3K Service Manual 4th Gen SM4013EN 200906

SERVICE MANUAL
3000
PRODUCT FAMILY
ALLISON 4th GENERATION CONTROLS
SM4013EN
200906
3000 PRODUCT FAMILY
SM4013EN
SERVICE MANUAL ALLISON 4th GENERATION CONTROLS
Service
Manual
2009 JUNE
SM4013EN
Allison Transmission
Allison 4th Generation Controls
VOCATIONAL MODELS
3000 Product Family
3000
3000
3000
3000
3000
3000
EVS
HS
MH
PTS
RDS
TRV
Printed in USA
3200
3200
3200
3200
3500
3500
MH
ORS
SP
TRV
EVS
ORS
3500 RDS
3500 SP
3700 SP
B 300
B 400
T 250
T
T
T
T
T
T
255
260
265
270
280
310
Copyright 2009 Allison Transmission, Inc.
T 325
T 350
T 375
SERVICE MANUAL3000 Product FamilyAllison 4th Generation

ControlsVOCATIONAL MODELS
TRADEMARK USAGE
The following trademarks are the property of the companies indicated:
Allison Diagnostic Optimized Connection (Allison DOC) is a trademark of Allison Transmission Inc.
Biobor JF is the registered trademark for a biological inhibitor manufactured by Hammonds Fuel
Additives Company.
DEXRON is a registered trademark of Allison Transmission Inc..
Spiralock is a registered trademark of Spiralock of Michigan.
Teon is a registered trademark of the DuPont Corporation.
TranSyndTM is a trademark of Castrol, Ltd.
VitonTM is a trademark of DuPont Corporation.
ii

IMPORTANT SAFETY INFORMATION

IT IS YOUR RESPONSIBILITY to be completely familiar with the warnings and cautions in this manual.
These warnings and cautions advise of specic methods or actions that can result in personal injury,
equipment damage, or cause the equipment to become unsafe. These warnings and cautions are not
exhaustive. Allison Transmission could not possibly know, evaluate, or advise the service trade of all
conceivable procedures by which service might be performed or of the possible hazardous consequences
of each procedure. Consequently, Allison Transmission has not undertaken any such broad evaluation.
Accordingly, ANYONE WHO USES A SERVICE PROCEDURE OR TOOL WHICH IS NOT RECOMMENDED
BY ALLISON TRANSMISSION MUST rst be thoroughly satised that neither personal safety nor equipment
safety will be jeopardized by the service methods used.
Proper service and repair is important to the safe and reliable operation of the equipment. The service
procedures recommended by Allison Transmission (or the vehicle manufacturer) and described in this
manual are effective methods for performing service and diagnostic operations. Some procedures require
using specially designed tools. Use special tools when and in the manner recommended.
The WARNINGS, CAUTIONS, and NOTES in this manual apply only to the Allison transmission and not
to other vehicle systems which may interact with the transmission. Be sure to review and observe any
vehicle system information provided by the vehicle manufacturer and/or body builder at all times the Allison
transmission is being serviced.
WARNINGS, CAUTIONS, NOTES

Three types of headings are used in this manual to attract your attention:
WARNING: A warning is used when an operating procedure, practice, etc., which, if not correctly
followed, could result in personal injury or loss of life.
CAUTION: A caution is used when an operating procedure, practice, etc., which, if not strictly
observed, could result in damage to or destruction of equipment.
NOTE: A note is used when an operating procedure, practice, etc., is essential to highlight.
iii

LIST OF WARNINGS
This manual contains the following warnings
IT IS YOUR RESPONSIBILITY TO BE FAMILIAR WITH ALL OF THEM.
To help prevent personal injury or property damage caused by sudden and unexpected
vehicle movement, do not check the uid until you:
Put the transmission in N (Neutral)and
Apply the parking brake and emergency brakes and make sure they are properly
engagedand
Chock the wheels and take any other steps necessary to keep the vehicle from
moving.
Avoid contact with the hot uid or the sump when draining transmission uid. Direct
contact with the hot uid or the hot sump may result in bodily injury.
To help avoid personal injury, such as burns, from hot transmission uid and/or to help
avoid equipment damage, do not stall the torque converter for more than ten seconds
maximum and monitor transmission uid temperature. Immediately return the engine
to idle if converter out (to cooler) temperature exceeds 150C (300F). Operating the
transmission at high engine power at transmission stall or near stall conditions causes
a rapid rise in the transmission uid temperature. The uid 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 under high heat load conditions
causes transmission and cooling system damage, and can possibly fail hydraulic lines
causing leaking high temperature uid.
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 service brake, and chock the wheels securely. Warn personnel to keep
clear of the vehicle and its travel path.
To help avoid personal injury and/or equipment damage, a driving transmission stall
test must be performed by a trained driver and a qualied technician.
Use appropriate safety equipment such as safety glasses, safety shoes, and gloves.
Do not burn discarded Teon seals toxic gases are produced by burning Teon.
Never dry bearings by spinning them with compressed air. A spinning bearing can
disintegrate, allowing balls or rollers to become lethal ying projectiles. Also, spinning
a bearing without lubrication can damage the bearing.
Avoid contact with the hot uid or the sump when draining transmission uid. Direct
contact with the hot uid or the hot sump may result in bodily injury.
iv

LIST OF WARNINGS (contd)

3000 Product Family transmission dry weights are as follows:

Base Transmission
243 kg (535 lb)
With PTO Provision
261 kg (575 lb)
With Retarder
279 kg (610 lb)
With PTO and Retarder
297 kg (655 lb)
With PTO, Retarder, and Integral Sump

Cooler
336.5 kg (740 lb)
3700 SP
530 kg (1170 lb)
Use proper tools and lifting equipment when installing or removing a transmission
from the repair stand.
To help avoid personal injury, securely support the cooler before removing the bolts
retaining the cooler to the manifold. The cooler weighs 29 kg (64 lb) use care when
handling the cooler.
The transfer case module assembly weighs approximately 270 kg (595 lb).
The control valve module assembly weighs approximately 25 kg (56 lb). Handle
carefully to avoid personal injury or control valve module damage. The control valve
module assembly used in a 3700 SP weighs approximately 29 kg (65 lb).
The retarder module assembly weighs approximately 64 kg (141 lb). Use care to
prevent injury to personnel while handling the retarder module assembly.
Piston springs are highly compressed. Be extremely careful during disassembly.
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.
Piston springs are highly compressed. Be extremely careful during installation.
Piston springs are highly compressed. Be extremely careful during removal. Personal
injury can occur if the spring force is not controlled.
Piston springs are highly compressed. Be extremely careful during installation.

LIST OF WARNINGS (contd)

Springs (108) and (112) are highly compressed. Be extremely careful during
disassembly. Personal injury can occur if the spring force is not controlled.
The retarder module assembly weighs approximately 64 kg (141 lb). Use care to
prevent injury to personnel while handling the retarder module assembly.
The transfer case module assembly weights approximately 270 kg (595 lb).
Transmissions installed in overhaul stands must be positioned vertically before
installing control valve module. Failure to do so could result in personal injury.
The control valve module assembly weighs approximately 25 kg (56 lb). Handle
carefully to avoid personal injury or control valve module damage. The control valve
module assembly used in a 3700 SP weighs approximately 29 kg (65 lb).
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 140
kg (64 lb), use care when handling the cooler.
Transmission dry weights are as follows:
Base transmission243 kg (535 lbs)
With Retarder279 kg (615 lbs)
With PTO provision261 kg (575 lbs)
With Retarder and PTO provision297 kg (655 lbs)
With PTO, Retarder, and Integral Sump Cooler336.5 kg (740 lbs)
3700 SP530 kg (1170 lbs)
Use proper tools and lifting equipment when installing or removing a transmission
from the repair stand.
vi
TABLE OF CONTENTS
TRADEMARK USAGE . . . . . . . . . . . . . . . . . . .i
e. Displaying Diagnostic Trouble Codes

(DTCs). . . . . . . . . . . . . . . . . . . . . . 110
IMPORTANT SAFETY INFORMATION . . . . . . . iii
f. Diagnostic Trouble Code (DTC)

Displays . . . . . . . . . . . . . . . . . . . . . 110
LIST OF WARNINGS . . . . . . . . . . . . . . . . . . . iv
g. Exiting Diagnostic Mode . . . . . . . . . . 111
Section 1. GENERAL INFORMATION

18. PRESERVATION AND STORAGE . . . . . . 111
11. SCOPE OF MANUAL . . . . . . . . . . . . . . .11
a. Preservation Methods . . . . . . . . . . . . 111
a. Content and Organization . . . . . . . . . .11

b. Illustrations . . . . . . . . . . . . . . . . . . . .11
b. Storage (New Transmissions, Before

Installation) . . . . . . . . . . . . . . . . . . . 111
c. Maintenance Information . . . . . . . . . . .11
c. One Year Storage (Without Fluid). . . . . 111
12. SUPPLEMENTARY INFORMATION . . . . . .16
d. One Year Storage (With Fluid). . . . . . . 112
13. ORDERING PARTS . . . . . . . . . . . . . . . .16
19. RESTORING TRANSMISSION TO

SERVICE . . . . . . . . . . . . . . . . . . . . . . 112
a. Transmission Nameplate . . . . . . . . . . .16
a. Transmission Exterior . . . . . . . . . . . . 112
b. Parts Catalog . . . . . . . . . . . . . . . . . .16
b. Sealed Breather and Openings . . . . . . 112

14. GENERAL DESCRIPTION . . . . . . . . . . . .16
c. New Transmissions . . . . . . . . . . . . . 112
a. Major Modules. . . . . . . . . . . . . . . . . .16
d. Stored Without Fluid . . . . . . . . . . . . . 112
b. General Features . . . . . . . . . . . . . . . .16

15. MAJOR MODULES . . . . . . . . . . . . . . . . .17
e. Stored With Fluid . . . . . . . . . . . . . . . 112

110. OPERATING INSTRUCTIONS . . . . . . . . 113
a. Input Module . . . . . . . . . . . . . . . . . . .17

b. Torque Converter . . . . . . . . . . . . . . . .17
c. Power Takeoff (PTO) Provision . . . . . . .17
d. Main Housing and Gear Module . . . . . .17
111. SPECIFICATIONS AND DATA . . . . . . . . . 113

112.
ELECTROMAGNETIC/RADIO
FREQUENCY INTERFERENCE . . . . . . . 114
e. Range Clutches . . . . . . . . . . . . . . . . .17

f. Gearing Ratios . . . . . . . . . . . . . . . . .17
Section 2. PREVENTIVE MAINTENANCE
g. Control System and Transmission

Control Module (TCM) . . . . . . . . . . . . .17
21. SCOPE . . . . . . . . . . . . . . . . . . . . . . . .21
h. Oil Filters . . . . . . . . . . . . . . . . . . . . .18
a. Oil Life Monitor . . . . . . . . . . . . . . . . .21
i.
Transmission Fluid Coolers . . . . . . . . .18
b. Filter Life Monitor . . . . . . . . . . . . . . . .21
j.
Output Conguration . . . . . . . . . . . . . .18
c. Transmission Health . . . . . . . . . . . . . .21
16. MODEL DESIGNATION CODE . . . . . . . . .18
d. Shift Selector Display . . . . . . . . . . . . .21
a. 3000 Product Family Vocational Model

Standard and Optional Features . . . . . .18
23. PERIODIC INSPECTION AND CARE . . . . .22
17. DIAGNOSTICS . . . . . . . . . . . . . . . . . . .19
22. Prognostics . . . . . . . . . . . . . . . . . . . . . .21
a. Exterior Cleaning and Inspection . . . . . .22
a. Before Starting . . . . . . . . . . . . . . . . .19
24. IMPORTANCE OF PROPER FLUID

LEVEL . . . . . . . . . . . . . . . . . . . . . . . . .22
b. CHECK TRANS Light . . . . . . . . . . . . .19
a. Transmission Fluid . . . . . . . . . . . . . . .22
c. Entering Diagnostic Mode . . . . . . . . . .19
b. Oil Level Sensor . . . . . . . . . . . . . . . .22
d. Diagnostic Trouble Codes (DTCs) . . . . 110
25. TRANSMISSION FLUID CHECK . . . . . . . .22
vii

b. Fluid Level Display Criteria . . . . . . . . . .22
c. Comparing Recorded Data to

Specications . . . . . . . . . . . . . . . . . 212
26. MANUAL FLUID LEVEL CHECK

PROCEDURE . . . . . . . . . . . . . . . . . . . .24
216. TRANSMISSION STALL TEST AND

NEUTRAL COOLDOWN CHECK . . . . . . 216
a. Preparation . . . . . . . . . . . . . . . . . . . .24
a. Purpose . . . . . . . . . . . . . . . . . . . . . 216
b. Consistency of Readings . . . . . . . . . . .24
b. Stall Testing Preparation . . . . . . . . . . 216
a. Electronic Check Procedure . . . . . . . . .22
27. COLD CHECK (Figure 21) . . . . . . . . . . .24

a. Purpose . . . . . . . . . . . . . . . . . . . . . .24
b. Cold Check Procedure . . . . . . . . . . . .24
28. HOT CHECK (Figure 21) . . . . . . . . . . . .24
a. Hot Check Procedure . . . . . . . . . . . . .25
29. KEEPING FLUID CLEAN . . . . . . . . . . . . .25
c. Performing a Transmission Stall Test . . 216

d. Driving Transmission Stall Test . . . . . . 217
e. Driving Transmission Stall Testing
Preparation . . . . . . . . . . . . . . . . . . . 217
f. Performing A Driving Transmission Stall
Test. . . . . . . . . . . . . . . . . . . . . . . . 218
g. Neutral Cool Down Check Procedure . . 218
h. Transmission Stall Test Results . . . . . . 218
210. FLUID RECOMMENDATIONS. . . . . . . . . .25

217. FLUID LEAK DIAGNOSIS . . . . . . . . . . . 219
211. FLUID AND FILTER CHANGE INTERVAL . .26
a. Fluid And Filter Changes . . . . . . . . . . .26
b. High Capacity Filters . . . . . . . . . . . . . .26
c. Fluid Analysis . . . . . . . . . . . . . . . . . .28
a. Finding the Leak . . . . . . . . . . . . . . . 219

b. Powder Method . . . . . . . . . . . . . . . . 219
c. Black Light and Dye Method . . . . . . . . 219
212. FLUID CONTAMINATION . . . . . . . . . . . . .28
d. Possible Points of Fluid Leaks and

Their Causes. . . . . . . . . . . . . . . . . . 219
a. Water . . . . . . . . . . . . . . . . . . . . . . .28
e. Repairing the Leak . . . . . . . . . . . . . . 220
b. Engine Coolant . . . . . . . . . . . . . . . . .28
218. OUTPUT FLANGE/YOKE AND OIL SEAL

MAINTENANCE (All, Except 3700 SP) . . . 220
c. Metal . . . . . . . . . . . . . . . . . . . . . . . .28
213. FLUID AND FILTER CHANGE
PROCEDURE . . . . . . . . . . . . . . . . . . . .28
a. Disassembly (Figure 25). . . . . . . . . . 220
a. Drain Fluid . . . . . . . . . . . . . . . . . . . .29
219. YOKE AND OIL SEAL MAINTENANCE

