converter retaining bolt and lockup sealring.
2. The splines of the ground sleeve and turbine
shaft must engage with their respective splines
in the torque converter module. The tangs on
the converter-pump hub must engage the
charging pump’s drive gear or the PTO oil
pump drive hub.
3. Using a hoist and sling, install torque converter
module 6 into the converter housing module
(Figure 6–24, View A).
4. Make sure that the torque converter is properly
seated. If PTO equipped, rotate the PTO gear to
engage the pump hub with the charging pump.
Proceed with the selective shim measurement.
5. Install converter end play gauge J 38548
and tighten the attaching bolt to 27–34 N·m
(20–25 lb ft). Prevent turbine shaft rotation by
using one of the following methods:
• Insert a screwdriver into the vanes on the
View B).
• If the control module is in place, apply air
pressure through the lockup pressure tap
Insert the heel bar into a torque converter
housing bolt hole. Insert two bolts into the
flexplate adapter bolt holes. Then place a
screwdriver at an angle to prevent converter
rotation (Figure 6–24, View C).
6–13
 4000 PRODUCT FAMILIES SERVICE MANUAL—ALLISON 4 th GENERATION

CUPPED END DOWN RESTRICT MOVEMENT

5 USE HOIST AND SLING
2 1
3 4

J 38564

VIEW A

VIEW B

VIEW C VIEW D VL06869.01.00

Figure 6–24. Torque Converter Module Installation and Selective Shim Measurement

6–14 Copyright © 2005 General Motors Corp.

 TRANSMISSION ASSEMBLY
NOTE:
Dimension C shown in Table 6–1 includes a
correction due to internal deflection caused by the
27–34 N·m (20–25 lb ft) bolt torque applied to gauge
J 38548. Correct torque value is critical to selection
of the proper shim.
6. Measure from top of tool J 38548 to face of
turbine shaft and record it as dimension B
(Figure 6–24, View D). Subtract dimension B
from dimension A to determine dimension C.
(Dimension A is the height of tool J 38548,
100.00 mm; 3.937 inch.)
7. Use dimension C and Table 6–1 to determine
proper selective shim part number. Remove
tool J 38548 and continue with installation of
the torque converter.
8. Keep the torque converter cover from turning
by using a heel bar, two bolts, and a screw-
driver (Figure 6–24, View C).
9. Install threaded plug 7 and O-ring 8 using a
3⁄4 inch Allen socket. Tighten plug to 50–60 N·m
(37–44 lb ft).
10. Install converter shipping brackets 1
(Foldout 12,B), or equivalent, to prevent
torque converter movement. Tighten the ship-
ping bracket bolts to 51–61 N·m (38–45 lb ft).

Table 6–1. Torque Converter Selective Shims

ID
Dimension C Use P/N Shim Thickness (Ref.) No.
0.4129–0.6598 mm (0.0163–0.0259 inch) 29505688 4.000 mm (0.157 inch) 0
0.6599–0.8378 mm (0.0260–0.0329 inch) 29505681 4.203 mm (0.165 inch) 1
0.8379–1.0158 mm (0.0330–0.0399 inch) 29505682 4.381 mm (0.172 inch) 2
1.0159–1.1938 mm (0.0400–0.0469 inch) 29505683 4.559 mm (0.179 inch) 3
1.1939–1.3708 mm (0.0470–0.0539 inch) 29505684 4.736 mm (0.186 inch) 4
1.3709–1.5488 mm (0.0540–0.0609 inch) 29505685 4.914 mm (0.193 inch) 5
1.5489–1.7268 mm (0.0610–0.0679 inch) 29505686 5.092 mm (0.200 inch) 6
1.7269–1.9048 mm (0.0680–0.0749 inch) 29507793 5.270 mm (0.207 inch) 7
1.9049–1.9733 mm (0.0750–0.0776 inch) 29507794 5.448 mm (0.214 inch) 8

Copyright © 2005 General Motors Corp. 6–15

 4000 PRODUCT FAMILIES SERVICE MANUAL—ALLISON 4 th GENERATION

w. Installation of Control Module (Figure 6–25)

NOTE:
Apply transmission fluid to the control module bolts
as they are installed. This will provide lubrication
during the installation and tightening and prevent
thread seizure.

1. Place the transmission in a vertical position,

front end upward.
2
2. Install two guide pins in two main housing bolt
holes.

WARNING!
Get help when lifting the control module.
Assistance from another person may be
1
required. The control module weighs
approximately 25 kg (55 lb).

3. Lubricate the feedthrough hole in the main

housing with oil-soluble grease. 3 4
V09785.00.00

4. Guide control module 1 onto the main housing

and pass feedthrough harness connector
through the feedthrough hole in the main
housing.
5. Align the control module bolt holes with the
guide pins. Make sure the feedthrough harness
standoff is aligned with the feedthrough hole in
the main housing.
6. Lower the control module over the guide pins
until it seats against the main housing.
7. Install filter cover assemblies prepared in
Paragraph 5–18.
Figure 6–25. Control Module Installation
x. Installing Integral Oil Cooler (Figure 6–26)
1. Install nine washers 6 on nine M10 x 1.5 x 70
bolts 7.
2. Install two bolts 7 into the upper corners of
cooler housing 3.
3. Install gasket 1 over bolts 7.
4. Position cooler housing 3 against the
transmission main housing.
5. Tighten two bolts 7 finger tight, making sure
gasket 1 is properly positioned.

6–16 Copyright © 2005 General Motors Corp.

 TRANSMISSION ASSEMBLY
6. Install the remaining seven bolts 7 into cooler
housing 3. Tighten nine bolts 7 to 51–61 N·m
(38–45 lb ft).
7. Install two O-rings 8 onto plate assembly 9.
8. Install plate assembly 9 into cooler housing 3
so that O-rings 8 seal against the transmission
main housing.
9. Install two bolts 12 into the upper corners of
cover 13.
10. Install gasket 14 over bolts 12.
11. Install cover 13 onto cooler housing 3. Tighten
two bolts 12 finger tight.
12. Install the fifteen remaining bolts 12. Tighten
bolts 12 to 51–61 N·m (38–45 lb ft).
13. Install two bolts 11. Tighten two bolts 11 to
100–120 N·m (74–88 lb ft).
y. Installing Integral Retarder Sump Oil Cooler
(Foldout 12,C)
1. Rotate the transmission so that the retarder is
facing up.
2. Install two headless guide bolts into the
retarder housing.
3. Install gasket 4 over the headless guide bolts.
4. Install cooler manifold 16 over the headless
guide bolts.
5. Install three M12 x 1.75 x 195 bolts 10.
Tighten bolts to 100–120 N·m (74–88 lb ft).
6. Remove the two headless guide bolts.
7. Install seven M10 x 1.5 x 187.5 bolts 9.
Tighten bolts to 51–61 N·m (38–45 lb ft).
8. Install M10 x 1.5 x 50 bolt 8. Tighten bolt to
51–61 N·m (38–45 lb ft).
9. Rotate the transmission so that the breather is
facing up.
10. Install two headless guide bolts into each man-
ifold to cooler mating surface.
11. Install gaskets 6 over the headless guide bolts.
WARNING!
To help avoid personal injury, securely support
the cooler in its installed position before
installing the bolts retaining the cooler to the
manifold. The cooler weighs 30 kg (64 lb); use
care when handling the cooler.
12. Install cooler 7 over the headless guide bolts
and install two M10 x 1.5 x 60 bolts 1 so that
the cooler is retained to the cooler manifold.
Do not install bolts into the inlet or outlet hose
adapter bolt holes. Tighten bolts finger tight.

5
4
3
1
11
8
4 2 9
5
6 7 10
8
19
18 17
11 19
18 17 10

16 11
15

12

14
13 11 V06843

Figure 6–26. Integral Oil Cooler Installation

Copyright © 2005 General Motors Corp. 6–17

 4000 PRODUCT FAMILIES SERVICE MANUAL—ALLISON 4 th GENERATION

13. Remove the two headless guide bolts. 20. If used, install the retarder accumulator hose
onto the fitting on cooler manifold 16.
14. Install two gaskets 3.
z. Installation of Externally Mounted Parts
15. Align and install two inlet or outlet hose adapt- (Figure 6–27)
ers 2.
1. If not previously installed, install
16. Install the remaining fourteen M10 x 1.5 x 60 transmission breather 20. Tighten breather to
bolts 1. 12–16 N·m (9–12 lb ft).

17. Evenly tighten sixteen M10 x 1.5 x 60 bolts 1
to 51–61 N·m (38–45 lb ft).
18. Install six bolts 5. Tighten bolts to 24–29 N·m
(18–21 lb ft).
19. Install water inlet and outlet hoses.
2. Install fill tube seal 9, fill tube 8, bracket 6,
and screw 5. Tighten screw to 24–29 N·m
(18–21 lb ft). Install dipstick 7.
3. If used, install new cooler port gasket 10. Install
remote mount manifold 11 and six bolts 12.
Tighten bolts to 51–61 N·m (38–45 lb ft).

20 ENGINE
2
SPEED TURBINE 1
SENSOR SPEED 4 7
SENSOR 3 5
6

9
OUTPUT 15
SPEED
SENSOR

13

16
17
18
19
10
11
12

14

V06837.03.00

Figure 6–27. Installation of Externally Mounted Parts

6–18 Copyright © 2005 General Motors Corp.

 TRANSMISSION ASSEMBLY
4. If removed, use special tool J 46150 to press a
new slinger 13 onto the flange or yoke.
5. Install output flange 15 or yoke 14.
6. Install O-rings 16 on plug 18.
7. Insert bolt 19 into plug 18.
8. Install O-ring 17 over the threaded end of
bolt 19, so that the O-ring seats against the
retainer plug.
9. Install retainer plug 18 into the yoke or flange.
Tighten bolt 19 to 70–80 N·m (51–60 lb ft).
aa. Installation of Power Takeoff
(Figure 6–28)
1. If removed, install two PTO pilot screws 4.
2. Install PTO gasket 3 and PTO assembly 2. Insert
one bolt 1 into each of the 6 o’clock and
12 o’clock positions. Install the remaining six
bolts. Tighten bolts to 51–61 N·m (38–45 lb ft).
ab. Removal of Transmission From Repair Stand
WARNING!
Dry weight of 4000 Product Family
transmissions with PTO provision and retarder
is 439 kg (968 lb); with PTO provision is 405 kg
(893 lb). The dry weight of 4700 and 4800 models
with PTO provision and retarder is 555 kg
(1224 lb), dry weight of 4700 and 4800 models
with PTO provision is 521 kg (1149 lb).
Using hoist, remove transmission and holding fixture
from repair stand and prepare for vehicle installation.
NOTE:
Refer to Mechanic’s Tips MT4015EN for preparing
transmission for installation and installing the
transmission into a vehicle.