(3700 SP) . . . . . . . . . . . . . . . . . . . . . . 221
b. Replace Filters (Figure 22) . . . . . . . . .29

c. Replace Filters3700 SP Transmission
(Figure 23) . . . . . . . . . . . . . . . . . . .29
d. Rell Transmission . . . . . . . . . . . . . . 210
b. Assembly . . . . . . . . . . . . . . . . . . . . 221
a. Disassembly (Figure 26). . . . . . . . . . 221

b. Assembly (Figure 26) . . . . . . . . . . . 222
220. ONVEHICLE MAINTENANCE . . . . . . . . 222
214. BREATHER. . . . . . . . . . . . . . . . . . . . . 211

a. Location and Purpose . . . . . . . . . . . . 211
b. Maintenance . . . . . . . . . . . . . . . . . . 211
Section 3. GENERAL OVERHAUL

INFORMATION
215. CHECKING CLUTCH PRESSURES . . . . . 211
31. SCOPE . . . . . . . . . . . . . . . . . . . . . . . .31
a. Transmission and Vehicle

Preparation . . . . . . . . . . . . . . . . . . . 211
32. TOOLS AND EQUIPMENT . . . . . . . . . . . .31
b. Recording Data . . . . . . . . . . . . . . . . 212
b. Special Tools. . . . . . . . . . . . . . . . . . .33
viii
a. Improvised Tools and Equipment . . . . . .31
TABLE OF CONTENTS
c. Mechanics Tools and Shop
Equipment . . . . . . . . . . . . . . . . . . . .33
33. REPLACEMENT PARTS . . . . . . . . . . . . .37
a. Ordering Information . . . . . . . . . . . . . .37
b. Parts Normally Replaced at Overhaul . . .37
34. CAREFUL HANDLING. . . . . . . . . . . . . . .37
g. LipType Seals. . . . . . . . . . . . . . . . . 317

h. ButtJoint Sealrings. . . . . . . . . . . . . . 317
i.
Bearings . . . . . . . . . . . . . . . . . . . . 317
37. REMOVING (OR INSTALLING)

TRANSMISSION (Figure 312,
Figure 313) . . . . . . . . . . . . . . . . . . . . 317
a. Drain Fluid . . . . . . . . . . . . . . . . . . . 318
35. CLEANING AND INSPECTION . . . . . . . . .37

a. Dirt Causes Malfunction . . . . . . . . . . . .37
b. Disconnecting Controls . . . . . . . . . . . 319
b. Cleaning Parts. . . . . . . . . . . . . . . . . .37
c. Uncoupling From Driveline, Vehicle,

And Engine . . . . . . . . . . . . . . . . . . . 319
c. Cleaning Bearings . . . . . . . . . . . . . . .37
d. Removing the Transmission . . . . . . . . 319
d. Keeping Bearings Clean . . . . . . . . . . .37
38. WEAR LIMITS . . . . . . . . . . . . . . . . . . . 320
e. Inspecting Bearings . . . . . . . . . . . . . .38

f. Inspecting Cast Parts and Machined
Surfaces . . . . . . . . . . . . . . . . . . . . .38
39. SPRING SPECIFICATIONS . . . . . . . . . . 320

310. TORQUE SPECIFICATIONS. . . . . . . . . . 320
g. Inspecting Bushings and Thrust

Washers. . . . . . . . . . . . . . . . . . . . . .39
311. ENGINE, TRANSMISSION ADAPTATION

REQUIREMENTS. . . . . . . . . . . . . . . . . 320
h. Inspecting Sealrings and Gaskets . . . . .39
a. Measuring Equipment . . . . . . . . . . . . 322
i.
Inspecting Gears . . . . . . . . . . . . . . . .39
j.
Inspecting Splined Parts . . . . . . . . . . 310
b. Flywheel Housing Pilot Bore

Diameter . . . . . . . . . . . . . . . . . . . . 322
k. Inspecting Threaded Parts . . . . . . . . . 310
c. Flywheel Housing Bore Runout . . . . . . 322
l.
Inspecting Retaining Rings . . . . . . . . . 310
d. Flywheel Housing Face Squareness . . . 322
m. Inspecting Springs . . . . . . . . . . . . . . 310

n. Inspecting Clutch Plates (Figure 35) . . 310
e. Crankshaft Hub Pilot or Adapter

Diameter . . . . . . . . . . . . . . . . . . . . 322
o. Inspecting Swaged and InterferenceFit

Parts . . . . . . . . . . . . . . . . . . . . . . . 310
f. Crankshaft Hub Pilot or Adapter

Squareness . . . . . . . . . . . . . . . . . . 322
p. Inspecting Retainer and Ball Assembly

in Retarder Stator . . . . . . . . . . . . . . . 310
g. Crankshaft Hub Pilot or Adapter

Concentricity . . . . . . . . . . . . . . . . . . 322
q. Inspecting Sealing Surfaces . . . . . . . . 310
h. Flexplate Bolt Hole Flatness . . . . . . . . 322
r. Inspecting Electrical Components . . . . 311
i.
36. ASSEMBLY PROCEDURES . . . . . . . . . . 316

a. Parts Lubrication . . . . . . . . . . . . . . . 316
b. Grease Used for Assembly . . . . . . . . . 316
c. Sealing Compounds and Nonsoluble
Greases . . . . . . . . . . . . . . . . . . . . . 316
d. Clutches and Pistons . . . . . . . . . . . . 316
e. Threaded Plugs and Hydraulic
Fittings. . . . . . . . . . . . . . . . . . . . . . 317
Torque Converter Axial Location . . . . . 322
312. CHECKING FLEXPLATE DRIVE

ASSEMBLY . . . . . . . . . . . . . . . . . . . . . 323
a. Flexplate Inspection . . . . . . . . . . . . . 323
b. Engine Crankshaft End Play . . . . . . . . 323
c. Flexplate Assembly Installation . . . . . . 323
313. CHASSIS AND DRIVELINE
INSPECTION. . . . . . . . . . . . . . . . . . . . 323
f. Coated Threaded Fasteners . . . . . . . . 317

ix

Section 4. TRANSMISSION
DISASSEMBLY
41. SCOPE . . . . . . . . . . . . . . . . . . . . . . . .41
a. Section . . . . . . . . . . . . . . . . . . . . . .41
b. Procedures . . . . . . . . . . . . . . . . . . . .41
c. Illustrations . . . . . . . . . . . . . . . . . . . .41
d. General Information . . . . . . . . . . . . . .41
e. Foldouts . . . . . . . . . . . . . . . . . . . . . .41
42. DISASSEMBLY OF TRANSMISSION . . . . .41
a. Mounting Transmission on Repair
Stand . . . . . . . . . . . . . . . . . . . . . . .41
b. Removal of Common Externally
Mounted Parts (Figure 42) . . . . . . . . .42
Section 5. MODULE REBUILD

51. SCOPE . . . . . . . . . . . . . . . . . . . . . . . .51
a. Section . . . . . . . . . . . . . . . . . . . . . .51
b. Procedures . . . . . . . . . . . . . . . . . . . .51
c. Illustrations . . . . . . . . . . . . . . . . . . . .51
d. Foldouts . . . . . . . . . . . . . . . . . . . . . .51
52. GENERAL INFORMATION FOR MODULE
REBUILD . . . . . . . . . . . . . . . . . . . . . . .51
53. TORQUE CONVERTER MODULE . . . . . . .51
c. Removal of Speed Sensors . . . . . . . . .43
a. Disassembly (Foldout 5) . . . . . . . . . . .51
d. Removal of Integral Oil Cooler

(Foldout 181) . . . . . . . . . . . . . . . . . .43
b. Assembly (Foldout 5) . . . . . . . . . . . . .52
e. Removing Integral Retarder Sump Oil

Cooler (Foldout 182) . . . . . . . . . . . . .44
f. Removal of PTO(s) (Foldout 192) . . . . .45
g. Removal of Transfer Case Module
3700SP . . . . . . . . . . . . . . . . . . . . . .45
h. Removal of Control Valve Module
(Figure 46) . . . . . . . . . . . . . . . . . . .46
i.
j.
Removal of Torque Converter Module

(Figure 47) . . . . . . . . . . . . . . . . . . .47
Removal of Converter Housing Module
(Figure 48) . . . . . . . . . . . . . . . . . . .48
k. Removal of Retarder Module

(Foldout 11A and Figure 49) . . . . . . . .48
l.
Removal of Transfer Case Adapter

Housing Module (Figure 410) . . . . . . .49
m. Removal of Rear Cover Module

(Figure 411). . . . . . . . . . . . . . . . . . .49
n. Removal of Main Shaft Module
(Figure 412) . . . . . . . . . . . . . . . . . 410
q. Removal of C3/C4 Clutch Assembly

From Main Housing Module
(Figure 417) . . . . . . . . . . . . . . . . . 411
54. TORQUE CONVERTER HOUSING

MODULE (Models With PTO Provision) . . . .57
a. Module Disassembly (Foldout 62) . . . . .57
b. Disassembly of the Bearing Retainer
Assembly . . . . . . . . . . . . . . . . . . . . .57
c. Disassembly of the PTO Gear
Assembly . . . . . . . . . . . . . . . . . . . . .57
d. Assembly of the PTO Gear Assembly . . .57
e. Assembly of the Bearing Retainer
Assembly . . . . . . . . . . . . . . . . . . . . .58
f. Module Assembly . . . . . . . . . . . . . . . .58
55. TORQUE CONVERTER HOUSING
MODULE (Models Without PTO
Provision) . . . . . . . . . . . . . . . . . . . . . . .58
a. Disassembly (Foldout 61) . . . . . . . . . .58
b. Assembly (Foldout 61) . . . . . . . . . . . .58
56. FRONT SUPPORT AND CHARGING OIL
PUMP MODULE. . . . . . . . . . . . . . . . . . .59
a. Module Disassembly (Foldout 71) . . . . .59
o. Removal of P2 Module, C5 Clutch

Plates, and P1 Module (Figure 413,
Figure 414) . . . . . . . . . . . . . . . . . . 410
b. Assembly of the Front Support . . . . . . 512
p. Removal of Front Support/Charging

Pump Module and Rotating Clutch
Module (Figure 415, Figure 416). . . . 410
57. ROTATING CLUTCH MODULE . . . . . . . . 515
c. Assembly of the Pump Housing

(Foldout 71) . . . . . . . . . . . . . . . . . . 513
a. Disassembly (Foldout 72) . . . . . . . . . 515
TABLE OF CONTENTS
b. Assembly (Foldout 72) . . . . . . . . . . . 520
58. C3/C4 AND MAIN HOUSING MODULE . . . 522
h. Assembly and Installation of

Retarder Control Body Assembly
(Foldout 11A) . . . . . . . . . . . . . . . . . 538
a. Disassembly (Foldout 81) . . . . . . . . . 522

b. Assembly (Foldout 81) . . . . . . . . . . . 523
513. REAR COVER MODULE . . . . . . . . . . . . 538

a. Disassembly (Foldout 11B) . . . . . . . . . 538
59. MAIN SHAFT MODULE . . . . . . . . . . . . . 525

a. Disassembly (3000 Product Family
Models, Except 3500 and 3700 SP
Models) (Foldout 82) . . . . . . . . . . . . 525
b. Assembly (3000 Product Family
Models, Except 3500, 3700 SP Models)
(Foldout 82) . . . . . . . . . . . . . . . . . . 526
c. Module Disassembly(3500
Transmission Model) (Foldout 91) . . . . 526
d. Module Assembly (3500 Transmission
Model) (Foldout 91) . . . . . . . . . . . . . 526
b. Disassembly of the P3 Planetary Carrier

Assembly (Foldout 11B) . . . . . . . . . . . 539
c. Disassembly of the Rear Cover
d. Assembly of Rear Cover
(Foldout 11B) . . . . . . . . . . . . . . . . . 540
e. Assembly of the P3 Planetary Carrier
f. Completion of the Rear Cover Module
(Foldout 11B) . . . . . . . . . . . . . . . . . 543
e. Module Disassembly (3700 SP

514. ADAPTER HOUSING AND P3

OVERHAUL . . . . . . . . . . . . . . . . . . . . 545
f. Module Assembly (3700 SP

a. Disassembly (Foldout 172) . . . . . . . . 545

b. Assembly (Foldout 172) . . . . . . . . . . 546
510. P1 PLANETARY MODULE . . . . . . . . . . . 527
515. SCAVENGE PUMP OVERHAUL . . . . . . . 547
511. P2 PLANETARY MODULE . . . . . . . . . . . 529
516. TRANSFER CASE MODULE . . . . . . . . . 549
a. Disassembly of Transfer Case

Module (Foldout 122, Foldout 13,
Foldout 14) . . . . . . . . . . . . . . . . . . . 549

512. RETARDER MODULE . . . . . . . . . . . . . . 531
a. Disassembly of Retarder Valve Body
(Foldout 11A) . . . . . . . . . . . . . . . . . 531
b. Disassembly of Retarder Housing
(Foldout 11A) . . . . . . . . . . . . . . . . . 532
c. Disassembly of P3 Planetary Carrier
Assembly (Foldout 11A) . . . . . . . . . . . 532
d. Disassembly of Retarder Stator
e. Assembly of Retarder Stator
(Foldout 11A) . . . . . . . . . . . . . . . . . 533
f. Assembly of P3 Planetary Carrier
g. Assembly of Retarder Housing
b. Disassembly of C6 Clutch
(Foldout 14) . . . . . . . . . . . . . . . . . . 551
c. Assembly of C6 Clutch (Foldout 14) . . . 551
d. Disassembly of C7 Clutch
(Foldout 13) . . . . . . . . . . . . . . . . . . 552
e. Assembly of C7 Clutch Housing
(Foldout 13) . . . . . . . . . . . . . . . . . . 552
f. Disassembly of Oil Pump
(Foldout 13) . . . . . . . . . . . . . . . . . . 553
g. Assembly of Oil Pump (Foldout 13) . . . 553
h. Disassembly of P4 Carrier
(Foldout 14) . . . . . . . . . . . . . . . . . . 553
i.
Assembly of P4 Carrier (Foldout 14) . . . 553
xi

j.
Disassembly of Drive, Idler, and Driven

Gears (Foldout 13) . . . . . . . . . . . . . . 554
j.
Assembly of C6 Control Valve Body

(Foldout 151, Foldout 152) . . . . . . . . 564
k. Assembly of Drive, Idler, and Driven

Gears (Foldout 13) . . . . . . . . . . . . . . 554
k. Assembly of Filter Life Valve Body

(Figure 573) . . . . . . . . . . . . . . . . . 564
l.
l.
Disassembly of the Front Output

Housing and Front Output Shaft
(Foldout 13) . . . . . . . . . . . . . . . . . . 554
Assembly of the Solenoid Valve Body

(Foldout 151, Foldout 152) . . . . . . . . 564
m. Assembly of the Front Output Housing

and Front Output Shaft (Foldout 13) . . . 554
m. Installation of Electrical Components

and Sensors (Foldout 151,
Foldout 152). . . . . . . . . . . . . . . . . . 564
n. Disassembly of the Rear Output

Housing (Foldout 14). . . . . . . . . . . . . 555
n. Installation of Filters (Foldout 151,

Foldout 152). . . . . . . . . . . . . . . . . . 565
o. Assembly of the Rear Output Housing

(Foldout 14) . . . . . . . . . . . . . . . . . . 555
p. Output Housing Bearing Preload
Procedure (Foldout 14) . . . . . . . . . . . 556
q. Disassembly of C7 Control Valve Body
(Foldout 14) . . . . . . . . . . . . . . . . . . 556
Section 6. TRANSMISSION ASSEMBLY

61. SCOPE . . . . . . . . . . . . . . . . . . . . . . . .61
a. Section . . . . . . . . . . . . . . . . . . . . . .61
b. Procedures . . . . . . . . . . . . . . . . . . . .61
r. Assembly of C7 Control Valve Body

Assembly (Foldout 14). . . . . . . . . . . . 556
c. Illustrations . . . . . . . . . . . . . . . . . . . .61
s. Assembly of Transfer Case

Module (Foldout 122, Foldout 13,
Foldout 14) . . . . . . . . . . . . . . . . . . . 557
e. Foldouts . . . . . . . . . . . . . . . . . . . . . .61
d. General Information . . . . . . . . . . . . . .61
62. ASSEMBLY OF TRANSMISSION. . . . . . . .61

a. Assembly of C3/C4 Clutch . . . . . . . . . .61
517. CONTROL VALVE MODULE (Foldout 151,

Foldout 152) . . . . . . . . . . . . . . . . . . . . 560
a. Removal of Filters . . . . . . . . . . . . . . 560
b. Removal of Electrical Components and
Sensors . . . . . . . . . . . . . . . . . . . . . 560
c. Installation of the Front

Support/Charging Pump Module
(Figure 63) . . . . . . . . . . . . . . . . . . .62
c. Disassembly of the Control Valve Body

(Foldout 151, Foldout 152) . . . . . . . . 561
d. Installation of the P1 Planetary Module

(Figure 64) . . . . . . . . . . . . . . . . . . .62
d. Disassembly of Filter Life Valve Body

(Figure 573) . . . . . . . . . . . . . . . . . 561
e. Installation of the P2 Planetary Module

(Figure 65) . . . . . . . . . . . . . . . . . . .62
e. Disassembly of C6 Control Valve Body

(Foldout 151, Foldout 152) . . . . . . . . 562
f. Installation of the C5 Clutch Pack

(Figure 65) . . . . . . . . . . . . . . . . . . .62
f. Disassembly of Control Valve Body

(Foldout 151, Foldout 152) . . . . . . . . 562
g. Installation of the Main Shaft

(Figure 66) . . . . . . . . . . . . . . . . . . .63
g. Disassembly of the Channel Plate

(Foldout 151, Foldout 152) . . . . . . . . 563
h. Main Shaft Selective Shim

Measurement For Close Ratio
Models (Figure 67) . . . . . . . . . . . . . .63
h. Assembly of the Channel Plate

(Foldout 151, Foldout 152) . . . . . . . . 563
i.
xii
b. Installation of the Rotating Clutch

Module (Figure 62) . . . . . . . . . . . . . .61
Assembly of the Main Valve Body

(Foldout 151, Foldout 152) . . . . . . . . 563
i.
Main Shaft Selective Shim

Measurement (Wide Ratio Models)
(Figure 68) . . . . . . . . . . . . . . . . . . .64
TABLE OF CONTENTS
j.
Main Shaft Selective Shim

Measurement For 3700 SP
(Figure 69) . . . . . . . . . . . . . . . . . . .65
82. SERVICE LITERATURE. . . . . . . . . . . . . .82
FOLDOUTS
k. Installation Retarder Module . . . . . . . . .67

l.
Installation of Rear Cover Module

(Figure 611). . . . . . . . . . . . . . . . . . .68
m. Installation of Transfer Case Adapter

Housing (Figure 612). . . . . . . . . . . . .68
n. Installation of Transfer Case Module
(Figure 613) . . . . . . . . . . . . . . . . . .69
o. Installation of the Converter Housing
Module (Figure 614) . . . . . . . . . . . . .69
p. Installation of the Torque Converter
Module (Figure 615) . . . . . . . . . . . . 610
1.
3000 Product Family TransmissionCross

Section
2.
3000 Product Family Transmission

(Except 3700 SP) with PTO Provision and
RetarderCross Section
3.
3500 TransmissionCross Section
4.
3700 SP TransmissionCross Section
5.
Torque Converter ModuleDisassembled

View
q. Installation of the Control Valve Module

(Figure 616) . . . . . . . . . . . . . . . . . 612
61. Converter Housing Module, Without PTO

ProvisionDisassembled View
r. Installation of Power Takeoff(s)

(Figure 617) . . . . . . . . . . . . . . . . . 612
62. Converter Housing Module, With PTO

ProvisionDisassembled View
s. Installation of Integral Oil Cooler

(Foldout 181) . . . . . . . . . . . . . . . . . 613
t. Installation of Integral Retarder Sump
Oil Cooler (Foldout 182) . . . . . . . . . . 614
u. Installation of Speed Sensors . . . . . . . 614
v. Installation of Common
ExternallyMounted Parts
(Figure 618) . . . . . . . . . . . . . . . . . 615
w. Removal of Transmission From Repair
Stand (Figure 620) . . . . . . . . . . . . . 617
Section 7. WEAR LIMITS AND SPRING

DATA
71. WEAR LIMITS DATA . . . . . . . . . . . . . . . .71
a. Maximum Variations . . . . . . . . . . . . . .71
71. Front Support and Oil Pump

ModuleDisassembled View
72. Rotating Clutch ModuleDisassembled
View
81. Main Housing ModuleDisassembled
View
82. 3000 Product Family Main Shaft
Module (Except 3500 and 3700
SP)Disassembled View
91. Main Shaft Module 3500Disassembled
View
92. Main Shaft Module 3700
SPDisassembled View
101. P1 Planetary ModuleDisassembled View
b. Cleaning and Inspection . . . . . . . . . . .71

102. P2 Planetary ModuleDisassembled View
72. SPRING DATA . . . . . . . . . . . . . . . . . . . .71
a. Spring Replacement . . . . . . . . . . . . . .71
11A. Retarder and P3 Planetary

b. Inspection. . . . . . . . . . . . . . . . . . . . .71
Section 8. CUSTOMER SERVICE

81. OWNER ASSISTANCE . . . . . . . . . . . . . .81
11B. Rear Cover and P3 Planetary

121. Transfer Case Special
ToolsDisassembled View
xiii

27.
3000 Product Family Hydraulic

SchematicFifth Range
28.

SchematicSixth Range
29.

SchematicRetarder OFF
30.

SchematicRetarder ON
31.

SchematicNeutral With Prognostics
32.

SchematicReverse Range With
Prognostics
162. Control Valve Module with

PrognosticsDisassembled View
33.

SchematicFirst Range With Prognostics
171. Output Flange and YokeDisassembled

View
34.

SchematicSecond Range With
Prognostics
35.

SchematicThird Range With Prognostics
36.

SchematicFourth Range With
Prognostics
37.

SchematicFifth Range With Prognostics
38.

SchematicSixth Range With Prognostics
122. Transfer Case, Special Disassembly/

Assembly InstructionsDisassembled
View
13.
Front Main Transfer CaseDisassembled

View
14.
Rear Main Transfer CaseDisassembled

View
151. Control Valve ModuleDisassembled

View
152. Control Valve ModuleDisassembled
View
161. Control Valve Module with
PrognosticsDisassembled View
172. Transfer Case Adapter

HousingDisassembled View
181. Oil CoolerDisassembled View
182. Integral Sump CoolerDisassembled View
191. Scavenge PumpDisassembled View
192. Support EquipmentDisassembled View
20.

SchematicNeutral
21.

SchematicReverse
22.

Schematic7Speed, Low Range
23.

SchematicFirst Range
24.

SchematicSecond Range
25.

SchematicThird Range
26.

SchematicFourth Range
xiv
SECTION 1GENERAL INFORMATION

11.
SCOPE OF MANUAL
a. Content and Organization. This service

manual describes the overhaul procedures for
3000 Product Family automatic transmissions
(Figure 11 through Figure 16). Power Takeoff
(PTO) and output retarder options may be added to
a base transmission model.
The major transmission components are
described and their functions explained.
Detailed instructions are provided for
disassembly, rebuild, and reassembly.
Parts inspection instructions are in 35.
CLEANING AND INSPECTION.
Wear limits and spring data are in 71. WEAR
LIMITS DATA and 72. SPRING DATA.
The 3000 Product Family consists of the following
transmission series and models:
Specialty Series:
3200 SP
3500 SP
3700 SP
Bus Urban Series:
B 295
B 300
B 400
T 200 Series:
T 250
T 255
T 260
T 265
T 270
T 280
Highway Series:
T 300 Series:
3000 HS
3000 RDS
T 310
3200 RDS
T 325
3500 RDS
T 350
T 375
Emergency Vehicle Series:

Power Takeoff (PTO) and output retarder options
may be added to a base transmission model.
3000 EVS
3500 EVS
b. Illustrations.
Motorhome Series:
3000 MH
3200 MH
Truck Recreational Vehicle Series:
3000 TRV
3200 TRV
3500 TRV
Off Road Series:
3200 ORS
3500 ORS
Pupil Transport/Shuttle Series:
3000 PTS
1. The text is supported with line drawings and

crosssectional views. Overhaul procedures
are illustrated by line drawings. Crosssections
show the relationship of assembled parts.
Crosssections, disassembled views, and
hydraulic schematics are on foldout pages in
the back of the manual.
2. Illustrations show correct procedures for all
models, including models not illustrated.
c. Maintenance Information. Each task described
in this manual has been successfully completed by
service organizations and individuals. Not every
service organization or individual possesses the
required special tools, training, or experience to
perform all described tasks. However, any task may
be performed if the following conditions are met:
11

1. The organization or individual has the required
knowledge of the task through:
Formal instruction at an Allison
Transmission or a distributor training
facility.
Onthejob instruction by an
Allison Transmission or distributor
representative.
Experience in performing the task.
2. The work environment is suitable to prevent
contamination or damage to transmission
parts or assemblies.
3. The required tools and xtures needed are
shown in Figure 33 and Table 31 (32.
TOOLS AND EQUIPMENT of this manual).
4. Reasonable and prudent maintenance
practices are used.
NOTE: Service organizations and
individuals are encouraged to contact
their local Allison Transmission distributor
for information and guidance on any task
outlined in this manual.
12
GENERAL INFORMATION
Figure 11. 3000 Product Family Transmission with PTO ProvisionLeftFront View
Figure 12. 3000 Product Family Transmission with PTO ProvisionRightRear View
13

Figure 13. 3000 Product Family Transmission with RetarderLeftRear View
Figure 14. 3000 Product Family Transmission with Retarder and Remote Sump Cooler Manifold
14
GENERAL INFORMATION
Figure 15. 3700 SP TransmissionRightFront View
Figure 16. 3700 SP TransmissionLeftRear View

15

12.
SUPPLEMENTARY INFORMATION
Supplementary information is issued, as required, if

any changes occur after publication of this manual.
Check with your dealer or distributor to be sure you
have the latest information.
13.
ORDERING PARTS
a. Transmission Nameplate. The nameplate

(Figure 17) is located on the right side of the
transmission and is imprinted with the following:
Transmission model
Serial number
Date code
TransID
Figure 17. Transmission Nameplate
Engineering groups (for Specialty Series

vocation models)
Use all of these numbers when ordering replacement
parts or requesting service information.
b. Parts Catalog. Replacement parts are listed
in Parts Catalog PC2150EN and the Parts Catalog
on the Allison Extranet. Do not order by the item
numbers used on disassembled views in this
manual. Use the parts catalog to determine the
correct part number. Order all replacement parts
from your distributor or authorized dealer. Check the
Yellow Pages for your nearest authorized service
outlet. Listings are under TransmissionTruck,
Tractor, Etc. Service outlets can also be
located on the Allison Transmission web site at
www.allisontransmission.com.
14.
GENERAL DESCRIPTION
Allison 3000 Product Family transmissions are a

complete transmission system that includes all
hardware needed for vehicle applications.
a. Major Modules. 3000 Product Family
transmissions contain the following major modules:
Input Module
Main Housing and Gear Module
Control Valve Module
Output Module
b. General Features. Features unique to 3000
Product Family transmissions are:
Four, ve, or six forward speed congurations
(mechanically, every 3000 Product
Family transmission model is a six speed
transmission. Calibrations are available to
use as a four or ve speed model). The 3700
Specialty Series (SP) has a transfer case and
seven forward speeds.
Lockup clutch with torsional damper
Integral retarder (optional)
Externally accessible oil lters, serviceable
without complete loss of transmission uid
Adaptive, electronic, closedloop controls with
selfdiagnostic capabilities
16
GENERAL INFORMATION
MY09 Prognostics (excluding 7speed)
15.
MAJOR MODULES
a. Input Module. The input module includes:

Engine adaptation
Torque converter
g. Control System and Transmission Control

Module (TCM). The control system is capable of
recognizing hydraulic and electronic conditions that
are not within the operating limits of the programmed
calibration. Some outoflimit conditions can be
corrected by the control system. All outoflimit
condition diagnostic trouble codes are stored for
later retrieval by a technician.
The Electronic Control System includes:
PTO provision
TCM
b. Torque Converter.
1. The torque converter includes a lockup clutch
and torsional damper for direct and smooth
transfer of engine power.
2. The available torque converter models are:
Torque Converter Model
TC 411
TC 413
TC 415
TC 417
Control valve module

Shift selector
Sensors
Wiring harness (customerfurnished)
The TCM is a microcomputer that receives and
processes signals from various switches and
sensors. TCMs are available in both 12V and 24V
congurations to match the conguration of the
vehicle electrical system.
Input from the operator is sent to the TCM via the
shift selector and vehicle interface wiring. The TCM
determines:
TC 418
TC 419
Shift sequences
TC 421
Shift timing
c. Power Takeoff (PTO) Provision. Provision
for a direct, enginedriven PTO is available at two
positions.
d. Main Housing and Gear Module. The main
housing and gear module includes:
Clutch apply and release pressures

Typical data sent to the TCM for compilation and
processing includes:
Shift selector position
Main housing
Throttle position
Oil pump charging system
Engine speed
Three planetary gear sets
Turbine speed
Two rotating clutches
Output speed
Three stationary clutches
Sump temperature
e. Range Clutches. Range clutches are multiple

disc, wettype clutches. Exhaust backll pressure
reduces ll time for quick response and smooth
shifts.
f. Gearing Ratios. Gear ratios are listed in
Table 11.
Retarder temperature
Engine water temperature
Pressure Switch 1 (PS1) pressure switch
status
Oil level
Any special functions operating
17

h. Oil Filters. Two disposable externalaccess
oil lters are part of the control valve module.
Each lter is in a separate cavity which permits
removal and replacement without complete loss of
transmission uid.
i. Transmission Fluid Coolers. The main
housing accepts remote or integral transmission
uid coolers.
2 Close Ratio (CR)