1 2
4
3

3
1

4
V06836

Figure 6–28. PTO Installation

Copyright © 2005 General Motors Corp. 6–19

 4000 PRODUCT FAMILIES SERVICE MANUAL—ALLISON 4 th GENERATION

NOTES

6–20 Copyright © 2005 General Motors Corp.

 SECTION 7—WEAR LIMITS AND SPRING DATA
7–1. WEAR LIMITS DATA
a. Maximum Variations. Wear limit information in
this Section shows the maximum wear at which
components are expected to function satisfactorily.
Table 7–1 lists the Wear Limits Data and is referenced
to the exploded views (Foldouts 4 through 12) in the
back of this manual.
b. Cleaning And Inspection. Parts must be clean to
permit effective inspection for wear or damage. Refer
to Section 3.
7–2. SPRING DATA
a. Spring Replacement. Springs should be replaced
if there are signs of overheating, wear due to rubbing
adjacent parts, or permanent set. Discard springs
which do not meet the load height specifications
according to Table 7–2, Spring Data.
b. Inspection. Inspection criteria (load vs. height)
and identification characteristics of the springs are
presented in Table 7–2. The Spring Data are keyed to
the exploded views (Foldouts 4 through 12) in the
back of this manual.
NOTE:
When more than one spring part number is listed
for the same location, refer to the 4000 Product
Family Parts Catalog PC2456EN to determine
which spring is used in your specific assembly
number.

Table 7–1. Wear Limits Data

Wear Limit
Illustration Description mm (inches)
Foldout 4,B TORQUE CONVERTER MODULE

10 Converter Cover Bushing, Maximum ID 66.91 2.634

12 Lockup Piston Assembly, Minimum Thickness 6.53 0.257

14 Damper Assembly Plate, Maximum Distortion 0.51 0.020

14 Damper Assembly Plate, Minimum Thickness 8.51 0.335

14, 18 Turbine-To-Damper, Maximum Spline Wear 0.38 0.015

15 Backplate, Maximum Distortion 0.15 0.006

15 Backplate, Minimum Wear Surface Thickness 11.79 0.464

18 Turbine Hub, Minimum OD 66.69 2.626

19 Turbine Hub Sealring, Maximum ID 61.77 2.432

24 Stator Thrust Plate, Minimum Thickness 9.45 0.372

36 Converter Pump Hub, Minimum OD 88.99 3.504

Foldout 5,B TORQUE CONVERTER HOUSING MODULE—PTO EQUIPPED

6 Bearing Retainer Bushing, Maximum ID 89.19 3.511

8, 14 Oil Pump Drive Hub Seal, Minimum End Gap 1.18 0.047

8, 14 Oil Pump Drive Hub Seal, Maximum End Gap 1.66 0.065

13 Oil Pump Drive Hub, Maximum Tang Wear 0.31 0.012

Copyright © 2005 General Motors Corp. 7–1

 4000 PRODUCT FAMILIES SERVICE MANUAL—ALLISON 4 th GENERATION

Table 7–1. Wear Limits Data (cont’d)

Wear Limit
Illustration Description mm (inches)
Foldout 6,A FRONT SUPPORT AND CHARGING PUMP MODULE

8 Pump Housing Bushing, Maximum ID 89.19 3.511

9, 10 Pump Housing Gear, Maximum Cavity Depth 19.04 0.750

9, 10 Pump Housing Gear, Maximum Cavity Diameter 150.25 5.915

9, 10, 11 Driven Gear-To-Pump Housing, Maximum Diametric Clearance 0.30 0.012

9, 10, 13 Gear-To-Plate, Maximum Side Clearance 0.10 0.004

11 Gear Set, Maximum Gear Tooth Tip Clearance 0.15 0.006

12 Pump Gear Bushing, Maximum ID 66.93 2.635

16, 17 Ground Sleeve, Minimum OD In Bushing Area 66.67 2.625

16, 17, 20 Spline OD, Maximum Total Runout 0.13 0.005

20 Front Support, Minimum OD 119.81 4.717

25 Front Support Seal, Minimum End Gap 1.00 0.040

25 Front Support Seal, Maximum End Gap 1.44 0.056

Foldout 6,B ROTATING CLUTCH MODULE

5 Turbine Shaft Bushing, Maximum ID 36.14 1.423

8 Turbine Seal, Minimum End Gap 0.65 0.026

8 Turbine Seal, Maximum End Gap 1.01 0.039

9 Drum Spline, Maximum Wear 0.38 0.015

12 Rotating Clutch Hub Bushing, Maximum ID 120.27 4.735

29 C1 Clutch Apply Plate, Minimum Thickness 5.90 0.232

29, 39 C1 Clutch Apply Plate or C2 Backplate, Maximum Distortion 0.15 0.006

30, 38 C1, C2 Friction Plate, Maximum Cone 0.25 0.010

30, 38 C1, C2 Friction Plate, Minimum Thickness 2.92 0.115

30, 38 C1, C2 Friction Plate, Minimum Oil Groove Depth 0.20 0.008

31, 37 C1, C2 Reaction Steel Plate, Maximum Cone 0.25 0.010

31, 37 C1, C2 Reaction Steel Plate, Minimum Thickness 2.41 0.095

32 C1 Clutch Backplate, Minimum Thickness @ ID 9.90 0.390

34, 36 C1, C2 Drive Hub, Maximum Spline Wear 0.38 0.015

39 C2 Backplate, Minimum Thickness 7.90 0.311

7–2 Copyright © 2005 General Motors Corp.

 WEAR LIMITS AND SPRING DATA
Table 7–1. Wear Limits Data (cont’d)

Wear Limit
Illustration Description mm (inches)
Foldout 7 MAIN HOUSING MODULE

4 Backplate, Maximum Step Wear 0.13 0.005

4 Backplate, Maximum Distortion 0.15 0.006

5, 18 P1 Ring Thrust Plate, Minimum Thickness At Wear Point 2.82 0.111

7 P1 Ring Gear Spline, Maximum Wear 0.38 0.015

8, 21, 29 C3, C4, C5 Friction Plate, Maximum Cone 0.25 0.010

8, 21, 29 C3, C4, C5 Friction Plate, Minimum Thickness 3.485 0.137

C3, C4 Friction Plate, Maximum Friction Material Erosion Around 4.00 0.157
8, 21
Lubrication Slots

9, 20, 30 C3, C4, C5 Reaction (Steel) Plate, Maximum Cone 0.25 0.010

9, 20, 30 C3, C4, C5 Reaction (Steel) Plate, Minimum Thickness 3.25 0.128

11, 23 C3, C4 Piston Return Plate, Minimum Thickness 4.91 0.193

19, 28 C3, C4 Clutch Housings, Maximum Spline Wear 1.15 0.045

43 Main Housing, Maximum Spline Wear 1.15 0.045

Foldout 8 MAIN SHAFT MODULE—WIDE RATIO AND CLOSE RATIO

7, 8 Main Shaft Bearing Journal, Minimum OD 52.98 2.085

7, 8 Main Shaft Pilots (both ends), Minimum OD 35.92 1.414

7, 8 Main Shaft Spines, Maximum Wear 0.38 0.015

Foldout 9,A P1 PLANETARY MODULE

3 P1 Planetary Carrier Assembly, Maximum Pinion End Play 0.94 0.037

9 P1 Carrier Bushing, Maximum ID 89.32 3.516

10, 13 P1 Pinion Thrust Washer, Minimum Thickness 1.40 0.055

10, 13 P1 Pinion Thrust Washer, Maximum Step Wear 0.12 0.005

15 P2 Ring Gear Spline, Maximum Wear 0.38 0.015

Foldout 9,B P2 PLANETARY MODULE

1 P2 Planetary Carrier Assembly, Maximum Pinion End Play 0.94 0.037

8 P2 Carrier Bushing, Maximum ID 53.23 2.096

9, 12 P2 Pinion Thrust Washer, Minimum Thickness 1.40 0.055

9, 12 P2 Pinion Thrust Washer, Maximum Step Wear 0.12 0.005

15 P3 Ring Gear Spline, Maximum Wear 0.38 0.015

Copyright © 2005 General Motors Corp. 7–3

 4000 PRODUCT FAMILIES SERVICE MANUAL—ALLISON 4 th GENERATION

Table 7–1. Wear Limits Data (cont’d)

Wear Limit
Illustration Description mm (inches)
Foldout 9,C P3 PLANETARY AND C6 ADAPTER HOUSING MODULE (4700 and 4800 models)

1 P3 Carrier Module, Maximum Pinion End Play 0.94 0.037

8 P3 Pinion Thrust Washer, Minimum Thickness 1.40 0.055

8 P3 Pinion Thrust Washer, Maximum Step Wear 0.12 0.005

27 C6 Reaction Plate, Minimum Thickness 3.24 0.128

27, 28 C6 Friction and Reaction Plate, Maximum cone 0.25 0.010

28 C6 Friction Plate, Minimum Thickness 3.68 0.145

32 P4 Carrier Assembly, Maximum Pinion End Play 0.94 0.037

38 P4 Carrier Bushing, Maximum ID 113.33 4.462

40 P4 Planetary Thrust Washer, Minimum Thickness 1.40 0.055

40 P4 Planetary Thrust Washer, Maximum Step Wear 0.12 0.005

Foldout 10,A REAR COVER AND P3 MODULE (except 4700 and 4800 models)

5 P3 Planetary Carrier Assembly, Maximum End Play 0.94 0.037

7 Output Shaft Bushing, Maximum ID 36.14 1.423

8 Output Shaft, Maximum Spline Wear 0.38 0.015

15, 18 P3 Pinion Thrust Washer, Minimum Thickness 1.40 0.055

15, 18 P3 Pinion Thrust Washer, Maximum Step Wear 0.12 0.005

Foldout 10,B REAR COVER AND OUTPUT SHAFT MODULE (47000 and 4800 models)

7 Output Shaft Bushing, Maximum ID 36.14 1.423

8 Output Shaft, Maximum Spline Wear 0.38 0.015

Foldout 10,C RETARDER AND P3 MODULE (except 4700 and 4800 models)

3 P3 Planetary Carrier Assembly, Maximum Pinion End Play 0.94 0.037

5 Output Shaft Bushing, Maximum ID 36.14 1.423

13, 16 P3 Pinion Thrust Washer, Minimum Thickness 1.40 0.055

13, 16 P3 Pinion Thrust Washer, Maximum Step Wear 0.12 0.005

27, 30 Retarder Rotor Sealring, Maximum ID 139.72 5.501

29 Rotor Hub, Maximum Spline Wear 0.38 0.015

7–4 Copyright © 2005 General Motors Corp.