0 Close Ratio (CR)
a. 3000 Product Family Vocational Model

Standard and Optional Features. The following
chart lists the standard (STD) and optional (OPT)
features of each 3000 Product Family vocational
model.
j. Output Conguration. The output module

includes either an integral retarder and an output
ange , or a rear cover that includes pads for
mounting a parking brake and a ange or yoke. A
yoke is not available with parking brakeequipped
transmissions. The 3700 SP has a transfer case
and adapter as an output module.
16.
MODEL DESIGNATION CODE
The following explains the transmission model

designation code stamped on the transmission
nameplate for vocational models.
Highway Series
3000 HS
Rugged Duty Series
3000 RDS, 3200 RDS,

3500 RDS
Emergency Vehicle Series
3000 EVS, 3500 EVS
Motorhome Series
3000 MH, 3200 MH
Truck Recreational
Vehicle Series
3000 TRV, 3200 TRV,

3500 TRV
OffRoad Series
3200 ORS, 3500 ORS
Pupil Transport/Shuttle
Series
3000 PTS
Specialty Series
3200 SP, 3500 SP, 3700

SP
Bus Series
B295, B300, B400
T 200 Series
T250, T255, T260, T265,

T270, T280
T 300 Series
T310, T325, T350, T375
3000 Product Family gear ratios (digit following the

3 in 3000):
7 Widest Ratio Coverage (WRC)
5 Wide Ratio (WR)
18
GENERAL INFORMATION
Vocational
Model
CR/WR/
WCR
Maximum
Forward
Ranges
PTO
Retarder
Deep Sump
Shallow
Sump
OLS
3000 EVS
CR
STD
OPT
STD
OPT
STD
3500 EVS
WR
STD
OPT
STD
OPT
STD
3000 HS
CR
N/A
OPT
STD
N/A
STD
3000 MH
CR
OPT
OPT
STD
N/A
STD
3200 MH
CR
OPT
OPT
STD
N/A
STD
3200 ORS
CR
STD
OPT
STD
N/A
STD
3500 ORS
WR
STD
OPT
STD
N/A
STD
3000 PTS
CR
NA
OPT
STD
N/A
STD
3000 RDS
CR
STD
OPT
STD
N/A
STD
3500 RDS
WR
STD
OPT
STD
N/A
STD
3200 SP
CR
OPT
N/A
STD
OPT
N/A
3500 SP
WR
STD
OPT
STD
OPT
STD
3700 SP
WRC
STD
OPT
STD
N/A
STD
3000 TRV
CR
OPT
OPT
STD
OPT
STD
3200 TRV
CR
OPT
OPT
STD
OPT
STD
B 300
CR
OPT
OPT
STD
OPT
STD
B 400
CR
OPT
OPT
STD
OPT
STD
17.
DIAGNOSTICS
c. Entering Diagnostic Mode.
NOTE: Refer to TS3989EN, Allison 4th

Generation Controls Troubleshooting
Manual for indepth troubleshooting
procedures.
a. Before Starting. Before attempting to repair
the transmission, identify the faulty condition and
its probable cause.
b. CHECK TRANS Light. Continued illumination
of the CHECK TRANS light during vehicle operation
indicates the Transmission Control Module (TCM)
has signaled a Diagnostic Trouble Code (DTC). At
startup, the CHECK TRANS light briey illuminates.
NOTE: The strip pushbutton shift selector

has no display or diagnostic capabilities.
Use the Allison DOC For PCService Tool
to display DTCs.
NOTE: An oil level sensor is standard

with 4th generation controls except in the
3700SP.
NOTE: Prognostics information

was optional beginning with MY09
transmissions. See SIL 11WT08 or
an Operators Manual to verify vehicle
requirements should Prognostics
information not display in the selector.
1. Accessing Oil Level, Prognostics, and
Diagnostic Trouble Codes Using a Lever Shift
Selector
19

The DISPLAY MODE/DIAGNOSTIC (DMD)
button provides access to:
Fluid level information
Prognostics information
Diagnostic trouble code information.
To access oil level, prognostics, and DTCs:
Simultaneously press the (Up) Arrow

and (Down) Arrow buttons again to
access the DTCs.
Move the shift lever to N (Neutral) and

apply the parking brake.
Press the MODE button to display the

next DTC. Repeat for code positions d3
through d5.
Press the DISPLAY MODE/

DIAGNOSTIC button once to access oil
level information (except 3700SP).
Press N (Neutral) to exit the diagnostic

mode.
Press the DMD again to access the DTC

information.
d. Diagnostic Trouble Codes (DTCs). DTCs

can be displayed on the display portion of the shift
selector or Allison DOC For PCService Tool. A
DTC is either active or historic. An active DTC is
any DTC that is current in the TCM decision making
process. Historic DTCs are DTCs retained in the
TCM memory and do not necessarily affect the
TCM decision making process. Active DTCs are
indicated on the shift selector by the MODE ON
indicator being illuminated.
Press the MODE button to view

subsequent code positions d2 through
d5.
e. Displaying Diagnostic Trouble Codes

(DTCs). The process for displaying DTCs differs
between the two basic styles of shift selectors:
Press the DMD again to access the Oil

Life Monitor (if Prognostics is available).
Press the DMD again to access the Filter
Life Monitor (if Prognostics is available).
Press the DMD again to access
the Transmission Health Monitor (if
Prognostics is available).
To exit the DTC mode, move the shift

lever to another position.
2. Accessing Oil Level, Prognostics, and
Diagnostic Trouble Codes Using a Pushbutton
Shift Selector
To access oil level, prognostics, and DTCs,
do the following:
Select N (Neutral) and apply the parking
brakes.
and (Down) Arrow buttons once to
access oil level information (except
3700SP).
and (Down) Arrow buttons again
to access the Oil Life Monitor (if
and (Down) Arrow buttons again
to access the Filter Life Monitor (if
110

and (Down) Arrow buttons again to
access the Transmission Health Monitor
(if Prognostics is available).
Pushbutton selectors: simultaneously press

the UPSHIFT and DOWNSHIFT arrows on
the selector.
Lever selectors: press the DMD button.
f. Diagnostic Trouble Code (DTC) Displays.
Once the display mode has been initiated:
If the transmission is equipped with an OLS,
the uid level is displayed rst.
If prognostics functions are enabled in the
TCM Controls calibration, the prognostics
readouts are displayed next.
DTCs are then displayed. Each DTC consists
of four sequential elements, each being either
one or two characters. The display for each
DTC repeats continuously until the next DTC
(if present) is accessed by pressing the MODE
button. The following example illustrates the
display cycle for the newest DTC in memory
(DTCP2534 is used for illustration purposes):
GENERAL INFORMATION
NOTE: d1=newest DTC, d5=oldest DTC in memory
d1
Code list position
DTC type
25
Main DTC
34
Subcode
d1 P 25
34
DTC repeats until next DTC (d2) is

accessed by pressing the MODE button
If the condition which generated the DTC is active,

the LED indicator on the selector is illuminated
simultaneously with the display of the DTC. If the
condition which generated the DTC no longer
exists, the LED is not illuminated and the DTC is
maintained only as a historical record of the prior
condition.
The code list or queue position (d1) is the rst
item displayed, followed by the DTC. Each item
is displayed for about one second. The display
cycles continuously until the next code list position
is accessed by pressing the MODE button. The
following example shows how DTCC1312 is
displayed on the pushbutton and lever selectors.
LEDs on Shift Selectors
SELECT
MONITOR
To view the second, third, fourth, and fth positions

(d2, d3, d4, and d5), momentarily press the MODE
button as explained above. Momentarily press the
MODE button after the fth position is displayed
to restart the sequence of code list positions. An
active DTC is indicated by the illumination of the
LED indicator when a code position is displayed
while in the diagnostic display mode. In normal
operating mode, the LED indicator illuminates to
show a secondary mode operation. Any code
position which does not have a DTC logged displays
for the DTC. No DTCs are logged after an empty
code position.
g. Exiting Diagnostic Mode. Use any of the
following methods to exit the diagnostic display
mode:
1. With pushbutton shift selectors,

simultaneously press the UPSHIFT and
DOWNSHIFT arrows or press any range
button, D (Drive), N (Neutral), or R (Reverse).
If the shift is not inhibited by an active DTC,
the TCM commands the transmission to shift
to the selected range.
2. With lever shift selectors, momentarily press
the MODE button or move the shift selector
to any shift position other than the one
selected when the diagnostic display mode
was activated. If the shift is inhibited due
to a service condition, the TCM continues
to command the current transmission range
attained and the lever should be returned to
its previous position.
3. Wait until timeout (approximately 2 minutes).
The systems automatically return to the
normal operating mode.
4. Turn off the vehicle engine with the ignition
switch, which turns power off to the TCM.
18.
PRESERVATION AND STORAGE
a. Preservation Methods. When the transmission

is stored or inactive for an extended period (one
or more years), specic preservation methods are
required to prevent damage from rust, corrosion,
and organic growth in the transmission uid.
Preservation methods described are for storage
with or without transmission uid. The methods are
the same whether a transmission is in or out of a
vehicle.
b. Storage (New Transmissions, Before
Installation). New transmissions are lled with
transmission uid and drained before shipment. The
residual uid in the transmission provides adequate
protection to safely store the transmission for one
full year without further treatment if stored indoors,
in conditions of normal climate, and with all shipping
plugs installed.
c. One Year Storage (Without Fluid).
1. Drain the uid.
2. Remove the breather and spray 30 ml (one
ounce) of VCI #10 (or equivalent) into the
transmission through the breather hole.
111

Reinstall breather. Also, spray 30 ml (one
ounce) through the ll tube hole.
3. Seal all openings and the breather with
moistureproof tape.
4. Coat all exposed, unpainted surfaces with
preservative grease such as petrolatum
(MILC 11796, Class 2).
8. Coat all exposed, unpainted surfaces with

preservative grease such as petrolatum
(MILC 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 equivalent).
5. If additional storage time is required, repeat

Steps 3 and 4 at yearly intervals.
d. One Year Storage (With Fluid).
1. Drain the uid and replace the oil lter
elements
2. Fill the transmission to operating level with a
mixture of one part VCI #10 (or equivalent)
to 30 parts transmission uid. Add 3 ml
(1/4 teaspoon per gallon) of Biobor JF (or
equivalent) per 3 ml (1/4 teaspoon per gallon)
of uid 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
ll the transmission. Include external lines,
lters, and the cooler.
3. Operate the transmission for approximately
ve minutes at 1500 rpm with the transmission
in neutral.
4. Make sure the transmission shifts through all
ranges and the lockup clutch is also activated.
5. Continue operating the transmission in
neutral at 1500 rpm until normal operating
temperature is reached.
6. If normal operating temperature is less than
107C (225F), shift the transmission to
forward range and stall the converter. Do not
exceed 107C (225F).
NOTE: If the unit does not have a
converterout temperature gauge, do not
stall the converter.
7. As soon as the transmission is cool enough to
touch, seal all openings and the breather with
moistureproof tape.
112
19.
RESTORING TRANSMISSION TO
SERVICE
CAUTION: Whenever a transmission is
overhauled, exchanged, or has undergone
repairs, the Transmission Control Valve
Module (TCM) must be RESET TO
UNADAPTED SHIFTS. This will cause the
TCM to erase previous adaptive information
and begin to adapt in Fast Adaptive Mode
from the base calibration. Use the Allison
DOC For PCService Tool (refer to the
Allison DOC Users Guide GN3433EN for
instructions) to RESET TO UNADAPTED
SHIFTS.
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 uid. Rell
the transmission to the proper level with an Allison
approved transmission uid.
d. Stored Without Fluid. If the transmission was
prepared for storage without uid, drain the residual
uid and replace the oil lter elements. Rell the
transmission to the proper level with an Allison
approved transmission uid.
e. Stored With Fluid. If the transmission was
prepared for storage with uid, it is not necessary
to drain and rell the transmission with new
transmission uid. Check for proper uid level. Add
or drain transmission uid, as required, to obtain
the proper level.
GENERAL INFORMATION
110. OPERATING INSTRUCTIONS
Detailed transmission operation information is in
the 3000 and 4000 Product Families Principles of
Operation Manual, PO4016EN, or vocational model
Operators Manuals (see Table 81). Refer to the
latest revision.
111.
SPECIFICATIONS AND DATA
The following specications and data provide a

quick reference to the major characteristics of the
transmission. More detailed information may be
obtained from Sales Tech Data books.
Table 11. 3000 Product Family Specications and Data Chart*
Gear Ratios:**
Range
3000/3200
3500
3700 SP
First
3.49:1
4.59:1
6.93:1
Second
1.86:1
2.26:1
4.18:1
Third
1.41:1
1.53:1
2.24:1
Fourth
1.00:1
1.00:1
1.69:1
Fifth
0.75:1
0.75:1
1.20:1
Sixth
0.65:1
0.65:1
0.90:1
Seventh
N/A
N/A
0.78:1
Reverse
5.03:1
5.00:1
6.03:1
HYDRAULIC SYSTEM:
Fluid type
Allison approved TES295 uid, MILL2104, MILL46167, MILPRF21260,

DEXRONVI, TES 389
Filters, main and cooler
Dual integral, replaceable cartridge type
Cooler
Remote mounted, optional integral
SIZES:
Base
Transmission
With PTO
Provision
With Retarder
With PTO
Provision and
Retarder
3700 SP
Length (transmission
mounting face to end of
output shaft)
719.4 mm
(28.32 in)
821.9 mm
(32.36 in)
718.6 mm
(28.29 in)
821.6 mm
(32.35 in)
1310.3 mm
(51.58 in)
Depth (centerline to lowest

point)
327.7 mm
(12.90 in)
327.7 mm
(12.90 in)
327.7 mm
(12.90 in)
327.7 mm
(12.90 in)
555.3 mm
(21.87 in)
Dry Weight
243 kg (535 lb)
261 kg (575 lb)
279 kg (615 lb)
297 kg (655 lb)
530 kg
(1170 lb)
Dry Weight with integral retarder sump cooler

*All
336.5 kg (740 lb)
data and specications are subject to change without notice.

ratios do not include torque converter multiplication.
**Gear
113

112.
ELECTROMAGNETIC/RADIO
FREQUENCY INTERFERENCE
All electrical and electronic systems generate

electromagnetic elds that can interfere with
other electronic systems. Allison Transmissions
electronic transmission controls comply with Federal
Communications Commission (FCC) regulations
and other guidelines concerning emitted radio
frequency interference for transportation electronics.
Some radiotelephone or twoway communications
radios (landmobile 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 Electromagnetic
Interference (EMI)/Radio Frequency Interference
(RFI) emitting equipment are responsible for
adhering to FCC regulations and other guidelines
concerning emitted radio frequency interference for
transportation electronics. Radio or other twoway
communication antenna, power, or ground leads
near the transmission wiring harness, control
devices, or power leads may create or be subject
to EMI. Refer to the latest revision of Allison 4th
Generation Controls Troubleshooting Manual,
TS3989EN, for detailed instructions regarding EMI
problems.
114
SECTION 2PREVENTIVE MAINTENANCE

21.
SCOPE
Proper care and regular maintenance enables

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, efcient service in their designed applications.
22.
b. Filter Life Monitor. Filter deterioration is

sensed by a differential pressure switch (PS2)
located in the control valve module. The pressure
difference between ltered lockup pressure and
unltered main pressure is compared to a calibrated
value. If the TCM determines the lter has
deteriorated, the prognostic service indicator icon
displays on the shift selector.
Calendar based lter change requirements still
apply and are not incorporated into prognostics.
Refer to the most current version of SIL 10TR99.
Prognostics
Model Year 09 transmissions (MY09 begins with

S/N 6510822005, 6520099957) are equipped
with a prognostics systemcomprised of control
valve module hardware, the shift selector, the
Transmission Control Module (TCM) conguration
and the calibrationdesigned to monitor uid life,
uid lter life, and clutch life. Prognostics may be
used only if a TES 295 uid is in the transmission.
If uid change, lter change, or clutch service is not
performed within a set period of time, a Diagnostic
Trouble Code (DTC) sets with a CHECK TRANS
light, and/or a SERVICE TRANS light (shown as the
wrench icon) in the shift selector or as an additional
light in the dash.
Prognostics can be reset through the Allison
DOC For PCService Tool or, if calibrated to
allow manual reset, through manipulating the shift
selector.
a. Oil Life Monitor. Transmission operating
parameters are monitored to determine remaining
uid and lter life, as well as:
NOTE: The lter life monitor feature is not

available with seven speed transmission
models.
c. Transmission Health. Transmission health
monitors the running clearance of C1, C2, C3, C4,
and C5 clutches to determine clutch plate wear.
Clutch running clearance, based upon clutch ll
volume, indicates remaining clutch life. The C6 and
lockup clutches are not monitored.
d. Shift Selector Display. Only six speed
transmissions using Allison pushbutton or lever
shift selectors can display the prognostic service
indicator icon. Pressing lever shift selector
Diagnostic button or simultaneously pressing the
pushbutton shift selector arrow buttons enters
the diagnostic mode and cycles the shift selector
display. Table 21 correlates the number of button
presses with the type of diagnostic display.
Table 21. Shift Selector Display
Press
or
Diagnostic
Operating time
Retarder operation
Display
Meaning
Output shaft revolutions
OLXX ##
Oil Level
Shift frequency
OM ##
Oil Life
Monitor
FM ##
Filter Life
Monitor
TM ##
Trans
Health
Monitor
d1 P ## ##
Diagnostic
Trouble
Code
When operating parameters reach or exceed a

calibrated value the TCM illuminates the prognostic
service indicator icon on the shift selector.
Calendar based uid change requirements still
apply and are not incorporated into prognostics.
Refer to the most current version of 10TR99.
21

Oil level display indicates the HI or LO and
the number of quarts high or low
Oil life monitor display indicates the
percentage of oil life remaining 88, 02
Filter life monitor display indicates the
percentage of lter life remaining95, 10
Trans Health display indicates the status of
clutch lifeOK, LO
DTC displays the diagnostic trouble code list
NOTE: For additional prognostics
information see SIL 11WT08.
23.
PERIODIC INSPECTION AND CARE
a. Exterior Cleaning and Inspection.

CAUTION: DO NOT pressurewash the
transmission electrical connectors. Water
and detergent will 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 boltstransmission and mounting
components
Fluid leaks (refer to SIL 12WT02)
repair immediately
Loose, dirty, or improperly adjusted
throttle sensor
Damaged or loose hoses
Worn, frayed, or improperly routed
electrical harnesses
Dented, worn, or outofphase driveline
Ujoints and slip ttings
Clogged or dirty breather
Check transmission uid for evidence of
engine coolant
24.
IMPORTANCE OF PROPER FLUID

LEVEL
a. Transmission Fluid. Transmission uid cools,

lubricates, and transmits hydraulic power. Always
maintain the correct uid level. If the level is too low,
the torque converter and clutches do not receive
enough uid and the transmission overheats. If
the level is too high, the uid aerates causing the
transmission to shift erratically and overheat. Fluid
may be expelled through the breather or dipstick
tube when the uid level is too high.
b. Oil Level Sensor. The Oil Level Sensor (OLS)
allows the operator to check the uid level from
either a fullfunction pushbutton or a lever shift
selector. When an Allison 4 th Generation Controls
striptype pushbutton selector is used, the OLS uid
level information can only be read using Allison
DOC For PC Service Tool.
25.
TRANSMISSION FLUID CHECK
a. Electronic Check Procedure. An Oil Level

Sensor (OLS) is standard for all 3000 product
families except the 3700 SP. The transmission
uid level can be displayed on the shift selector or
Allison DOC For PCService Tool display. Use the
following procedure to display uid level information.
1. For a pushbutton selector, simultaneously
press the (Up) and (Down) arrow buttons
once.
2. On the lever shift selector, press the DISPLAY
MODE button once.
3. For the Allison DOC For PCService Tool,
refer to the Allison DOC For PCService
Tool User Guide GN3433EN.
b. Fluid Level Display Criteria. As soon as uid
level information is requested, the Transmission
Control Module (TCM) checks to see if the
conditions are right to allow display. Certain
operating conditions must be met for a period of two
minutes before uid level is displayed. The display
ashes and an 8, 7,....1 countdown occurs. Fluid
level information displays after the countdown if the
following conditions have been met:
Engine at idle
22
PREVENTIVE MAINTENANCE
Sump uid temperature at 60104C
(140220F)
Display
(Former)
Display (MY08,
Cal/Sfw or
newer)
Interpretation
of Display
oL95
oL FL
Sensor failure
Transmission output shaft stopped

Transmission in N (Neutral).
* A number between 8 and 1 that ashes during the

countdown period.
OLS functioning properly

Shift selector display uid level information is
displayed two characters at a time as shown in
Table 22.
Table 22. Fluid Level Shift Sector Display
Display Sequence
Interpretation of Display
oL, oK
Fluid level is correct
oL Lo 01
Fluid level is 1 quart low
oL HI 01
Fluid level is1 quart high
oL, , (N)
Invalid For Display

N = numerical display
(alphabetical for MY08
and newer)
The shift selector shows invalid for display codes

two characters at a time. An invalid for display code
is returned when the uid level data is requested,
but an operational condition has not been met. The
invalid for display codes and their meaning are
shown in Table 23.
Table 23. Invalid for Display Codes
NOTE: Report sensor failure to a

distributor or dealer in your area.
(Check the Allison Transmission web
site www.allisontransmission.com or
a telephone directory for an Allison
Transmission distributor or dealer
nearest you.)
On Allison diagnostic tools, invalid for display
messages are shown in the Oil () eld of the Data
Monitor as shown in Table 24.
Table 24. Invalid for Display Messages
Display Code
DDR Message
OL
SETTLING TIME X
OL
ENGINE SPEED LOW
OL
ENGINE SPEED HIGH
OL
SELECT N (Neutral)
OL
SUMP TEMP LO
OL
SUMP TEMP HIGH
OL
OUTPUT SPEED HIGH
OL
CHECK CODES
Display
(Former)
Display (MY08,
Cal/Sfw or
newer)
Interpretation
of Display
oL 0X
oL 0X
Settling time
too short*
oL EL
Engine rpm
too low
Pushbutton shift selectorpress the N

(Neutral) button once.
oL EH
Engine rpm
too high
Lever shift selectorpress the MODE button

once or move the lever.
oL SN
N (Neutral) must
be selected
oL TL
Sump uid
temperature
too low
For Allison DOC For PCService Tool, follow

directions in the Allison DOC User Guide
GN3433EN.
oL TH
Sump uid
temperature
too high
oL SH
Output shaft
rotation
oL50
oL59
oL65
oL70
oL79
oL89
Exit Fluid Level Mode as follows:
23

26.
MANUAL FLUID LEVEL CHECK

PROCEDURE
WARNING: To help prevent personal injury
or property damage caused by sudden
and unexpected vehicle movement, do not
check the uid until you:
Put the transmission in N
(Neutral)and
Apply the parking brake and
emergency brakes and make sure
they are properly engagedand
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 uid ll 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 check
the uid level reading at least twice using the
following Cold Check and Hot Check procedures.
Consistency (repeatable readings) is important
to maintaining proper uid level. If inconsistent
readings persist, check the transmission breather
to be sure it is not clogged. If readings are still
inconsistent, contact your nearest Allison distributor
or dealer.
27.
COLD CHECK (Figure 21)
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 (500800 rpm) for
about one minute. Shift to D (Drive) and then
to R (Reverse) to clear the hydraulic system
of air. Then shift to N (Neutral) and allow the
engine to remain at idle (500800 rpm).
3. With the engine running, remove the dipstick
from the tube and wipe clean.
4. Insert the dipstick into the tube until it stops
and remove. Check the uid level. Repeat the
check procedure to verify the reading.
5. If the uid level is within the COLD CHECK
band, the transmission can be operated until
the uid is hot enough to perform a HOT
CHECK procedure. If the uid level is not
within the COLD CHECK band, add or drain
as necessary to bring the uid level to the
middle of the COLD CHECK band.
6. Perform a hot check at the rst opportunity
after normal operating temperature is
reached7193C (160200F).
28.
HOT CHECK (Figure 21)

CAUTION: When performing the Hot Check
procedure, the uid must be at operating
temperature to be sure of an accurate check
and help prevent transmission damage.
The uid level rises as temperature
increases. During operation, an overfull
transmission can become overheated
leading to transmission damage.
a. Purpose. The cold check determines if the

transmission has enough uid to be operated safely
until a hot check can be made.
CAUTION: The uid level rises as
uid temperature rises. DO NOT ll
above COLD CHECK band if the
transmission uid is below normal operating
temperatures. During operation an overfull
transmission can become overheated,
leading to transmission damage.
24
5. If the uid level is not within the HOT RUN
band, add or drain as necessary to bring the
uid level to within the band. Safe operating
level is within the HOT RUN band on the
dipstick (refer to Figure 21).
29.
KEEPING FLUID CLEAN

CAUTION: Containers or llers that
have been used for antifreeze or engine
coolant solution must NEVER be used for
transmission uid. 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, llers, etc.
Lay the dipstick in a clean place while lling the
transmission.
Figure 21. Fluid Dipstick Markings

a. Hot Check Procedure.
1. Operate the transmission in D (Drive) range
until normal operating temperature is reached:
Sump temperature7193C
(160200F)
Converterout temperature82104C
(180220F).
If a transmission temperature gauge is not
present, check uid level when the engine
water temperature gauge has stabilized and
the transmission has been operated under
load for at least one hour.
2. Park the vehicle on a level surface and shift
to N (Neutral). Apply the parking brake and
block the wheels. Allow the engine to idle
(500800 rpm).
3. With the engine running, remove the dipstick
from the tube and wipe clean.
4. Insert the dipstick into the tube until it stops
and remove. Check uid level. Repeat the
check procedure to verify the reading.
210. FLUID RECOMMENDATIONS

NOTE: Effective January 1, 2007, General
Motors no longer licenses DEXRONIII
uids. Fluid specication TES 389 uid
gives OEMs and customers another
approved uid choice. TES 389 uids have
the same uid and lter change intervals as
the former DEXRONIII.
CAUTION: Beginning with S/N

6510717281, S/N 6520083093, S/N
6610220990, S/N 6620005821, S/N
9370007661, S/N 9320006231, S/N
9470006080, and S/N 9420007560,
material of specic seals has been modied
to be compatible with DEXRONVI
uids. Transmissions prior to the above
serial numbers are not compatible with
DEXRONVI uids. Seal compatibility can
be identied by a "D6C" or 8 color marks
on the face of the seal. See SIL 6WT07
for more information.
a. The hydraulic uids (oils) used in Allison
transmissions directly affect transmission
performance, reliability, and durability. Use an
25

Allison approved TES 295 uid, DEXRONVI,
or TES 389 for regular duty, onhighway
applications.
b. To verify your uid is qualied for use in
Allison transmissions, check for an Allison
approved TES 295 label, a DEXRONVI,
or a TES 389 uid license, or approval
number on the uid container, or consult the
lubricant manufacturer. Consult your Allison
Transmission dealer or distributor before using
any uid types except those uids qualied for
use in Allison transmissions.
CAUTION: Disregarding minimum uid
temperature limits can result in transmission
malfunction or reduced transmission life.
c. When choosing the optimum viscosity grade
of uid to use, take duty cycle, preheat
capabilities, and/or geographical location into
consideration. Table 25 lists the minimum
uid temperatures at which the transmission
may be safely operated. Preheat with
auxiliary heating equipment or by running the
equipment or vehicle with the transmission in
neutral for a minimum of 20 minutes before
attempting range operation.
Table 25. Transmission Fluid Operating
Temperature Requirements
SAE Viscosity
Grade* Or Fluid
Type
Minimum Operating Temperature

Degrees (C)
Degrees (F)
MILPRF46167
32
26
SAE 0W30
(Arctic)
30
22
TranSyndTM/
TES 389
35
31
DEXRONVI/
TES 389
25
13
SAE 10W
25
13
SAE 15W40
20
SAE 30W
32
SAE 40W
10
50
211.
FLUID AND FILTER CHANGE