 WEAR LIMITS AND SPRING DATA
Table 7–1. Wear Limits Data (cont’d)

Wear Limit
Illustration Description mm (inches)
Foldout 10,D RETARDER AND OUTPUT SHAFT MODULE (4700 and 4800 models)

4 Output Shaft Bushing, Maximum ID 36.14 1.423

5 Output Shaft, Maximum Spline Wear 0.38 0.015

16, 19 Retarder Rotor Sealring, Maximum ID 139.72 5.501

18 Rotor Hub, Maximum Spline Wear 0.38 0.015

Foldout 12,A OUTPUT FLANGE AND YOKE

1, 4, 5, 6, 9, Output Seal Journal, Minimum OD 85.0 3.346

10, 11, 12

Copyright © 2005 General Motors Corp. 7–5

 Table 7–2. Spring Data

7–6
Approx. Length under load
Spring Free
Color No. of Wire Dia OD Length mm N
Foldout Ref. Spring Part No. Code Coils mm (in.) mm (in.) mm (in.) (in.) (lb)
17.8 5.7 0.9
4,B 26 Stator 29501300 No Code N/A N/A N/A
(0.70) (0.224) (0.2)
3.25 17.96 52.4 40.7 474
6,A 22 Main Relief 29507709 No Code 10
(0.128) (0.707) (2.06) (1.60) (106.5)
2.04* 19.06* 70.76* 28.2 5185**
6,B 20 C2 Return 29505719 No Code 11.5*
(0.080) (0.750) (2.786) (1.110) (1165.6)
2.10* 16.0* 57.53* 34.8 4649**
6,B 25 C1 Return 29509453 No Code 12*
(0.083) (0.630) (2.265) (1.37) (1045.4)
2.17* 16.8* 52.89* 34.5 4893**
6,B 25 C1 Return 29537301 No Code 11.8*
(0.085) (0.661) (2.082) (1.358) (1100.0)
2.10* 15.0* 55.55* 39.25 143.5**
7 10 C3 Return 29542504 Pink 13.8
(0.083) (0.590) (2.187) (1.545) (32.3)
2.10* 15.0* 55.55* 39.25 143.5**
7 22 C4 Return 29542504 Pink 13.8
(0.083) (0.590) (2.187) (1.545) (32.3)
2.03* 17.00* 53.80 37.7 3611**
9,C 17 C5 Return 29530488 No Code 11.6*
(0.080) (0.669) (2.11) (1.48) (811.8)
2.10* 57.3* 37.6 3086**
10,A 22 C5 Return 29503036 No Code 12* 17.00*
(0.083) (2.26) (1.48) (693.8)

Copyright © 2005 General Motors Corp.

2.10* 57.3* 37.6 3086**
10,B 12 C5 Return 29503036 No Code 12* 17.00*
(0.083) (2.26) (1.48) (693.8)
2.10* 57.3* 37.6 3086**
10,C 20 C5 Return 29503036 No Code 12* 17.00*
(0.083) (2.26) (1.48) (693.8)
2.10* 57.3* 37.6 3086**
10,D 9 C5 Return 29503036 No Code 12* 17.00*
(0.083) (2.26) (1.48) (693.8)
4.12 36.17 114.3 91.1 213.3
10,C 35 Retarder Flow Valve 29515692 No Code 11.4
(0.162) (1.424) (4.500) (3.587) (47.95)
4.12 36.17 114.3 91.1 213.3
10,D 25 Retarder Flow Valve 29515692 No Code 11.4
(0.162) (1.424) (4.500) (3.587) (47.95)
0.61 8.00 29.2 18.2 2.67
4000 PRODUCT FAMILIES SERVICE MANUAL—ALLISON 4 th GENERATION

10,C 70 Exhaust Backfill 23049391 No Code 20.40

(0.024) (0.315) (1.15) (0.716) (0.60)
 Table 7–2. Spring Data (cont’d)
Approx. Length under load
Spring Free
Color No. of Wire Dia OD Length mm N
Foldout Ref. Spring Part No. Code Coils mm (in.) mm (in.) mm (in.) (in.) (lb)
0.61 8.00 29.2 18.2 2.67
10,D 59 Exhaust Backfill 23049391 No Code 20.40
(0.024) (0.315) (1.15) (0.716) (0.60)
Lt. Green/ 0.97 12.19 38.15 17.70 14.70
10C 78 Regulator Valve 29529310 10.45
Silver (0.038) (0.480) (1.502) (0.697) (3.31)
Lt. Green/ 0.97 12.19 38.15 17.70 14.70
10D 67 Regulator Valve 29529310 10.45
Silver (0.038) (0.480) (1.502) (0.697) (3.31)
Lt. Green/ 0.97 12.19 38.15 17.70 14.70
10C 85 Relay Valve 29529310 10.45
Silver (0.038) (0.480) (1.502) (0.697) (3.31)
Lt. Green/ 0.97 12.19 38.15 17.70 14.70
10D 74 Relay Valve 29529310 10.45
Silver (0.038) (0.480) (1.502) (0.697) (3.31)
Dk. Green 0.94 7.43 30.82 18.20 27.59
11 50 Accumulator 8678805 15.90
Dk. Blue (0.037) (0.293) (1.213) (0.717) (6.20)
1.37 16.26 46.2 29.2 16.7–18.9
11 130 C1 Latch 29542929 Blue 12
(0.054) (0.640) (1.82) (1.15) (3.75–4.25)
1.32 11.43 41.3 19.0 64.1–78.3
11 123 C2 Latch 29542929 Lt. Green 11
(0.052) (0.450) (1.63) (0.75) (14.4–17.6)
1.22 10.75 16.71 12.84 18.14–21.86
11 175 C6 Enable 29542949 No code 6.90
(0.048) (0.423) (0.658) (0.506) (4.08–4.91)

Copyright © 2005 General Motors Corp.

0.67 11.05† 6.5 3.45 3.2–4.2
11 180 C6 Clutch 29542936 No code 4
(0.026) (0.435) (0.26) (0.14) (0.72–0.94)
WEAR LIMITS AND SPRING DATA

1.37 14.10 42.1 17.0 49.2–60.2

11 100 Connector Flow 23049326 No Code 10
(0.054) (0.555) (1.66) (0.67) (11.06–13.53)
1.83 14.8 44.6 24.2 131–145
11 112 Control Main 29542926 Orange 10
(0.072) (0.583) (1.76) (0.95) (29.5–32.6)
1.53 11.00 30.3 22.8 53.7–59.3
11 134 Converter Regulator 29507456 Pink 10.20
(0.060) (0.433) (1.19) (0.90) (12.1–13.3)

7–7
 Table 7–2. Spring Data (cont’d)

7–8
Approx. Length under load
Spring Free
Color No. of Wire Dia OD Length mm N
Foldout Ref. Spring Part No. Code Coils mm (in.) mm (in.) mm (in.) (in.) (lb)
1.30 10.50 27.03 15.49 2.45
11 79 Diagnostic 29542941 No Code 9
(0.039) (0.433) (1.06) (1.02) (0.78)
1.22 11.10 46.3 23.5 46.5–51.3
11 104 Lube Regulator 23049327 Red 13
(0.048) (0.437) (1.82) (0.93) (10.5–11.5)
2.87 22.0 98.5 54.6 305–337
11 108 Main Regulator 29500963 Lt. Blue 15
(0.113) (0.866) (3.88) (2.15) (68.6–75.8)
0.67 11.05† 6.5 3.45 3.2–4.2
11 71 PCS1 29542936 No code 4
(0.026) (0.435) (0.26) (0.14) (0.72–0.94)
0.67 11.05† 6.5 3.45 3.2–4.2
11 76 PCS2 29542936 No Code 4
(0.026) (0.435) (0.26) (0.14) (0.72–0.94)
0.67 11.05† 6.5 3.45 3.2–4.2
11 84 PCS3 29542936 No Code 4
(0.026) (0.435) (0.26) (0.14) (0.72–0.94)
0.67 11.05† 6.5 3.45 3.2–4.2
11 89 PCS4 29542936 No Code 4
(0.026) (0.435) (0.26) (0.14) (0.72–0.94)
0.67 11.05† 6.5 3.45 3.2–4.2
11 66 TCC 29542938 No Code 4
(0.026) (0.435) (0.26) (0.14) (0.72–0.94)

* Individual Springs

Copyright © 2005 General Motors Corp.

** For the complete Spring Assembly
† OD at larger end
4000 PRODUCT FAMILIES SERVICE MANUAL—ALLISON 4 th GENERATION
 SECTION 8—CUSTOMER SERVICE
8–1. OWNER ASSISTANCE
The satisfaction and goodwill of the owners of Allison
transmissions are of primary concern to Allison
Transmission, its distributors, and their dealers.
As an owner of an Allison transmission, you have ser-
vice locations throughout the world that are eager to
meet your parts and service needs with:
• Expert service by trained personnel
• Emergency service 24 hours a day in many
areas
• Complete parts support
• Sales teams to help determine your
transmission requirements
• Product information and literature.
Normally, any situation that arises in connection with
the sale, operation, or service of your transmission will
be handled by the distributor or dealer in your area.
Check the telephone directory for the Allison
Transmission service outlet nearest you or utilize
Allison Transmission’s Sales and Service Locator tool
on the Allison Transmission web site at
www.allisontransmission.com. You may also refer to
Allison Transmission’s Worldwide Sales and Service
Directory (SA2229EN).
We recognize, however, that despite the best intentions
of everyone concerned, misunderstandings may occur.
To further assure your complete satisfaction, we have
developed the following three-step procedure to be
followed in the event a problem has not been handled
satisfactorily.
Step One—Discuss your problem with a member of
management from the distributorship or dealership.
Frequently, complaints are the result of a breakdown
in communication and can quickly be resolved by a
member of management. If you have already
discussed the problem with the Sales or Service
Manager, contact the General Manager. All Allison
Transmission dealers are associated with an Allison
Transmission distributor. If the problem originates
with a dealer, explain the matter to a management
member of the distributorship with whom the dealer
has his service agreement. The dealer will provide his
Allison Transmission distributor’s name, address, and
telephone number on request.
Copyright © 2005 General Motors Corp.
Step Two—When it appears the problem cannot be
readily resolved at the distributor level without
additional assistance, contact the Allison Technical
Assistance Center at 800-252-5283. They will place
you in contact with the Regional Customer Support
Manager for your area.
For prompt assistance, please have the following infor-
mation available.
• Name and location of authorized distributor or
dealer
• Type and make of vehicle/equipment
• Transmission model number, serial number,
and assembly number (if equipped with
electronic controls, also provide the TCM
assembly number)
• Transmission delivery date and accumulated
miles and/or hours of operation
• Nature of problem
• Chronological summary of your transmission’s
history
Step Three—If you are still not satisfied after contact-
ing the Regional Customer Support Manager, present
the entire matter to the Home Office by writing to the
following address:
Allison Transmission
Manager, Warranty Administration
P.O. Box 894, Mail Code 462-470-PF9
Indianapolis, IN 46206-0894
The inclusion of all pertinent information will assist
the Home Office in expediting the matter.
When contacting the Home Office, please keep in
mind that ultimately the problem will likely be re-
solved at the distributorship or dealership utilizing
their facilities, equipment, and personnel. Therefore, it
is suggested that Step 1 be followed when experienc-
ing a problem.
Your purchase of an Allison Transmission product is
greatly appreciated, and it is our sincere desire to
assure complete satisfaction.
8–1
 4000 PRODUCT FAMILIES SERVICE MANUAL—ALLISON 4 th GENERATION

8–2. SERVICE LITERATURE Table 8–1. 4000 Product Family

(Table 8–1) Service Literature
Additional service literature is available. This service Literature
Publication Type
literature provides fully illustrated instructions for Number
operation, maintenance, service, overhaul, and parts Allison DOC™ For PC–Service Tool User GN3433EN
support for your transmission. To be sure that you get Guide
maximum performance and service life from your Automatic Transmission Fluid GN2055EN
transmission, you may order publications from: Technician’s Guide
*Operator’s Manual (Bus Series) OM3749EN
SGI, Inc.
Attn: Allison Literature Fulfillment Desk *Operator’s Manual (Emergency OM3656EN
8350 Allison Avenue Vehicle Series)
Indianapolis, IN 46268 *Operator’s Manual (Highway Series) OM3750EN
TOLL FREE: 888-666-5799 *Operator’s Manual (International Models) OM4119EN
INTERNATIONAL: 317-471-4995 *Operator’s Manual (Motorhome Series) OM3349EN
*Operator’s Manual (Rugged Duty Series) OM3752EN
*Operator’s Manual (Specialty Series) OM3753EN
*Operator’s Manual (Truck Recreational OM3654EN
Vehicle Series)
*Mechanic’s Tips MT4015EN
*Mechanic’s Tips (T Series) MT4085EN
Parts Catalog PC2456EN
Parts Catalog CD-ROM CD2456EN
Principles of Operation PO4016EN
Service Manual SM4014EN
Troubleshooting Manual TS3989EN
*Worldwide Sales And Service Directory SA2229EN
* Also Available On The Internet At www.allisontransmission.com

8–2 Copyright © 2005 General Motors Corp.

 F OLDOUT 1

1 2 3 4 5 6 7 8 9 10 11 12 13 14

1 — Lockup clutch/ damper

2 — Converter turbine
3 — Converter stator
4 — Converter pump
5 — Oil pump
6 — Front support
7 — Main housing
8 — Main shaft
9 — C3 clutch
10 — C4 clutch
11 — P2 sun gear
12 — C5 clutch
13 — P3 sun gear
14 — Output shaft
15 — Rear cover
16 — C5 piston
17 — P3 module
18 — Oil level sensor
19 — Control module
20 — P2 module
21 — P1 module
22 — C2 clutch
23 — C1 clutch
24 — Turbine shaft
25 — Ground sleeve
26 — Converter housing module

26 25 24 23 22 21 20 19 18 17 16 15 V05513.01.02

Foldout 1. 4000 Product Family Transmission (Close Ratio)—Cross Section

 F OLDOUT 2

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15

1 — Lockup clutch/damper
2 — Converter turbine
3 — Converter stator
4 — Converter pump
5 — Charging oil pump
6 — Front support
7 — Breather
8 — Main housing
9 — Main shaft
10 — C3 clutch
11 — C4 clutch
12 — P2 sun gear
13 — C5 clutch
14 — P3 sun gear
15 — Output shaft
16 — Rear cover
17 — C5 piston
18 — P3 module
19 — Oil level sensor
20 — Control module
21 — P2 module
22 — P1 module
23 — C2 clutch
24 — C1 clutch
25 — Turbine shaft
26 — PTO drive gear
27 — Ground sleeve
28 — Converter housing module

28 27 26 25 24 23 22 21 20 19 18 17 16 V05515.01.02

Foldout 2. 4500 Model (Wide Ratio) Transmission With PTO Provision—Cross Section
 F OLDOUT 3

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17

1 — Lockup clutch/ damper

2 — Converter turbine
3 — Converter stator
4 — Converter pump
5 — Charging oil pump
6 — Front support
7 — Main housing
8 — Main shaft
9 — C3 clutch
10 — C4 clutch
11 — P2 sun gear
12 — C5 clutch
13 — P3 sun gear
14 — Retarder stator
15 — Retarder rotor
16 — Retarder module
17 — Retarder housing
18 — C5 piston
19 — P3 module
20 — Control module
21 — P2 module
22 — P1 module
23 — C2 clutch
24 — C1 clutch
25 — Turbine shaft
26 — Ground sleeve
27 — Converter housing module

27 26 25 24 23 22 21 20 19 18 V05514.01.01

Foldout 3. 4000 Product Family (Close Ratio) Transmission With Retarder—Cross Section
4000 PRODUCT FAMILIES SERVICE MANUAL—ALLISON 4 th GENERATION

Legend For Foldout 3,A Is On The Opposite Side Of This Page.

Copyright © 2005 General Motors Corp. Foldout 3,A

 4000 PRODUCT FAMILIES SERVICE MANUAL—ALLISON 4 th GENERATION

Legend For Foldout 3,A

1 — Lockup clutch/damper
2 — Converter turbine
3 — Converter stator
4 — Converter pump
5 — Charging oil pump
6 — Front support
7 — Main housing
8 — Main shaft
9 — C3 clutch
10 — C4 clutch
11 — P2 sun gear
12 — Shim
13 — C5 clutch
14 — P3 sun gear
15 — C5 piston assembly
16 — C6 adapter housing module
17 — C6 clutch
18 — P4 ring gear
19 — Rear cover
20 — Output shaft
21 — C6 piston
22 — P4 planetary
23 — P4 sun gear
24 — Selective shim
25 — P4 shaft flange
26 — P3 planetary
27 — Oil level sensor
28 — Control valve assembly
29 — P2 planetary
30 — P1 planetary
31 — C2 clutch
32 — C1 clutch
33 — Turbine shaft
34 — Converter ground sleeve
35 — Converter housing

Foldout 3,A Copyright © 2005 General Motors Corp.

 F OLDOUT 3,A
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20

35 34 33 25 24 23 22 21

32 31 30 29 28 27 26 V05265.05.00

Foldout 3,A. 4700 and 4800 Model Transmission—Cross Section

4000 PRODUCT FAMILIES SERVICE MANUAL—ALLISON 4 th GENERATION

Legend For Foldout 3,B Is On The Opposite Side Of This Page.

Copyright © 2005 General Motors Corp. Foldout 3,B

 4000 PRODUCT FAMILIES SERVICE MANUAL—ALLISON 4 th GENERATION

Legend For Foldout 3,B

1 — Lockup clutch/damper
2 — Converter turbine
3 — Converter stator
4 — Converter pump
5 — Charging oil pump
6 — Front support
7 — Main housing
8 — Main shaft
9 — C3 clutch
10 — C4 clutch
11 — P2 sun gear
12 — Shim
13 — C5 clutch
14 — P3 sun gear
15 — C5 piston assembly
16 — C6 adapter housing module
17 — C6 clutch
18 — P4 ring gear
19 — Retarder stator
20 — Retarder rotor
21 — Retarder and output shaft module
22 — Output shaft
23 — C6 piston
24 — P4 planetary
25 — P4 sun gear
26 — Selective shim
27 — P4 shaft flange
28 — P3 planetary
29 — Control valve assembly
30 — P2 planetary
31 — P1 planetary
32 — C2 clutch
33 — C1 clutch
34 — Turbine shaft
35 — Converter ground sleeve
36 — Converter housing

Foldout 3,B Copyright © 2005 General Motors Corp.

 F OLDOUT 3,B
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22

36 35 34 27 26 25 24 23

33 32 31 30 29 28 V09805.00.00

Foldout 3,B. 4700 and 4800 Model Transmission With Retarder—Cross Section
4000 PRODUCT FAMILIES SERVICE MANUAL—ALLISON 4 th GENERATION

Legend For Foldout 3,C Is On The Opposite Side Of This Page.

Copyright © 2005 General Motors Corp. Foldout 3,C

 4000 PRODUCT FAMILIES SERVICE MANUAL—ALLISON 4 th GENERATION

Legend For Foldout 3,C

1 — Lockup clutch/damper
2 — Converter turbine
3 — Converter stator
4 — Converter pump
5 — Charging oil pump
6 — Front support
7 — Oil vent assembly
8 — Main housing
9 — Main shaft
10 — C3 clutch
11 — C4 clutch
12 — P2 sun gear
13 — Shim
14 — C5 clutch
15 — P3 sun gear
16 — C5 piston assembly
17 — C6 adapter housing module
18 — C6 clutch
19 — P4 ring gear
20 — Retarder stator
21 — Retarder rotor
22 — Retarder and output shaft module
23 — Output shaft
24 — C6 piston
25 — P4 planetary
26 — P4 sun gear
27 — Selective shim
28 — P4 shaft flange
29 — P3 planetary
30 — Control valve assembly
31 — P2 planetary
32 — P1 planetary
33 — C2 clutch
34 — C1 clutch
35 — Turbine shaft
36 — PTO drive gear
37 — Converter ground sleeve
38 — Converter housing

Foldout 3,C Copyright © 2005 General Motors Corp.