INTERVAL
CAUTION: Transmission uid and lter
change frequency is determined by the
severity of transmission service. More
frequent changes may be necessary than
recommended in the general guidelines
when operating conditions create high
levels of contamination or overheating.
a. Fluid And Filter Changes. If using gold series

lters, change the main lter after the rst 8000 km
(5000 miles) then follow the recommended uid
and lter change intervals in Table 26.Table 26 is
given only as a general guide for uid and lter
change intervals.
Local conditions, severity of operation, or duty
cycle may require more or less frequent uid
change intervals that differ from the published
recommended uid change intervals of Allison
Transmission. Transmission protection and uid
change intervals can be optimized by the use
of uid analysis. Change lters at or before the
recommended intervals. Refer to SIL 10TR99.
b. High Capacity Filters. Allison 3000 Product
Families transmission high capacity lters were
released into production beginning July 2006.
High capacity lters allow extended lter change
intervals when used with an Allison approved TES
295 uid. High capacity lters can be identied
by P/N 29545777 or 29545780 stamped into the
lter end cap. Previous Allison 3000 Product
Families transmission lters can be identied by
P/N 29538231 or 29538232 stamped into the lter
end cap. When replacing gold series lters with
high capacity lters in transmissions containing
100 percent Allison approved TES 295 uid, it is
allowed to follow high capacity uid and lter change
intervals. Refer to Table 26.
*SAE W designation means winter weight based on cold

temperature properties.
26
Table 26. Fluid Change Intervals

MILPRF2104
MILPRF21260
MILPRF46167
Allison Approved NonTES 295 Fluids
Allison Approved TES 295
General
Severe
General
Severe
General
Severe
25,000 miles
(40,000 km)
12 months
12,000 miles
(20,000 km)
6 months
25,000 miles
(40,000 km)
12 months
12,000 miles
(20,000 km)
6 months
150,000 miles
(240,000 km)
48 months
75,000 miles
(120,000 km)
36 months
HIGH CAPACITY FILTERS a, AND WHEN PROGNOSTICS IS TURNED OFF OR NOT CALIBRATED IN TCM
12,000 miles
(20,000 km)
6 months
25,000 miles
(40,000 km)
12 months
12,000 miles
(20,000 km)
6 months
PROGNOSTICS
300,000 miles
(480,000 km)
48 months
150,000 miles
(240,000 km)
48 months
NOTE: If prognostics is turned off or not calibrated in the TCM,use of high capacity lter and uid change intervals must be followed.
N.A.
N.A.
N.A.
N.A.
Change uid when indicated by prognostics

or 60 months, whichever comes rst. Also
change lters with uid (high capacity lters
and prognostics turned on).
NOTE: Change uid/lters at or before recommended mileage, months, or hours have elapsed, whichever occurs rst.
NOTE: Local conditions, severity of operation or duty cycle may require more or less frequent uid change intervals that differ from the published recommended
uid change intervals. In the absence of a uid analysis program, the uid change intervals listed in the charts above should be used.
NOTE: General Vocation: Intercity Coach with duty cycle less than or equal to one stop per mile and all other vocations not listed in severe vocation.
NOTE: Severe Vocation: All Retarders, On/Off Highway, Refuse, Transit, Shuttle Transit, 2000 MH, and Intercity Coach with duty cycle greater than one stop
per mile.
a
b
High capacity lters released in models starting with S/N 6510670912, 65200667342
Prognostics released on models starting with S/N 6510822005, 6520099957
25,000 miles
(40,000 km)
12 months
27

c. Fluid Analysis. Optimize transmission
protection and uid change intervals by monitoring
uid oxidation according to the tests and limits
shown in Table 27. Consult your local telephone
directory for uid analysis rms. For consistent and
accurate uid analysis, use only one uid analysis
rm. Refer to the Technicians Guide for Automatic
Transmission Fluid, GN2055EN, or SIL 17TR96
for additional information.
Table 27. Fluid Oxidation Measurement Limits
Test
Limit
Viscosity
25% change from new

uid
Total Acid Number
+3.0* change from new

uid
Water
0.2 percent by volume

maximum
*mg
Transmission uid 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 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, seals,
gaskets, and bearings contaminated with engine
coolant.
of KOH to neutralize a gram of uid.
c. Metal.
212. FLUID CONTAMINATION

CAUTION: Transmission uid and lters
must be changed whenever there is
evidence of dirt or a high temperature
condition. A high temperature condition
is indicated when the transmission uid
is discolored, has a strong odor or has
exceeded oil analysis limits shown in
Table 26.
CAUTION: Upon discovering transmission

uid contamination, if there is any doubt
about the total cleanup of the cooler,
replace the cooler. Contamination
remaining in the cooler can recontaminate
the transmission uid.
a. Water.
1. At each uid change, examine the drained
uid for evidence of dirt or water. A normal
amount of condensation will appear in the uid
during operation.
CAUTION: If excessive metal

contamination has occurred, replace
the oil cooler and visually inspect all
bearings in the transmission.
Visible metal particles in the transmission uid
(except for the minute particles normally trapped
in the oil lter) may indicate internal transmission
damage. When these particles are found in the
sump, the transmission must be disassembled
and closely inspected to nd 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.
213. FLUID AND FILTER CHANGE

PROCEDURE
NOTE: Do not drain the uid If only the
lters are being replaced.
2. Obvious water contamination of the

transmission uid requires inspecting and
pressure testing the cooler (heat exchanger)
for leaks between the water and uid areas.
28
a. Drain Fluid.
WARNING: Avoid contact with the hot uid
or the sump when draining transmission
uid. Direct contact with the hot uid or the
hot sump may result in bodily injury.
4. Install six M10 x 1.5 x 100 bolts (6) into each

cover (5) and tighten them to 5161 Nm
(3845 lb ft).
1. Drain the transmission uid when the uid

is at operating temperature7193C
(160200F). Hot uid ows quicker and
drains more completely.
2. For all models except 3700 SP, remove drain
plug assembly (9) (Figure 22) from the
control valve module and allow the uid to
drain into a suitable container. For a 3700 SP,
remove drain plug assemblies (7) and (10)
(Figure 23) from the control valve module
and transfer case. Allow the uid to drain into
suitable containers.
3. Examine the uid as described in 212.
FLUID CONTAMINATION.
b. Replace Filters (Figure 22).
CAUTION: Do not interchange the deep
and shallow sump lters. Installation of
the wrong lter can cause damage to the
transmission.
1. To replace the oil lters, remove 12 bolts (6),
two lter covers (5), two gaskets (4), two
Orings (3), two Orings (2), and two lters (1)
from the bottom of the control valve module.
2. When installing parts, lubricate and install new
Oring (2) and (3) on each cover (5). Lubricate
the Oring inside the lter (1) and push lter
onto each cover (5). Install new gasket (4)
on each cover (5) and align the holes in the
gasket with holes in the cover.
CAUTION: Do not use the bolts to draw
lter covers to the sump. This can damage
the covers, seals, or sump.
3. Install lter (1) and cover (5) assemblies into
the lter compartment. Index each lter/cover
assembly to the holes in the channel
plate/sump. Seat the seals by pushing the
lter/cover assemblies in by hand.
Figure 22. Filter Change

c. Replace Filters3700 SP Transmission
(Figure 23).
CAUTION: Do not interchange the deep
and shallow sump lters. Installation of
the wrong lter can cause damage to the
transmission.
1. To replace the oil lters, remove 12 bolts (6),
two lter covers (5), two gaskets (4), two
Orings (3), and two Orings (2).
2. When installing parts, lubricate and install new
Orings (2) and (3) on cover (5). Lubricate
Oring inside the lter (1) and push the lter
onto cover (5). Install new gasket and align
the holes with those in the cover (5).
29

CAUTION: Do not use the bolts to draw
lter covers to the sump. This can damage
the covers, seals, or sump.
replace Oring (7) or plug (8) as required. For

3700 SP models, remove and inspect drain
plug assemblies (7) and (10) (Figure 23) and
replace Orings ((8) and (11) or plugs (9) and
(12) as required.
3. Install lter (1) and cover (5) assemblies into

the lter compartment. Index each lter/cover
assembly to the holes in the channel
plate/sump. Seat the seals by pushing the
lter/cover assemblies in by hand.
4. Install six M10 x 1.5 x 100 bolts (6) into each
cover (5) and tighten them to 5161 Nm
(3845 lb ft).
NOTE: Whenever metallic particles, larger

than those normally found in lters, are
present on plug (12), disassemble the
transfer case to nd and repair the source
of the contamination.
2. Tighten drain plugs to 2532 Nm (1824 lb ft)
after inspection is completed.
3. After rell, check the uid level (refer
to Paragraphs 27. COLD CHECK
(Figure 21) and 28a. Hot Check
Procedure).
NOTE: When the transmission is not
completely disassembled or when just
lters or uid is changed, some uid
remains in the transmission so rell quantity
will be less than for a dry unit.
4. Refer to Table 28 for typical initial ll (dry unit)
and for uid amounts required to ll coolers
and the remote retarder accumulator.
Table 28. Fluid Fill Quantities
Item Being Filled
Initial Fill*
3000 Product
Family
4.00 in. Sump
27.0 L (29.0 qt)
2.00 in. Sump
25.0 L (26.0 qt)
3700 SP
7.00 in. Sump
37.0 L (39.0 qt)
Additional Fill For Cooler*
Figure 23. 3700 SP Filter Change

d. Rell Transmission.
Directmount
1.0 L (1.1 qt)
Retarder
2.5 L (2.6 qt)
Additional Fill For Retarder Accumulator*
CAUTION: The seal material in

transmissions beginning with transmission
S/N 6510717075 has been changed to be
compatible with DEXRONVI uids. DO
NOT use DEXRONVI in transmission
with earlier serial numbers.
Remote
*Does
Accumulator
not include hoses or ttings.
1. For all models except the 3700 SP, inspect

drain plug assembly (9) (Figure 22) and
210
Nonretarder
0.9 L (0.95 qt)
214. BREATHER
a. Location and Purpose. The breather is located
on top of the transmission converter housing. It
serves to prevent air pressure buildup within the
transmission and must be kept clean and open.
CAUTION: Be sure that the hydraulic

ttings have the same thread as the plugs
removed (71620 UNF2A). Fittings must
be straight thread, Oring style. Failure to
do this will result in damage to the control
valve module.
b. Maintenance.
1. The amount of dust and dirt encountered
determines 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. Install hydraulic ttings suitable for attaching

pressure gauges or transducers.
2. Always use a properly sized wrench to remove

or replace the breather. Pliers or a pipe
wrench can crush or damage the stem and
produce metal chips which could enter the
transmission.
4. Be sure the engine speed can be monitored.

(Allison DOC For PCService Tool may be
used for this purpose.)
215. CHECKING CLUTCH PRESSURES

Measuring individual clutch pressures helps
determine if a transmission malfunction is due to
a mechanical or an electrical problem. Properly
making these pressure measurements requires
transmission and vehicle (or test stand) preparation,
recording of data, and comparing recorded data
against specications provided. These instructions
are for all 3000 Product Families transmissions.
3. Connect pressure gauges or transducers.

Pressure Gauge Set P/N J26417A
is available for this purpose. Refer to
Table 29 for test conditions and to
Table 210 for pressure levels expected.
5. Be sure the transmission sump uid

temperature can be measured. (Allison DOC
For PCService Tool may be used for this
purpose.)
6. Be sure the transmission has enough uid for
cold operation until an operating temperature
uid level can be set.
7. Bring the transmission to normal operating
temperature of 7193C (160200F).
Inspect for uid leaks in the added pressure
gauge/transducer lines. Repair leaks as
needed. Be sure that uid level is correct.
NOTE: Determine if there are Diagnostic

Trouble Codes (DTCs) set which are
related to the transmission difculty you are
evaluating. Proceed to make mechanical
preparations for measuring clutch pressures
after DTCs have rst been evaluated.
a. Transmission and Vehicle Preparation.
1. Remove the plugs from the pressure tap
locations where the measurement is desired
(refer to Figure 24).
211

NOTE: Measure 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 uid
temperature values shown in Table 29.
The lockup clutch is functioning correctly
when engine speed and turbine speed
values are equal as recorded from the
Allison DOC For PCService Tool.
2. Refer to Table 29 and locate the transmission
model that you are testing.
3. Operate the transmission at the conditions
shown in Table 29 and record engine speed,
transmission sump uid temperature, main
hydraulic pressure, and clutch pressures in
the ranges where a problem is suspected.
c. Comparing Recorded Data to Specications.
1. Be sure the engine speed and transmission
sump uid temperatures are within the values
specied in Table 29.
2. Compare the main pressure and clutch
pressure data recorded in 215b. Recording
Data, with the specications in Table 210.
3. If clutch pressures are within specications,
return the transmission and vehicle to their
original conguration and proceed with
electrical troubleshooting.
4. If clutch pressures are not within specication,
take corrective action to replace the internal
parts of the transmission necessary to correct
the problem.
Figure 24. Clutch Pressure Check Points
b. Recording Data.
1. The Allison DOC For PCService Tool
allows checking of individual range clutch
pressures with the vehicle stationary. Clutch
Test instructions are located in the Action
Request section of the Allison DOCTM For
PC Service Tool User Guide, GN3433EN.
Follow instructions to check clutch pressures
in individual ranges.
212
5. Measure pressure values after the

transmission has been repaired.
6. Return the transmission to its original
conguration. (Remove instrumentation
and install any components removed for
pressure testing. Pressure tap plugs should
be reinstalled and tightened to 1013 Nm
(710 lb ft.).
Table 29. Clutch Pressure Test Conditions
Transmission
Model/ Test Type
Engine rpm
Sump Fluid Temp
Range
Clutches
Pressurized
3000 Product
FamilyIdle Check
580620
7193C (160200F)
N (Neutral)
R (Reverse)
Low C
1C
C5
C3 C5
C3 C6
C1 C5
3000 Product
FamilyHigh Speed
20802120
7193C (160200F)
R (Reverse)
N (Neutral)
1C
2C
C3 C5
C5
C1 C5
C1 C4
3000 Product
FamilyHigh Speed
20802120
2L
3L
4L
5L
6L
3700 SPHigh
Speed
20802120
R (Reverse)
N (Neutral)
C5 LoC
1C
2C
2L
3L
4L
5L
6L
C1
C1
C1
C2
C2
C4
C3
C2
C3
C4
LU
LU
LU
LU
LU
C3 C5
C5
C3 C6
C1 C5
C1 C4
C1 C4 LU
C1 C3 LU
C1 C2 LU
C2 C3 LU
C2 C4 LU
213
214
Table 210. Main Pressure and Clutch Pressure Specications (Sump Fluid Temperature Same as in Table 25)
Engine rpm
Range
Main Press.
Spec
kPa (psi)
Clutches
Applied
Range Clutch
Press. Spec
*kPa (psi)
Lube Press.
Spec*
kPa (psi)
Lockup
Clutch Press.
Spec
kPa (psi)
Dropbox Main
Press. Spec*
kPa (psi)
3000 Product
FamilyIdle
580620
Neutral Main
Mod OFF
15152035
(220295)
C5
14402035
(210295)
1035 (15)
NA
14402035
(210295)
Neutral Main
Mod ON
13101725
(190250)
C5
12351725
(180250)
1035 (15)
NA
12351725
(180250)
Reverse Main
Mod OFF
14502035
(210295)
C3, C5
13752035
(200295)
1035 (15)
NA
13752035
(200295)
Reverse Main
Mod ON
11701585
(170230)
C3, C5
10951585
(160230)
1035 (15)
NA
10951585
(160230)
Low C (3000
7Speed) Main
Mod OFF
12401725
(180250)
C3, C6
11651725
(170250)
1035 (15)
NA
11651725
(170250)
Low C (3000
7Speed) Main
Mod ON
8701340
(125195)
C3, C6
7951340
(115195)
1035 (15)
NA
7951340
(115195)
1C Main Mod
OFF
12401725
(180250)
C1, C5
11651725
(170250)
1035 (15)
NA
11651725
(170250)
1C Main Mod
ON
8701340
(125195)
C1, C5
7951340
(115195)
1035 (15)
NA
7951340
(115195)
2C Main Mod
OFF
12401725
(180250)
C1, C4
11651725
(170250)
1035 (15)
NA
11651725
(170250)
2C Main Mod
ON
8701340
(125195)
C1, C4
7951340
(115195)
1035 (15)
NA
7951340
(115195)