 F OLDOUT 3,C
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23

38 37 36 35 34 33 29 28 27 26 25 24
32 31 30 V05646.05.00

Foldout 3,C. 4700 and 4800 Model Transmission With Retarder and PTO Provision—Cross Section
 F OLDOUT 4,A

2 3
4
5
6
7 8
1 — Crank hub adapter 23 — Flexplate
2 — Bolt, M8 x 1.25 x 20 (12), A 24 — Flexplate 1 9
10
3 — Flexplate assembly 25 — Bolt, M8 x 1.25 x 25 (28), A
4 — Bolt plate (6) 26 — Flexplate adapter assembly
5 — Flexplate 27 — Ring gear
13 11
6 — Flexplate (3) 28 — Flexplate adapter 12
7 — Bolt, M8 x 1.25 x 25 (28), A 29 — Wear plate 14
15
8 — Flexplate adapter assembly 30 — Bolt, 5⁄16-18 x 2 (6), A
16
9 — Ring gear 31 — Bolt, M8 x 1.25 x 25 (12), A
10 — Flexplate adapter 32 — Flexplate assembly 17

11 — Wear plate 33 — Bolt plate (6) 18

12 — Bolt, M8 x 1.25 x 45 (12), A 34 — Flexplate

13 — Ring gear assembly 35 — Flexplate
20 21 19
14 — Ring gear 36 — Bolt, M8 x 1.25 x 25 (16 or 28), A
15 — Flexplate 37 — Flexplate adapter assembly 22
23
16 — Flexplate (3) 38 — Ring gear 24
17 — Bolt, M8 x 1.25 x 25 (28), A 39 — Flexplate adapter
25 26
18 — Flexplate adapter 40 — Wear plate 27
19 — Wear plate 41 — Bolt (2), A
28
20 — Bolt, M8 x 1.25 x 25 (12), A
Torque N·m lb ft 31
21 — Flexplate assembly 32
A 24–29 18–21 33
22 — Bolt plate (6) 29
34
30
35

36
37
38
39

40
41

L00182

Foldout 4,A. Flexplate and Adapter—Exploded View

 F OLDOUT 4,B

1
2 7

1 — Converter end plug 22 — Stator thrust plate assembly 8 9

6
2 — O-ring 23 — LH stator thrust washer 3 10
3 — Converter end plug, A 24 — Stator race
4
4 — Torque converter module 25 — Stator spring (13) 11
5
5 — Nut (36), B 26 — Stator roller (13)
12
6 — Torque converter cover assembly 27 — Stator and cam assembly
7 — Converter cover 28 — Shim, 0.27 mm (0.011 inch)
13
8 — Bushing — Shim, 0.48 mm (0.019 inch) 16 17
9 — Lockup piston sealring — Shim, 0.711 mm (0.028 inch) 15
10 — Lockup piston assembly 29 — Thrust bearing race 18
19
11 — Lockup piston sealring 30 — Pump thrust bearing assembly
21
12 — Damper assembly 31 — O-ring 22
13 — Lockup clutch backplate 32 — Thrust bearing race 23
24
14 — Bolt, M8 x 1.25 (44), C 33 — Torque converter pump assembly 26
15 — Thrust bearing assembly 34 — T-head bolt (36) 27 14
16 — Turbine hub sealring
28
17 — Turbine hub assembly Torque N·m lb ft
29
18 — Thrust bearing assembly A 50–60 37–44 25 30
19 — Star plate B 30–35 22–26 20 31
20 — Stator assembly C 24–29 18–21
21 — Retaining ring

32

33
34

V06850.01.00

Foldout 4,B. Torque Converter Module—Exploded View

4000 PRODUCT FAMILIES SERVICE MANUAL—ALLISON 4 th GENERATION

Legend For Foldout 5 Is On The Opposite Side Of This Page.

Copyright © 2005 General Motors Corp. Foldout 5

 4000 PRODUCT FAMILIES SERVICE MANUAL—ALLISON 4 th GENERATION
A B
1 — Converter housing module
2 — Breather assembly, M12 x 1.5, A
3 — Converter housing
4 — Speed sensor assembly
5 — O-ring
6 — Speed sensor retainer
7 — Bolt, M8 x 1.25 x 20, B
8 — Sensor shipping cover
9 — Converter housing gasket
10 — Bolt, M10 x 1.5 x 35 (25), C
Torque N·m
A 12–16
B 24–29
C 51–61
Foldout 5
Legend For Foldout 5
1 — Converter housing module
2 — Bolt, M10 x 1.5 x 35 (11), A
3 — Bearing retainer assembly
4 — Oil seal assembly
5 — Bearing retainer/bushing assembly
6 — Bushing
7 — Bearing retainer
8 — Sealring
9 — Sealring
10 — PTO gear assembly
11 — Ball bearing (2)
lb ft
9–12
12 — PTO gear
18–21 13 — Oil pump drive hub
38–45 14 — Sealring
15 — Speed sensor assembly
16 — O-ring
17 — Speed sensor retainer
18 — Bolt, M8 x 1.25 x 20, B
19 — Converter housing
20 — Breather assembly, M12 x 1.5, C
21 — Bolt, M10 x 1.5 x 35 (25), A
22 — Converter housing gasket
23 — Sensor shipping cover
24 — Bolt, M10 x 1.5 x 25 (10), A
25 — PTO cover
26 — PTO cover gasket
27 — Bolt, M10 x 1.5 x 25 (10), A
28 — PTO cover
29 — PTO cover gasket
Torque N·m lb ft
A 51–61 38–45
B 24–29 18–21
C 12–16 9–12
Copyright © 2005 General Motors Corp.
 F OLDOUT 5
A B

2
1
4

3
24
2
25
3 5 26

6
7

8
4
9

6 20
10 15

16 17 18
10 5 11
9
7 12

21 13

11
14
23
19

8
22

29
28
27

V05395 V03918.02

Foldout 5,A. Converter Housing Module—Exploded View Foldout 5,B. Converter Housing Module With PTO Provision—Exploded View
4000 PRODUCT FAMILIES SERVICE MANUAL—ALLISON 4 th GENERATION

Legend For Foldout 6 Is On The Opposite Side Of This Page.

Copyright © 2005 General Motors Corp. Foldout 6

 4000 PRODUCT FAMILIES SERVICE MANUAL—ALLISON 4 th GENERATION

Legend For Foldout 6

A 7 — Turbine shaft (PTO)

1 — Bolt, M10 x 1.5 x 65 (7), A 8 — Sealring (3)
2 — Bolt, M10 x 1.5 x 35 (7), A 9 — Rotating clutch drum
3 — Front support module 10 — Thrust bearing
4 — O-ring 11 — Rotating clutch hub assembly (complete)
5 — Oil seal assembly 12 — Rotating clutch hub bushing
6 — Bolt, M10 x 1.5 x 65 (8), A 13 — Rotating clutch hub assembly
7 — Pump housing assembly 14 — Thrust bearing
8 — Bushing 15 — Turbine shaft retaining ring
9 — Pump housing 16 — C2 piston sealring
10 — Pump housing (PTO) 17 — C1 piston sealring
11 — Pump gear set 18 — External sealring
12 — Bushing 19 — C2 piston
13 — Wear plate 20 — C2 spring assembly
14 — Bolt, M10 x 1.5 x 25 (14), A 21 — C2 spring plate
15 — Front support assembly (complete) 22 — Internal retaining ring
16 — Ground sleeve (PTO) 23 — C1 sealring
17 — Ground sleeve 24 — C1 piston
18 — Front support assembly 25 — C1 spring assembly
19 — Dowel pin, 10 x 32 (2) 26 — Rotating clutch balance piston
20 — Front support 27 — Rotating clutch balance piston sealring
21 — Front support sleeve 28 — Balance piston retaining ring
22 — Spring 29 — C1 clutch apply plate
23 — Ball 30 — C1 friction plate (7)
24 — Dowel pin 31 — C1 reaction plate (6)
25 — Sealring (3) 32 — C1 clutch backplate
26 — Roller bearing assembly 33 — External retaining ring
34 — C1 drive hub
Torque N·m lb ft
35 — Thrust bearing (2)
A 51–61 38–45
36 — C2 drive hub
B 37 — C2 reaction plate (7)
38 — C2 friction plate (7)
1 — Rotating clutch module
39 — C2 clutch backplate
2 — O-ring
40 — Internal retaining ring
3 — Turbine shaft assembly
41 — Sun gear assembly (complete)
4 — Turbine shaft
42 — Thrust bearing
5 — Turbine shaft bushing
43 — Internal retaining ring
6 — Turbine shaft assembly (PTO)

Foldout 6 Copyright © 2005 General Motors Corp.

 F OLDOUT 6
A B

2
3
4
8
2
5 9
7

1
7 11
8 6 10
4
12 13
5 9
3
21

14
22 15
1 16
17
23 18
10
24 19
11
6 25
12 13 16 20
15 26
27
28
33 29
14 18
17 30
20 34 31
19
35

36
21
35

25 37
38 32

26
23 22

24

39

40
41

42

V02818.01 43 V06870.01.00

Foldout 6,A. Front Support and Oil Pump Module—Exploded View Foldout 6,B. Rotating Clutch Module—Exploded View
 F OLDOUT 7

4 1
1 — C3/C4 clutch assembly 22 — Internal harness connector cap
5
2 — Bolt, M10 x 1.5 x 90 (14), A 23 — Identification plate
6
3 — C3 backplate assembly (complete) 24 — Rivet
4 — Clutch backplate assembly 25 — Bolt, M8 x 1.25 x 20, B 7
5 — P1 ring thrust plate (6) 26 — Speed sensor assembly 8

6 — P1 planetary ring gear 27 — O-ring

14 11
7 — C3 clutch friction plate (5) 28 — Speed sensor bracket 15
8 — C3 clutch reaction plate (5) 29 — Speed sensor shipping cover
9
9 — C3 piston return plate assembly 30 — Main housing assembly 10
29
10 — C3 clutch piston assembly 31 — Main housing
12
11 — C3 clutch housing assembly 32 — Recoil insert 26
(complete) 33 — Fill tube seal 16
27 13
12 — P1 ring thrust plate (6) 34 — Oil fill tube
13 — C3 clutch housing 35 — Tapping screw, M8 x 25, B 17
25
14 — C4 clutch reaction plate (6) 36 — Oil fill tube bracket 28
34
37 18
15 — C4 clutch friction plate (5) 35
37 — Oil level indicator
23 24
16 — C4 piston return plate assembly
Torque N·m lb ft 36
17 — C4 clutch piston assembly 33
18 — C4 clutch housing A 51–61 38–45
19 — C5 clutch friction plate (8) B 24–29 18–21
20 — C5 clutch reaction plate (9)
22
21 — Bolt, M10 x 1.5 x 35 (14), A 31

21
19
20

30

32
V04763.06.00

Foldout 7. Main Housing Module—Exploded View

 F OLDOUT 8

WIDE RATIO
4
1
5
2
6

1 — Shim (non-selective)—4700 and 4800 models

1 — Shim (selective)—except 4700 models, 0.245–0.295 mm (0.0097–0.0116 inch) (marked with 1 slot)
1 — Shim (selective)—except 4700 models 4070, 0.515–0.565 mm (0.02103–0.0222 inch) (marked with 2 slots)
1 — Shim (selective)—except 4700 models, 0.785–0.835 mm (0.0310–0.0328 inch) (marked with 3 slots)
1 — Shim (selective)—except 4700 models, 1.055–1.105 mm (0.0416–0.0435 inch) (marked with 4 slots) 7
1 — Shim (selective)—except 4700 models, 1.325–1.375 mm (0.0522–0.0541 inch) (marked with 5 slots)
1 — Shim (selective)—except 4700 models, 1.595–1.645 mm (0.0628–0.0647 inch) (marked with 6 slots)
1 — Shim (selective)—except 4700 models, 1.865–1.915 mm (0.0735–0.0753 inch) (not marked with slots)
2 — Thrust bearing

Wide Ratio Close Ratio CLOSE RATIO

3 — Main shaft module 3 — Main shaft module 4
4 — External retaining ring (spiral) 4 — External retaining ring (spiral) 1
5 — P2 sun gear 5 — P2 sun gear 5
2
6 — Bearing spacer 6 — Bearing spacer 6
7 — Main shaft 7 — P3 sun gear
8 — Main shaft
3

V06878

Foldout 8. Main Shaft Module—Exploded View

4000 PRODUCT FAMILIES SERVICE MANUAL—ALLISON 4 th GENERATION

Legend For Foldout 9 Is On The Opposite Side Of This Page.

Copyright © 2005 General Motors Corp. Foldout 9

 4000 PRODUCT FAMILIES SERVICE MANUAL—ALLISON 4 th GENERATION

Legend For Foldout 9

A B
1 — P1 planetary module 1 — P2 planetary module
2 — Internal retaining ring 2 — Retaining ring
3 — P1 planetary carrier assembly 3 — P2 planetary carrier assembly
4 — Retaining ring 4 — Internal retaining ring
5 — P1 indexing ring 5 — P2 indexing ring
6 — P1 pinion spindle (6) 6 — Carrier and bushing assembly
7 — P1 planetary carrier/bushing assembly 7 — P2 planetary carrier
8 — P1 planetary carrier 8 — Bushing
9 — P1 carrier bushing 9 — Thrust washer (4)
10 — P1 thrust washer (6) 10 — Roller bearing (8)
11 — P1 pinion gear (6) 11 — P2 pinion gear (4)
12 — Roller bearing assembly (12) 12 — Thrust washer (4)
13 — P1 thrust washer (6) 13 — P2 pinion spindle (4)
14 — Thrust bearing assembly 14 — Thrust bearing assembly
15 — P2 ring gear 15 — P3 planetary ring gear

Foldout 9 Copyright © 2005 General Motors Corp.

 F OLDOUT 9,A,B
A B

1
2

14

15
4 3
3

4 5

5
6
7

7 8 15
8

9
14

9
13
10

10
11
11
12 12
13

V06852

V03630.01

Foldout 9,A. P1 Planetary Module—Exploded View Foldout 9,B. P2 Planetary Module—Exploded View
 F OLDOUT 9,C

1 — P3 carrier module 24 — Pressure tap plug 2 12 16 14

3 17 15
2 — Internal retaining ring, 219 OD 25 — O-ring, 8.92 ID
3 — P3 indexing ring 26 — Ball bearing assembly 4 1 18

4 — P3 planetary carrier 27 — C6 reaction plate (9) 5

19
5 — P4 shaft flange 28 — C6 friction plate (8) 7 6
8
6 — Shim locating ring 29 — C6 backplate 9 20
13
7 — P3 planetary spindle (4) 30 — P4 sun gear 10
8
8 — P3 thrust washer (8) 31 — Thrust bearing
9 — P3 pinion gear (4) 32 — P4 carrier assembly
10 — Roller bearing assembly (8) 33 — Internal retaining ring 11
11 — Flange head bolt, M12 x 1.75 x 45 (14), A 34 — Internal retaining ring, 235 OD
12 — Shim, (selective), 0.27 mm 35 — Indexing ring
— Shim, (selective), 0.54 mm 36 — P4 carrier and bushing assembly
— Shim, (selective), 0.81 mm
37 — P4 carrier
— Shim, (selective), 1.08 mm 22 26
— Shim, (selective), 1.35 mm 38 — P4 carrier bushing
21 27
— Shim, (selective), 1.62 mm 39 — P4 planetary spindle (6) 28

— Shim, (selective), 1.89 mm 40 — P4 planetary thrust washer (12)

— Shim, (selective), 2.16 mm 41 — P4 pinion gear (6) 23
— Shim, (selective), 2.43 mm 25
42 — Caged needle bearing (12) 24
13 — Adapter housing gasket
43 — C6 clutch drum hub 23
14 — C6 adapter housing module 25
44 — Thrust bearing assembly 24
15 — Piston assembly 30 29
45 — P4 ring gear and hub assembly
16 — External retaining ring
46 — P4 ring gear 31
17 — Piston return spring assembly 32
47 — P4 ring gear hub
18 — Piston
48 — Retaining ring
19 — Piston OD sealring 43
49 — Star tolerance ring
20 — Piston ID lip-type sealring
44
21 — Adapter housing assembly Torque N·m lb ft
A 100–120 74–88 45
22 — Adapter housing 46

23 — Plug assembly (2), B B 10–13 7–10

33 47
34 37 49
38 36 48
35 39

41
42

40
V06854.01.00

Foldout 9,C. P3 Planetary Module and C6 Adapter Housing Module (4700 and 4800 Models)—Exploded View
 F OLDOUT 10,A

1 — Rear cover gasket 25 — Internal sealring

2 — Bolt, M12 x 1.7 x 45 (19), A 26 — Roller bearing cup
3 — Washer 27 — Rear cover assembly
4 — Rear cover and P3 planetary module 28 — Brass washer
5 — P3 planetary carrier assembly 29 — Plug, 3⁄4-16 straight thread, B 19
21
6 — Output shaft assembly 29 — Tachograph plug, C 1
22
7 — Bushing 30 — Rear cover
8 — Output shaft 31 — Dowel pin (2) 3
23 4 2
5
9 — Internal retaining ring 32 — Speed sensor assembly 20
24
10 — P3 indexing ring 33 — O-ring 35
25 32
11 — P3 planetary carrier 34 — Speed sensor retainer
26 41
12 — Thrust washer 35 — Bolt, M8 x 1.25 x 20, B 34
6
7 27 33
13 — External retaining ring 36 — Roller bearing cup 30
9
14 — P3 planetary spindle (4) 37 — Cone and roller bearing assembly 8
10
15 — P3 thrust washer (4) 38 — Belleville washer 31
11
16 — P3 pinion gear (4) 39 — Bearing retainer locknut, D
17 — Roller bearing assembly (4 groups of 2) 40 — Output seal assembly 29
12 28
18 — P3 thrust washer (4) 41 — Speed sensor shipping cover 13
31
19 — Cone and roller bearing assembly
Torque N·m lb ft
20 — Rear cover assembly A 100–120 74–88 14 36
21 — External retaining ring B 24–29 18–21
22 — Spring and retainer assembly C 60–67 45–49
D 74–88 55–65
23 — C5 clutch piston 15
16
24 — Piston sealring 37
17
38
18
39

40

V06856.01.00

Foldout 10,A. Rear Cover and P3 Planetary Module—Exploded View

 F OLDOUT 10,B

1 — Rear cover gasket

2 — Bolt, M12 x 1.75 x 45 (14), A 2

3 — Bracket
4 — Bolt, M12 x 1.75 x 222.5 (5), A 3

5 — Rear cover module

6 — Output shaft assembly
7 — Bushing 1

8 — Output shaft
9 — Roller bearing assembly
7 4
10 — Rear cover assembly 6 5
11 — External retaining ring
12 — C5 piston spring return retainer assembly 8
9
13 — C5 clutch piston 11
14 — External sealring
12
15 — Internal lip-type sealring
16 — Roller bearing cup 13
17 — Rear cover assembly 10
14
18 — Rear cover 23
15 22
19 — Tachograph plug, B
16 30
20 — Washer 24
17 25
21 — Roller bearing cup 18
22 — Speed sensor assembly
23 — Self-locking bolt, M8 x 1.25 x 20, C
24 — Speed sensor retainer 26
25 — O-ring 27 19 20
26 — Roller bearing assembly
28
27 — Belleville washer
28 — Bearing retainer locknut 29

29 — Output seal assembly 21

30 — Sensor shipping cover

Torque N·m lb ft
A 100–120 74–88
B 60–67 44–50
C 24–29 18–21

V06858.01.00

Foldout 10B. Rear Cover and Output Shaft Module (4700 and 4800 Models)—Exploded View
 4000 PRODUCT FAMILIES SERVICE MANUAL—ALLISON 4 th GENERATION

Legend For Foldout 10,C

1 — Stator housing gasket 31 — Retarder housing assembly

2 — Retarder and P3 planetary module 32 — Retaining ring
3 — P3 planetary carrier assembly 33 — Valve plug
4 — Output shaft assembly 34 — O-ring
5 — Bushing 35 — Valve spring
6 — Output shaft 36 — Retarder valve
7 — Internal retaining ring 37 — Spring pin
8 — P3 indexing ring 38 — Retarder housing subassembly
9 — P3 planetary carrier 39 — Tachograph plug, A
10 — Thrust washer 40 — Washer
11 — External retaining ring 41 — Retarder housing
12 — P3 planetary spindle (4) 42 — Gasket
13 — P3 thrust washer (4) 43 — Cover
14 — P3 pinion gear (4) 44 — Bolt, M8 x 1.25 x 25 (9), B
15 — Roller bearing assembly (4 groups of 2) 45 — Temperature sensor assembly (TID2)
16 — P3 thrust washer (4) 46 — O-ring
17 — Cone and roller bearing assembly 47 — Retainer
18 — Retarder stator assembly 48 — Bolt, M8 x 1.25 x 20, B
19 — External retaining ring 49 — Valve plug
20 — Spring and retainer assembly 50 — Retaining ring
21 — C5 clutch piston 51 — Roller bearing cup
22 — C5 piston outer sealring 52 — Bolt, M8 x 1.25 x 25 (3), C
23 — C5 piston inner sealring 53 — Speed sensor assembly
24 — Roller bearing cup 54 — O-ring
25 — Retarder stator 55 — Speed sensor retainer
26 — O-ring 56 — Bolt, M8 x 1.25 x 20, B
27 — Retarder sealring 57 — Cone and roller bearing assembly
28 — Retarder housing gasket 58 — Belleville washer
29 — Rotor assembly 59 — Bearing retainer locknut, D
30 — Retarder sealring 60 — Oil seal assembly