Transmission
Model/Test Type
Table 210. Main Pressure and Clutch Pressure Specications (Sump Fluid Temperature Same as in Table 25) (contd)
215
Engine rpm
Range
Main Press.
Spec
kPa (psi)
Clutches
Applied
Range Clutch
Press. Spec
*kPa (psi)
Lube Press.
Spec*
kPa (psi)
Lockup
Clutch Press.
Spec
kPa (psi)
Dropbox Main
Press. Spec*
kPa (psi)
3000 Product
FamilyHigh
Speed
20802120
Neutral Main
Mod OFF
18052205
(260320)
C5, LU
17302205
(250320)
160240
(2335)
050 (07.3)
17302205
(250320)
Neutral Main
Mod ON
14151725
(205250)
C5, LU
13351725
(195250)
160240
(2335)
050 (07.3)
13351725
(195250)
Reverse
18052205
(260320)
C3, C5, LU
17302205
(250320)
160240
(2335)
050 (07.3)
17302205
(250320)
Low C (3000
7Speed)
15501965
(225285)
C3, C6
14751965
(215285)
160240
(2335)
NA
14751965
(215285)
1C
15501965
(225285)
C1, C5, LU
14751965
(215285)
160240
(2335)
050 (07.3)
14751965
(215285)
2C
15501965
(225285)
C1, C4, LU
14751965
(215285)
160240
(2335)
050 (07.3)
14751965
(215285)
2L
10801365
(155200)
C1, C4, LU
10051365
(145200)
160240
(2335)
10051365
(145200)
10051365
(145200)
3C
15501965
(225285)
C1, C3
14751965
(215285)
160240
(2335)
NA
14751965
(215285)
3L
10801365
(155200)
C1, C3, LU
10051365
(145200)
160240
(2335)
10051365
(145200)
10051365
(145200)
4C
15501965
(225285)
C1, C2
14751965
(215285)
125200
(1830)
NA
14751965
(215285)
4L
10801365
(155200)
C1, C2, LU
10051365
(145200)
125200
(1830)
10051365
(145200)
10051365
(145200)
5C
15501965
(225285)
C2, C3
14751965
(215285)
125200
(1830)
NA
14751965
(215285)
5L
10801365
(155200)
C2, C3, LU
10051365
(145200)
125200
(1830)
10051365
(145200)
10051365
(145200)
6C
13451590
(220290)
C2, C4
12701590
(185230)
125200
(1830)
NA
12701590
(185230)
6L
10351415
(150205)
C2, C4, LU
9601415
(140205)
125200
(1830)
9601415
(140205)
9601415
(140205)
*To pass this specication, 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 specication.
Transmission
Model/Test Type

216. TRANSMISSION STALL TEST AND
NEUTRAL COOLDOWN 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 troubleshooting procedure onlynever perform
a stall test as a general check or during routine
maintenance.
7. Connect Allison DOC For PCService Tool to

the vehicle diagnostic data connector or install
an accurate tachometer (do not rely on the
vehicle tachometer).
8. Install a temperature gauge with the probe in
the transmission converter out (to cooler) line.
Allison DOC For PCService Tool displays
sump temperature only.
9. Install wheel chocks.
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 specications established by the
vehicle manufacturer.
NOTE: Obtain engine speed data from the
engine manufacturer or from the equipment
dealer or distributor. Some engine
manufacturers provide a programmable
parameter to limit engine speed when the
transmission output speed is 0 rpm, such
as at a stop. Set this parameter to a higher
value than the expected transmission stall
speed before performing the stall test.
b. Stall Testing Preparation. If a transmission
stall test is to be performed, make sure the following
preparations have been made before conducting
the transmission stall test.
1. The manufacturer concurs with performing a
fullthrottle 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
transmission 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. Perform a cold check of the transmission uid
level and adjust as necessary.
10. A driver is in the drivers position.

11. The vehicles brakes are fully locked.
WARNING: To help avoid personal injury,
such as burns, from hot transmission
uid and/or to help avoid equipment
damage, do not stall the torque converter
for more than ten seconds maximum and
monitor transmission uid temperature.
Immediately return the engine to idle
if converter out (to cooler) temperature
exceeds 150C (300F). Operating the
transmission at high engine power at
transmission stall or near stall conditions
causes a rapid rise in the transmission uid
temperature. The uid 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 under high heat
load conditions causes transmission and
cooling system damage, and can possibly
fail hydraulic lines causing leaking high
temperature uid.
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 service 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 N (Neutral) allow
the transmission to warm to normal operating
temperature:
Sump temperature: 7193C (160200F)
216
Converter out temperature: 82104C
(180220F)
2. Perform a hot check of the transmission uid
level and adjust as necessary
3. Turn all engine accessories off.
4. Place Allison DOC For PCService Tool
in clutch test mode. Use the shift selector
to select D (Drive). Next, select 4 (Fourth
Range) on the Range Panel thats displayed
on the computer screen during Clutch Test
mode. Do not try to use the shift selector
to try to attain 4 (Fourth Range). Using 4
(Fourth Range) reduces the torque imposed
on the transmission driveline. Do not perform
a transmission stall test in R (Reverse).
CAUTION: To help avoid transmission or
driveline damage, full throttle stall tests
must not be performed in R (Reverse)
range, all models, or low ranges, 7speed
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 uid temperature that can
damage the transmission. Never maintain a
stall condition once engine speed stabilizes
or converter out (to cooler) temperature
exceeds 150C (300F). During a stall
condition, converter out temperature rises
much faster than the internal (sump)
temperature. Never use sump uid
temperature to determine the length of the
stall condition. If the stall test is repeated,
do not let the engine overheat.
11. At the end of two minutes, record converter

out (to cooler) temperature.
12. Proceed to the Neutral Cool Down Check,
216g. Neutral Cool Down Check Procedure.
d. Driving Transmission Stall Test.
NOTE: If the vehicle is equipped with a
smoke controlled or an emission controlled
engine or engine control programming
inhibiting engine acceleration, the following
stall test procedure can be used.
WARNING: To help avoid personal

injury and/or equipment damage, a driving
transmission stall test must be performed by
a trained driver and a qualied technician.
e. Driving Transmission Stall Testing
Preparation. If a driving transmission stall test is to
be performed, make sure the following preparations
have been made before conducting the test.
1. The manufacturer concurs with performing a
fullthrottle 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 the
transmission stall test can be safely
performed.
4. Make sure the fuel control linkage goes to full
throttle and does not stick when released (if
applicable).
5. Inspect the engine air induction system and
exhaust system to make sure there are no
restrictions.
6. Perform a cold check of the transmission uid
8. Record converter out (to cooler) temperature.
7. Connect Allison DOC For PCService Tool to

the vehicle diagnostic data connector.
9. Reduce engine speed to idle and shift the

transmission to N (Neutral).
8. Install an accurate tachometer (do not rely on

the vehicle tachometer).
10. Raise engine speed to 12001500 rpm for two

minutes to cool the transmission uid.
9. Install a temperature gauge with the probe

in the transmission converter out (to cooler)
217

hose. Allison DOC For PCService Tool
displays sump temperature only.
f. Performing A Driving Transmission Stall
Test.
CAUTION: The transmission stall
test procedure causes a rapid rise in
transmission uid temperature that can
damage the transmission. Never maintain
a stall condition once engine speed
stabilizes or converter out (to cooler)
temperature exceeds 150C (300F).
During a stall condition, converter out
temperature rises much faster than the
internal (sump) temperature. Never use
sump uid temperature to determine the
length of the stall condition. If the stall test
is repeated, do not let the engine overheat.
1. Start the engine. While in N (Neutral) allow
the transmission to warm to normal operating
temperature:
a. Sump temperature 7193C
(160200F)
b. Converter out temperature 82104C
(180220F)
2. Perform a hot check of the transmission uid
10. Raise engine speed to 12001500 rpm for two

minutes to cool the transmission uid. At the
end of two minutes, record converter out (to
cooler) temperature.
11. Proceed to the Neutral Cool Down Check
216g. Neutral Cool Down Check Procedure.
g. Neutral Cool Down Check Procedure.
1. At the end of two minutes the converter out
(to cooler) uid temperature should return to
within normal operating temperature range.
2. If the transmission uid does not cool within
two minutes, the cause could be a stuck
torque converter stator or an issue with the
transmission cooler, lines or ttings.
h. Transmission Stall Test Results.
NOTE: Environmental conditions, such
as ambient temperature, altitude, and
engine accessory loss variations affect
the power input to the converter. Due
to such conditions, stall speed can vary
from specication 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 specication an
engine issue is indicated.
3. Turn all engine accessories off.

4. While located in an isolated area, begin the
driving transmission stall test.
If engine stall speed is more than 150 rpm above

specication, a transmission issue is indicated.
5. Select a hold range that limits road speed,

usually 2 (Second Range) or 3 (Third
Range). Never perform a driving stall test
in R (Reverse) or Low range (seven speed
models).
Conditions that can cause stall speed to 150 rpm

above specication could be:
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. When the vehicle comes to a
complete stop, record the engine speed.
8. Record converter out (to cooler) temperature.
9. Reduce the engine speed to idle and shift the
transmission to N (Neutral).
218
Transmission uid cavitation or aeration. Verify

proper uid level using the Oil Level Sensor (OLS),
if equipped, or dipstick.
Slipping clutch
Torque converter malfunction
Sticking or damaged torque converter valve.
A low stall speed (at least 33 percent lower than
published stall speed) could indicate an engine issue
or a freewheeling stator in the torque converter.
217. FLUID LEAK DIAGNOSIS
Most uid leaks can be located and repaired by
visually nding the leak and replacing or repairing
the necessary parts. On some occasions, a uid
leak may be difcult to locate or repair. The following
procedure may help in locating and repairing most
leaks.
a. Finding the Leak.
1. Identify the uid. Determine whether it is
engine oil, automatic transmission uid, or
hydraulic uid from a specic vehicle system.
1. Pour the specied amount of dye into the

transmission ll 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 uid appears as a brightly
colored path leading to the source.
d. Possible Points of Fluid Leaks and Their
Causes.
Attaching bolts not correctly tightened
Improperly installed or damaged gasket
2. Operate the vehicle to reach normal operating

temperature and park the vehicle. After a few
minutes look for dripping uid to identify the
approximate location of the leak.
Mounting face damaged
3. Inspect around the suspected area. Inspect

all gasket mating surfaces for leaks. A mirror
is useful for nding leaks in areas that are
hard to reach.
Oil cooler connector ttings loose or damaged
4. If the leak still cannot be found, it may be

necessary to 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, inspect the suspected leak
area. If the leak is not located, use the powder
or black light and dye methods.
Converter seal damaged
Filler pipe or plug seal damaged or missing

Filler pipe bracket dislocated
Output shaft seals worn or damaged
Pressure port plugs loose
Seal lip cut (check converter hub for damage)
Garter spring missing from seal
Converter leak in weld area
Damaged or missing converter Oring seal
Porous casting
Overlledincorrect dipstick
Plugged breather
b. Powder Method.
Water or coolant in uiduid appears milky
1. Clean the suspected area.

2. Apply an aerosoltype white powder, such as
foot powder, to the suspected area.
Incorrect electronic uid level indication

Drainback holes plugged
3. Operate the vehicle under normal operating

conditions.
Fluid level/pressure is too high
4. Visually inspect the suspected area and trace

the leak path over the white powder surface
to the source.
Improperly tightened fasteners or dirty/

damaged threads
c. Black Light and Dye Method.

NOTE: A dye and black light kit is
available for nding leaks. Refer to the
manufacturers directions when using the
kit. Refer to kit directions for the color of
the uid and dye mix.
Plugged vent or drainback holes
Warped anges or sealing surface

Scratches, burrs, or other damage to a sealing
surface
Damaged or worn gasket
Cracked or porous casting
Improper sealant used (where applicable)
Fluid level/pressure is too high
219

Plugged vent or drainback holes
Damaged seal bore
Damaged or worn seal
Improper seal installation
Cracks in component
Output shaft surface scratched, nicked, or
damaged
Loose or worn bearing causing excess seal
wear
Improper driveline installation
e. Repairing the Leak. Once the leak has been
located and traced back to its source, repair the
leaking components. If a gasket is replaced, but the
sealing ange is bent, the new gasket will not repair
the leak. The bent ange must also be repaired.
218. OUTPUT FLANGE/YOKE AND OIL

SEAL MAINTENANCE (All, Except
3700 SP)
a. Disassembly (Figure 25).
1. If installed, remove eight washers (8) and
eight bolts (9) and brake drum (7).
2. Remove one bolt (10).
3. Remove ange (3) or yoke (4), one Oring (13)
and retainer plug (11).
4. If present, remove four bolts (6) and parking
brake assembly (5).
5. Inspect the journal sealing area. Minimum
allowable diameter is 89.78 mm (3.535 inch).
Inspect slinger (2) (if installed) and replace if
necessary
6. Remove output seal (1) using P/N J24171
or equivalent.
220
Figure 25. Output Flange and Oil Seal3000 Product Family (Except 3700 SP)
b. Assembly .
1. For all models, except those with parking
brake, install the output seal (1) using installer
J39928 and J359211 Drive Sleeve. If
equipped with a parking brake, install the
rear seal using installer J359214 and
J359211 Drive Sleeve. Place the seal on
the installer tool so the seal P/N faces outward
after the seal is installed. Drive the seal
into its bore until the installer tool bottoms
out squarely against its locating surface.
Lubricate the seal.
2. If used, install parking brake assembly (5)
and retain with four bolts (6). Tighten bolts to
228266 Nm (168196 lb ft).
7. Install retainer plug (11) into the yoke (4) or

ange (3). Tighten bolt (10) to 7080 Nm
(5259 lb ft).
8. Install brake drum (7) and eight bolts (9) and
eight washers (8). Tighten bolts (9) to 5666
Nm (4149 lb ft).
219. YOKE AND OIL SEAL

MAINTENANCE (3700 SP)
a. Disassembly (Figure 26).
1. Hold yoke (5) or (3) and remove output nuts
(1) and at washers (2).
3. Install ange (3) or yoke (4).
2. Remove yoke (5) and (3) by using a slide

hammer or a similar tool.
4. Install Oring (13) on retainer plug (11).