Copyright © 2005 General Motors Corp. Foldout 10,C

 4000 PRODUCT FAMILIES SERVICE MANUAL—ALLISON 4 th GENERATION
Legend For Foldout 10,C (cont’d)

61 — Sensor shipping cover 87 — Retarder control valve cover gasket

62 — Bolt, M12 x 1.75 x 55 (12), E 88 — Retarder control valve cover
63 — Separator plate 89 — Bolt, M8 x 1.25 x 30 (3), B
64 — Retarder connector cover 90 — Pressure tap plug assembly
65 — Retarder control valve assembly
91 — O-ring
66 — Straight thread plug assembly
92 — Pressure tap plug, F
67 — Straight thread plug
93 — Bolt, M8 x 1.25 x 115 (9), B
68 — O-ring
94 — Bolt, M12 x 1.75 x 165 (4), E
69 — Spring
70 — Exhaust backfill valve 95 — Bolt, M12 x 1.75 x 105 (2), E

71 — Solenoid and connector assembly 96 — Bolt, M10 x 1.5 x 160 (4), G

72 — Solenoid 97 — Gasket
73 — O-ring seal 98 — Jumper manifold
74 — O-ring 99 — Bolt, M10 x 1.5 x 30, G
75 — Retarder control valve body 100 — Remote side manifold
76 — Solenoid retaining pin 101 — Bolt, M10 x 1.5 x 160 (3), G
77 — Regulator valve
78 — Spring Torque N·m lb ft
A 60–67 45–49
79 — Straight thread plug assembly
B 24–29 18–21
80 — O-ring C 12–15 9–11
81 — Straight thread plug D * *
82 — Straight thread plug assembly E 100–120 74–88
F 10–13 7–10
83 — Straight thread plug
G 51–61 38–45
84 — O-ring
85 — Spring
* Before module is installed 193–207 N·m (143–152 lb ft);
86 — Relay valve After Module is installed 74–88 N·m (55–64 lb ft)

Foldout 10,C Copyright © 2005 General Motors Corp.

 F OLDOUT 10,C
1

17
19
20
21
18
22
3
2
4 23
5 24 25
6
7
8
26
9

10
11
12

13
14
15
65
16
66 67
68
62 69
71 70
90
52 48 89
64
47 72 92
27 45 91
73
74 93
46 75
61
28 88
63 76 87
29 30 54 55 56
77 86
38 53 78
41 79 85 82
50 80
40 49 51 84
81
39 83
37 57
58
31 59
35 36 60
33 42
32 43
34 44

94
91 100
96
95 97 101
98
99
V06859.01.01

Foldout 10,C. Retarder and P3 Module—Exploded View

 F OLDOUT 10,D
1 — Stator housing gasket 53 — Retarder connector cover
54 — Retarder control valve assembly 1
2 — Retarder module 4
3 — Output shaft assembly 55 — Straight thread plug assembly 3
4 — Bushing, 28 ID 56 — Straight thread plug
5 — Output shaft 57 — O-ring
5
6 — Cone and roller bearing assembly 58 — Spring
7 — Retarder stator assembly 59 — Exhaust backfill valve 6
8
8 — External retaining ring, 181 ID 60 — Solenoid and connector assembly 9
9 — C5 piston return spring and retainer assembly 61 — Solenoid 10
62 — O-ring seal 7
10 — C5 clutch piston
63 — O-ring 11
11 — External sealring, 315.17 ID
12 — Internal lip-type sealring, 214.06 OD 64 — Retarder control valve body 2
13 — Roller bearing cup 65 — Solenoid retaining pin
12
14 — Retarder stator housing 66 — Regulator valve
67 — Spring 13
15 — O-ring, 11.48 ID
16 — Rotating sealring, 146 OD 68 — Straight thread plug assembly
17 — Retarder housing gasket 69 — O-ring
14
18 — Rotor assembly 70 — Straight thread plug
19 — Rotating sealring, 146 OD 71 — Straight thread plug assembly 15
20 — Flange head bolt, M8 x 1.25 x 25 (3), A 72 — Straight thread plug
21 — Retarder housing assembly 73 — O-ring
22 — Internal retaining ring, 45.82 OD 74 — Spring
23 — Valve plug 75 — Relay valve
24 — O-ring, 34.6 ID 76 — Retarder control valve cover gasket
25 — Valve spring, 36.17 OD x 114.3 77 — Retarder control valve cover 54
26 — Retarder valve 78 — Bolt, M8 x 1.25 x 30 (3), B
27 — Spring pin, 5 x 45 79 — Pressure tap plug assembly
55 56
28 — Plug and retarder housing assembly 80 — O-ring 57
81 — Pressure tap plug, F 58
29 — Tachograph plug, M18 x 1.5, B 60 59
30 — Washer, M18 82 — Bolt, M8 x 1.25 x 115 (9), B 79
78
31 — Retarder housing 83 — Gasket 20 38 53
51 61 81
32 — Gasket 84 — Jumper manifold 37 80
16 35 62
33 — Cover 85 — Bolt, M10 x 1.5 x 30, G 63 82
34 — Bolt, M8 x 1.25 x 25 (9), D 86 — Remote side manifold 36 64
35 — Temperature sensor assembly 50
87 — Bolt, M10 x 1.5 x 354 (3), G 77
36 — O-ring 17
37 — Thermistor protection bracket 88 — Bolt, M10 x 1.5 x 345 (7), G 52 65 76
38 — Self-locking bolt, M8 x 1.25 x 20, D 89 — Bolt, M12 x 1.75 x 350 (4), E 18 19 47 48 49 75
90 — Bolt, M12 x 1.75 x 105 (2), E 66
39 — Valve plug 28 46
40 — Internal retaining ring, 45.82 OD 31 68 67 74 71
40 69
Torque N·m lb ft 30 39 41 73
41 — Roller bearing cup 29 70
42 — Cone and roller bearing assembly A 12–15 9–11 72
43 — Belleville washer B 60–67 45–49 27 42
44 — Bearing retainer locknut, C C * * 43
45 — Oil seal assembly D 24–29 18–21 21 44
46 — Speed sensor assembly E 100–120 74–88 25 26 45
F 10–13 7–10 23 32
47 — O-ring, 15.37 ID 22
G 51–61 38–45 33
48 — Speed sensor retainer 24 34 89
49 — Self-locking bolt, M8 x 1.25 x 20, D
50 — Sensor cover * Before module is installed 193–207 N·m (143–152 lb ft); 88
51 — Flange head bolt, M12 x 1.75 x 55 (12), E 86
After Module is installed 74–88 N·m (55–64 lb ft) 83
52 — Separator plate 90 84
87
85

V06860.01.01
Foldout 10D. Retarder and Output Shaft Module (4700 and 4800 Models)—Exploded View
 4000 PRODUCT FAMILIES SERVICE MANUAL—ALLISON 4 th GENERATION

Legend For Foldout 11

1 — Control valve module 51 — Accumulator plug (2)

2 — Suction filter assembly kit 52 — Accumulator plug (2)
3 — Bolt, M6 x 1.0 x 30, A 53 — Accumulator spring (2)
4 — Suction filter assembly 54 — Switch assembly
5 — Suction filter 55 — Switch
6 — Face seal 56 — Bracket
7 — Suction filter gasket
57 — Bolt, M6 x 1.0 x 95 (12), A
8 — Control harness assembly
9 — Connector assembly 58 — Solenoid body assembly
10 — Electronic connector 59 — Body assembly valve and pin
11 — Seal 60 — Valve body
12 — Sealring 61 — Pin (3)
13 — Standoff assembly 62 — Variable bleed solenoid (TCC)
14 — Cavity plug 63 — O-ring
15 — Bolt, 20F connector, C 64 — O-ring
16 — Temperature sensor (OILT) 65 — TCC valve
17 — Connector assembly 66 — Spring
18 — Connector, 2-Way 67 — Variable bleed solenoid (PCS1)
19 — Pin terminal 68 — O-ring
20 — Pin terminal 69 — O-ring
21 — Secondary lock 70 — PCS1 valve
22 — Connector Assembly (OLS) 71 — Spring
23 — Terminal 72 — Variable bleed solenoid (PCS2)
24 — Terminal 73 — O-ring
25 — Connector, 2-way 74 — O-ring
26 — Connector assembly (SS1) 75 — PCS2 valve
27 — Terminal 76 — Spring
28 — Terminal 77 — Clip
29 — Connector, 2-way 78 — Diagnostic valve
30 — Channel 79 — Spring
31 — Solenoid connector assembly (SS2) 80 — Variable bleed solenoid (PCS3)
32 — Connector, 2-way 81 — O-ring
33 — Terminal 82 — O-ring
34 — Terminal 83 — PCS3 valve
35 — 2-Way solenoid connector (PCS4) 84 — Spring
36 — 2-Way solenoid connector (PCS5) 85 — Variable bleed solenoid (PCS4)
37 — 2-Way solenoid connector (PCS6) 86 — O-ring
38 — 2-Way solenoid connector (PCS1) 87 — O-ring
39 — 2-Way connector (C3 pressure switch) 88 — PCS4 valve
40 — Terminal 89 — Spring
41 — Terminal 90 — Variable bleed solenoid (Main Mod)
42 — 2-Way connector 91 — O-ring
43 — 2-Way solenoid connector (TCC) 92 — O-ring
44 — 2-Way solenoid connector (PCS2) 93 — Solenoid separator plate
45 — 2-Way solenoid connector (PCS3) 94 — Bolt, M6 x 1.0 x 60 (2), A
46 — Shoulder bolt, M6 1.0 x 45 (3), B 95 — Main valve body assembly
47 — Bracket 96 — Retention pin 5 OD x 43
48 — Bolt, M6 1.0 x 45 (2), A 97 — Converter flow valve
49 — Face Seal 98 — Spring
50 — Accumulator spring (2) 99 — Valve stop

Copyright © 2005 General Motors Corp. Foldout 11

 4000 PRODUCT FAMILIES SERVICE MANUAL—ALLISON 4 th GENERATION

Legend For Foldout 11 (cont’d)

100 — Retention pin 3 OD 43 144 — O-ring

101 — Lube regulator valve 145 — Pressure tap plug (9), A
102 — Spring 146 — Filter cover (2)
103 — Valve stop 147 — Filter cover gasket (2)
104 — Retention pin 5 OD x 43 148 — O-ring (2)
105 — Main regulator valve 149 — O-ring (2)
106 — Spring 150 — Oil filter (2)
107 — Valve stop 151 — Accumulator plug
108 — Control main valve 152 — Accumulator spring
109 — Spring 153 — Accumulator retaining bracket
110 — Clip 154 — Bolt, M6 x 1.0 x 60 (4), A
111 — Retention pin, 2.5 OD x 40 155 — C6 clutch body assembly
112 — Solenoid assembly 156 — C6 clutch body
113 — O-ring 157 — Spring
114 — O-ring 158 — Retention pin 2.5 OD x 30
115 — Control valve body 159 — C6 enable valve
116 — Spring pin, 5 OD x 55 160 — Solenoid assembly
117 — C2 latch valve 161 — O-ring
118 — Spring 162 — O-ring
119 — Valve stop 163 — Solenoid protective plate
120 — Retention pin, 5 OD x 43 164 — Push-on nut
121 — Exhaust backfill valve 165 — Spring
122 — Spring 166 — C6 clutch trim valve
123 — Valve stop 167 — Solenoid assembly
124 — Retention pin, 5 OD x 43 168 — O-ring
125 — C1 latch valve 169 — O-ring
126 — Spring 170 — Solenoid retaining bracket
127 — Valve stop 171 — Screw
128 — Retention pin, 5 OD x 43 172 — Case gasket
129 — Converter regulator valve 173 — Bolt, M10 x 1.5 x 55 (34), E
130 — Spring 174 — Bolt, M10 x 1.5 x 100 (25, 4 inch sump), E
131 — Valve stop
132 — Retention pin 3 OD x 43 Torque N·m lb ft
133 — Bolt M6 x 1.0 x 45 (2), A A 10–13 7–10
134 — Oil level sensor assembly B 5–8 4–6
135 — Ferrule Viton® (2) C 2.5–3.5 22–31 lb inch
136 — Separator plate
137 — Channel plate gasket D 25–32 18–24
138 — Channel plate assembly E 51–61 38–45
139 — Dowel pin (2)
140 — Channel plate
141 — Oil drain plug assembly, D
142 — O-ring
143 — Pressure tap plug assembly

Foldout 11 Copyright © 2005 General Motors Corp.

 F OLDOUT 11
1 (Cont'd)

93 95 99
10 98 133
1 9 96 97 134
100 103
11 128
102
132 124 104
8 101
12 120 107
94
43 106 135
111
44 14 46 105 110
39
42 45 109
40 41 13 108
3 112
30 129 114
2 38 130 113
26 131 125
6 126 115
29
4 37 127
28 121 172
5 27 15 116
25 122
24 123
36 23 117
35 22 21 118
20
32 19 119 150
7 33 18 136
34 16
31 17
137
149
54 57 47
62 154 148
48 63
55 64 153
49 147 138
65
53 66 152
56 139
50
67 146
52 151
58 68 140
51 69
70 155
71 156
90 92 61
91 72
73 157
74 159 160
59 60 161
75 171 158 162
76
85 87 141
86 89
88 143 144
170 142
169 145
168 163 164
80 82 167 166
81 84 165
78
83 79
77

V09483.00.00 173
174 V09482.00.00

Foldout 11. Control Valve Module—Exploded View

4000 PRODUCT FAMILIES SERVICE MANUAL—ALLISON 4 th GENERATION

Legend For Foldout 12 Is On The Opposite Side Of This Page.

Copyright © 2005 General Motors Corp. Foldout 12

 4000 PRODUCT FAMILIES SERVICE MANUAL—ALLISON 4 th GENERATION
A 11 — Temperature gauge kit
1 — Output flange
2 — Output flange assembly
3 — Slinger
4 — Output flange
5 — Output flange
6 — Output flange
7 — Output yoke assembly
8 — Slinger
9 — Output yoke
10 — Output yoke
11 — Output yoke
12 — Dropbox coupling
13 — Shipping cover
14 — Shipping cover
15 — O-ring, 75.9 mm ID
16 — O-ring, 9.1 mm ID
17 — Retaining plate
18 — Bolt, M14 x 2 x 70, B
Torque N·m
A 30–35
B 70–80
B aluminum end cap
1 — Converter shipping bracket (3)
2 — Bolt, M10 x 1.5 x 25 (3), A
3 — Rear support bracket (front)
4 — Rear support bracket (rear)
5 — Remote mount cooler
5 — Retarder oil cooler
6 — Remote mount gasket
7 — Remote mount manifold
8 — Cooler port cover
9 — Bolt, M10 x 1.5 x 28 (6), A
10 — 90 degree fitting
Foldout 12
Legend For Foldout 12
12 — Temperature sender adapter
13 — Shipping plug (2)
14 — Straight fitting
15 — Shipping plug assembly
16 — Cooler port plug (2)
17 — Pilot screw (2)
18 — PTO gasket
19 — Bolt, M10 x 1.5 x 35 (8), A
20 — Clutched drive PTO assembly
21 — Hose assembly
22 — 90 degree hose fitting
23 — Pilot screw (2)
24 — PTO gasket
25 — Bolt, M10 x 1.5 x 25 (8), A
26 — Hose assembly
27 — 90 degree fitting
28 — Bolt, tie rod, 3⁄8-24 x 7 (4) for use with steel
end cap
28 — Bolt, tie rod, 3⁄8-16 x 75⁄8 (4) for use with
aluminum end cap
lb ft
29 — Steel gas cap
22–26
29 — Aluminum gas cap
51–60
30 — O-ring (2) 91.7 mm ID for use with steel end
cap
30 — O-ring (2) 101.6 mm ID for use with
31 — Steel hydraulic cap
31 — Aluminum hydraulic cap
32 — External lip-type seal, 31⁄2 inch ID
33 — Sealring
34 — Piston
35 — Cylinder body for use with steel end cap
35 — Cylinder body for use with aluminum end cap
Torque N·m lb ft
A 51–61 38–45
Copyright © 2005 General Motors Corp.
 F OLDOUT 12A,B
A B
3
1
4

5
3 2

4 13
14
15
16
5
11

8 10
12
120
150
0
12 250 °C
300
°F

0
10
TRANS
OIL
TEMP

6
31
6 7 20
30 9
8 30 19
7 17
29

28 18
9

10 32
33 21
13 22
34
32

33

11
1
2
15
24
16 25
17 1 2
18

12
14

27
23 26

V07030.03.00 V07331.01.00

Foldout 12,A. Output Flange And Yoke—Exploded View Foldout 12,B. Support Equipment—Exploded View
 F OLDOUT 12,C
1

1 — Bolt, M10 x 1.5 x 60 (16), B

2 — Hose adapter
3 — Gasket, manifold to water (2)
4 — Gasket, integral cooler 2
5 — Bolt, M8 x 1.5 x 25 (6), A
6 — Gasket, manifold to cooler (2)
7 — Cooler, integral
8 — Bolt, M10 x 1.5 x 50, B 3
9 — Bolt, M10 x 1.5 x 187.5 (7), B 11 12
10 — Bolt, M12 x 1.75 x 195 (8), C 4
11 — Manifold assembly, integral cooler 13

12 — Plug assembly, shipping, SAE No. 16

13 — O-ring 24 15
14 — Plug assembly, pressure tap 23
14
15 — O-ring, 11.6 mm ID
16
16 — Manifold, integral, strapped 21
17 — Plug assembly, pressure tap
22
18 — O-ring, 8.9 mm ID
19 — Plug assembly, pressure tap 17
20 — Plug, pressure tap
21 — Plug assembly, pressure tap 18

22 — O-ring, 9.3 mm ID 10 19 20
23 — Plug assembly, pressure tap
24 — O-ring, 8.9 mm ID 9
5
Torque N·m lb ft
A 24–29 18–21
B 51–61 38–45 8
C 100–120 74–88 6
6

V07034.01.00

Foldout 12,C. Integral Retarder Sump Cooler—Exploded View

 F OLDOUT 13
LOCKUP

LUBE
CONVERTER OUT COOLER
FILTER

LUBE LUBE
CONVERTER IN

TORQUE ALLISON 4th GENERATION

CONVERTER Orifice HYDRAULIC SCHEMATIC — NEUTRAL
3000 AND 4000 PRODUCT FAMILIES
EX EX

CONVERTER CONVERTER
FLOW REGULATOR EX
LUBE
REGULATOR

REAR
SPLITLINE

TCC * EX PCS1 EX PCS2 EX PCS3 EX PCS4

N/C N/O N/O N/C N/C
EX EX EX EX
EX

Accum- Accum- Accum- Accum-

CONTROL MAIN
ulator ulator ulator ulator MAIN
EX
EX EX EX EX EX MAIN
FILTER

SS1
N/C

Pressure
Orifice EX Relief

***
PS1 EX
DIAGNOSTIC PCS6 EX
EX N/C SS2 MAIN
EX N/C REGULATOR
EX PUMP

6-Speed
Only EX EXHAUST
BACKFILL Accum-
ulator

MAIN SUCTION
EX MOD ** FILTER
EX N/C
C2 EX EX
LATCH EX
C1
LATCH SUMP
C1 C2 C3 C4 C5 C6
NOTES:
LEGEND:
* TCC Solenoid is generally ON from 2nd-range thru 6th-range
MAIN COOLER/LUBE
C1 C2 C3 C4 C5 C6 ** Main Mod Solenoid may be ON in Reverse, Neutral, Low (7-speed), CONTROL MAIN EX. BACKFILL
1st, or 2nd as determined by calibration. EXHAUST CONVERTER
*** PS1 = Diagnostic Pressure Switch SUCTION C5
= 7-Speed Transmissions only MAIN MOD
V09253.00.00

Foldout 13. 4000 Product Family Hydraulic Schematic—Neutral