Lubricate the Oring.
3. Remove oil seals (4) using tool

P/N J24171A.
5. Insert bolt (10) through retainer plug (11).
4. Inspect the front and rear output yokes and the

front and rear oil seals for wear and damage.
6. Install a new Oring (12) over bolt (10) so the

Oring seats against the retainer plug (11).
221

Item
Input and Output Speed
Sensors
42c. Removal of Speed

Sensors
Integral Oil Cooler
42d. Removal of Integral

Oil Cooler (Foldout 181)
Integral Retarder Sump

Oil Cooler
42e. Removing Integral

Retarder Sump Oil Cooler
(Foldout 182)
PTO(s)
42f. Removal of PTO(s)

(Foldout 192)
Scavenge Pump
Control Valve Module
Figure 26. Output Flange and Oil Seal3700 SP

b. Assembly (Figure 26).
1. Inspect front output yoke (3) and rear output
yoke (5) for wear on the output seal journal.
No scoring is permitted and should be
removed by using a soft stone or crocus cloth.
Minimum allowable seal journal diameter is
76.20 mm (3.000 inch).
2. Install oil seals (4) using P/N J38547 and
P/N J359211.
3. Install rear output yoke (5) and front output
yoke (3) by using a slide hammer or a similar
tool.
4. Apply sealant on both sides of at washers (2)
and install the at washers (2).
5. Install output nuts (1) and tighten the nuts to
610815 Nm (450600 lb ft).
220. ONVEHICLE MAINTENANCE

The following may be serviced or removed with the
transmission mounted in the vehicle. Refer to the
indicated paragraph for removal instructions
Item
Yoke Maintenance
222
Paragraph
Paragraph
218. OUTPUT
FLANGE/YOKE AND OIL
SEAL MAINTENANCE
(All, Except 3700 SP) or
Figure 26
42g. Removal of
Transfer Case Module
3700SP(1)
42h. Removal of Control
Valve Module (Figure 46)
SECTION 3GENERAL OVERHAUL INFORMATION

31.
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 specications
Locating torque specications for plugs, bolts,
and nuts
32.
TOOLS AND EQUIPMENT
a. Improvised Tools and Equipment. The

following items may be improvised.
Work Table500 kg (1000 lb) capacity
(Figure 31)
Overhaul StandJ29109 or equivalent
(Figure 32)
31

Figure 31. Work Table
Figure 32. Overhaul Stand

32
GENERAL OVERHAUL INFORMATION

b. Special Tools. Special tools are illustrated
in Figure 33. They are identied in Table 31,
following the special tool illustrations.
c. Mechanics 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, boxend
wrenches, and Allen wrenches)
Retaining ring pliers
Micrometer (metric preferred)
Depth micrometer (metric preferred)
Dial indicator set (metric preferred)
Metric headless guide bolts set
M10 eye bolt
M16 eye bolt
Suitable hoist500 kg (1000 lb) capacity
A 12 Nm (100 lb in.) torque wrench
A 350 Nm (250 lb ft) torque wrench
A press for disassembly and assembly of
springloaded clutches and interferencet
parts
Clean, lintfree shop cloths (do not use waste
cloths)
Containers for parts
Supply of wood blocks
Petrolatum
Container of mineral spirits for cleaning parts
CAUTION: Caustic cleaning compounds
will damage some transmission parts. Use
only mineral spirits to clean transmission
parts.
WARNING: Use appropriate safety

equipment such as safety glasses, safety
shoes, and gloves.
33
Figure 33. Special Tools

34

Table 31. Special Tools* (Figure 33)
Item
KentMoore Tool No.
**
Description
Reference Paragraph
J3940
Bearing Race Remover
512c, e, l, n, t, v 513a, c
516l, n, o
J8092
Drive Handle
53b 55e 56b, c 57b

511b 512g, p, x 513e
514b 515b 516a, c, e
J24171A
Slide Hammer and Jaw Set
218a 219a 55b 56a

512c, l, t 513a 516l, n
16
J26417A
Pressure Gauge Set
215a
8E
J2846734
Handle
57a
J29109
Repair Stand
62a
J33163
Valve Body Parts Tray Set
517a
J35921
Bearing and Seal Installers
6A
J359211
Output Bearing
Installer/Drive Sleeve
218b 219b 55e 56b,

c 512h, q, y 513e, f
516a, m, o
6B
J359213
Oil Pump (Input) Seal

Installer
55e 56c
6C
J359214B
Output Seal Installer

Adapter (Models With
Parking Brake)
218b 513f
J35922
Bearing/Bushing Installers
7A
J359221
Turbine Shaft/Output
Shaft/P2 Planetary Bushing
Installer
57b 511b 512g, p, x

513d, e
7B
J359222
Oil Pump Body

Bushing/Ground Sleeve
Bearing/ P1 Sun Gear
Bushing Installer
55e 56b, c 57b
7C
J359223
Output Bearing Cup

Installer
512f, o, q, w, y 513f
J35923
Spring Compressor Set C1,

C2, and C5
8A
J359231
Piston Spring Compressor

(C1)
57a, b
8B
J359232

(C5)
57a, b 512e, f, n, o, v
513c, d 514a, b
8C
J359233

(C2), Use With J 359262
57a, b
8D
J359234
Compressor Base
57a, b 514a, b
J35924
Main Pressure Spring

Remover/Installer
517f, i
10A
J359252
Spanner Nut Wrench
512c, h, l, q, t, y 513a, f
11
J35926
Main Case Holding Fixture
42a, f 62a
35

Table 31. Special Tools (Figure 33) (contd)
Item
KentMoore Tool No.
**
Description
Reference Paragraph
27
J38547
Front And Rear Output Seal

Installer (MD 3070)
219b 516m, o
12
J 38548
Torque Converter End Play

Gauge
53b 62q
13
J38564A,B,C
Torque Converter Bolt Tool
42h 62q
14
J38565
PTO Bearing/Sleeve
Installer
55d 56b
15
J38566
Pump Gear, Torque

Converter Cover Bushing
Installer
53b
23
J38568
Bearing Cup Installers
23A
J385681
Drive/Driven Bearing Cup

Installer
516a
23B
J385682
Idler Bearing Cup Installer
516a
23C
J385683
Fwd/Rear Output Bearing

Cup Installer
516m
22
J38569
P3 Carrier/C6/C7 Housing
Bushing Installer
514b 516c, e
24
J38572
Transfer Case Holding

Fixture
42a, f 516a 62o
26
J38573
C6 Spring Compressor
516b, c
25
J38579
Bearing Installers
25A
J385791
Drive/Driven Bearing
Installer
516k
25B
J385792
Fwd/Rear Output and Idler

Bearing Installer
516k, m, o
19
J39354
Rivet Installer
58b
28
J39623
Bearing End Play Checker
516s
21
J39928A
Output Seal Installer
218b 513f 62k, l, m
20
J41462
Main Pressure Relief Spring

Compressor
56a 56c
17
J42048
Retarder Flow Valve Spring

Compressor
512c, h, l, q, t, y
29
J47028
Scavenge Pump Bearing

Installer
515b
10B
J47347
Output Shaft Holding Tool
512b, g 513a, f
30
J47942
Spring Compressor, Valve

Body
517e, h
*We
believe this source and its tools to be reliable. These tools may be available from other manufacturers. Allison
Transmission, Inc. does not endorse, indicate any preference for, or assume any responsibility for the products or tools
from these rms, or for any such items that may be available from other sources.
**SPX (KentMoore Service Solutions) 28635 Mound Road, Warren, Michigan 48092
36

33.
REPLACEMENT PARTS
a. Ordering Information. Refer to

the latest version of Parts Catalog
PC2150EN, or Allison Transmission Extranet
(www.allisontransmission.com/extranet), for parts
information. Do not order replacement parts using
the reference numbers in this service manual.
35.
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 closet
parts, such as valves, to malfunction.
b. Cleaning Parts.
b. Parts Normally Replaced at Overhaul. The

following parts are normally replaced at each
transmission overhaul:
Gaskets
Orings
Bushings
Input and output shaft seals
Thrust washers
Retaining rings damaged by removal or
abnormal wear
Spiral retaining ring (4) (Foldout 81)
Piston sealrings
Oil lters
Suction lter (2) (Foldout 151)
Clutch packs, as required
2. Dry all parts, except bearing assemblies, with

compressed air. To prevent rust, lubricate
steamcleaned parts as soon as they are dry.
3. Clean uid passages by working a piece of
soft wire through the passages and ushing
them with mineral spirits. Dry the passages
with compressed air.
4. Examine parts, especially uid passages,
after cleaning to make certain they are entirely
clean. Reclean parts if necessary.
c. Cleaning Bearings.
WARNING: Do not burn discarded Teon

seals toxic gases are produced by burning
Teon.
34.
1. Clean all metallic transmission parts, except

bearings and frictionfaced clutch plates, by
steamcleaning or with volatile mineral spirits.
Do not use caustic soda solution for steam
cleaning. Clean frictionfaced clutch plates
and bearings with mineral spirits only.
CAREFUL HANDLING
Handle parts and subassemblies carefully to

prevent nicking, scratching, and denting. Parts that
t closely together and have a specic 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.
1. Bearings that have been in service should be

thoroughly cleaned in volatile mineral spirits.
2. Soak particularly dirty bearings or ones lled
with hardened grease in mineral spirits before
trying to clean them.
WARNING: Never dry bearings by spinning
them with compressed air. A spinning
bearing can disintegrate, allowing balls or
rollers to become lethal ying projectiles.
Also, spinning a bearing without lubrication
can damage the bearing.
3. Before inspection, lubricate the bearings with
transmission uid.
d. 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 provide
maximum bearing life:
37

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, lintfree paper.
If a bearing is not installed immediately, wrap
or cover the lubricated bearing with clean
paper or lintfree cloth to keep out dust.
e. Inspecting Bearings.
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
defects are found.
3. Inspect a defective bearings 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 the 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.
If a press is not available, carefully seat the
bearing with a drift and hammer.
NOTE: When installing thrust bearings
on to a pilot or bore, take care to ensure
that the llet on either the ID or the OD
of the bearing mates with the llet of
the respective pilot or bore (Figure 34).
Failure to do so will result in bearing failure
and transmission damage.
38
Figure 34. Thrust Bearing Orientation

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 uid 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 ushing it
out 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. Clean damaged threads with the
correct size tap.
CAUTION: Some parts have Spiralock
threaded holes. A repairable threaded hole
can only be repaired using a Spiralock
tap. A standard tap will eliminate the
locking feature and require that the part
be replaced. Spiralock taps are available
from: Spiralock Corporation, Madison
Tech Center, 25235 DeQuindre, PO Box
71629, Madison Heights, MI, 480710629
Phone: (800) 5212688.

edges in piston grooves or on a mating
surface that could damage a new seal.
As of this printing, the following parts have

Spiralock threaded holes:
Torque converter coverexplate
adapter bolt holes and lockup clutch
backplate bolt holes.
2. Replace all composition gaskets.
Output shaft with singlebolt ange

retention.
4. Install a new hooktype sealring if the old ring

shows any wear on its outside diameter, or if
there is excessive side wear.
3. Inspect hooktype sealrings for wear, broken

hooks, and distortion.
5. Inspect the ribs inside the main housing for

reaction plate wear grooves in the side of the
ribs. Replace housings that have splines worn
beyond wear limits. (Refer to Wear Limits,
Table 71 in Section 7)
5. Measure sealring end gap by inserting the

sealring into its respective sealing bore. Use
a feeler gauge to measure end gap. Discard
sealrings having excessive end gap. (Refer
to Section 7. WEAR LIMITS AND SPRING
DATA.)
6. Replace housings or other cast parts that are

cracked.
7. Inspect all machined surfaces for damage that
could cause uid leakage or other malfunction.
Rework or replace defective parts.
6. 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.
8. Inspect the oil tracks of the control valve

module and main housing for porosity,
broken lands, cracks, dirt, and land surface
imperfections. These imperfections will cause
severe uid leakage leading to transmission
failure.
7. Inspect piston sealring grooves for nicks,

burrs, dents, or displaced metal that could
damage the 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.
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 installing, carefully inspect bushings
for signs of distress.
CAUTION: When removing a defective
bushing do not damage the bushing bore.
2. Replace bushings that are out ofround,
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 liptype seals for
nicks, cuts, tears, splits, and pattern damage.
A damaged seal can indicate rough or sharp
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.
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 on experience.
Backlash cannot be used to establish critical
gear wear. Backlash tolerances are of such
nature that a gear usually pits, scuffs, scores,
39

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 t of the
splined parts.
2. Spline wear is determined by comparing feeler
gauge thickness with the thickness of the
worn area on the spline. Replace parts having
excessive spline wear. (Refer to Section
7. WEAR LIMITS AND SPRING DATA). If
spline wear limits are not specied in 38.
WEAR LIMITS, then use 0.38 mm (0.015 inch)
maximum wear as the specication.
burrs and minor surface irregularities using a

soft stone. Replace plates which have any
defects.
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 35). Discard plates having excessive
cone. (Refer to Section 7. WEAR LIMITS
AND SPRING DATA).
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 Section 7. WEAR
LIMITS AND SPRING DATA).
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 ne le. Replace damaged parts.
l. Inspecting Retaining Rings. Inspect all
retaining rings for nicks, distortion, or excessive
wear. Replace the retaining ring if any defects are
found. The retaining ring must snap tightly into its
groove to function properly.
m. Inspecting Springs. Inspect springs for signs
of overheating, permanent set, or wear due to
rubbing adjacent parts. Replace the spring if any
one of these defects are found. (Refer to Table 72.)
n. Inspecting Clutch Plates (Figure 35).
1. Inspect frictionfaced clutch plates (internally
splined 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 honing
stone. Replace plates which have any defects.
2. Inspect steel plates (externaltanged plates)
for burrs, scoring, excessive wear, excessive
cone, distortion, imbedded metal, galling,
cracks, breaks, or damaged tangs. Remove
310
Figure 35. Method of Measuring Clutch

Plate Cone
o. Inspecting Swaged and InterferenceFit
Parts. If there is evidence of looseness, the
assembly should be replaced.
p. Inspecting Retainer and Ball Assembly in
Retarder Stator. Inspect balls in the retarder stator
for free movement. Inspect the staking that retains
the balls. Any restriction could prevent the ball from
seating during retarder application.
q. Inspecting Sealing Surfaces.
1. Inspect surfaces in contact with hooktype,
scarfcut, and buttjoint 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.

2. Inspect surfaces in contact with springloaded,
liptype seals for nicks, scratches, roughness,
or other surface irregularities. Inspect for
embedded particles, stepwear, and dirt on
anges or other components exposed to
external contamination. Remove the defects
and restore the nish. Replace the part if
scores or scratches permit uid leakage.
NOTE: Beginning January 2006 and with
S/N 6510630089 and S/N 6520057820,
all speed sensors were redesigned. See
Figure 37 to identify former or current
speed sensor types. See Table 32 for
all speed sensor specications of former
and current type. See TS3989 for
DTC, connector, and circuit information.
Information about this change may also be
found in SIL 5WT06.
r.
Figure 36. Speed Sensor Orientation
Inspecting Electrical Components.

1. Perform the following steps for the input,
turbine, and output speed sensors.
Replace speed sensor if the speed
sensor shows signs of cracking and/or
oil leakage.
Replace the speed sensor if the
attachment bracket is bent or damaged
or the speed sensor is loose in its bore.
Make sure the speed sensor connection
is oriented as shown in Figure 36.
Measure the resistance of the speed
sensor. If the resistance does not meet
the following specications, replace the
speed sensor.
311

Figure 37. Speed Sensors

Table 32. Speed Sensor Specications
Current Resistance
(Ohms) January, 2006
Former Resistance
(Ohms) Before January,
2006
Temp F
Temp C
250
200
40
40
340
300
68
20
450
400
230
110
2. Measure the resistance of Main Mod, TCC,

and PCS1 through PCS6. If the resistance
does not meet specications shown in
Figure 38 and Table 33, replace the
solenoid.
312
Figure 38. Main Mod, TCC, and PCS1 through PCS6Solenoid Resistance vs. Temperature
Table 33. Sump Solenoid Resistance
Sump Temperature
Resistance
(Ohms)
(C)
(F)
32
4.65
20
68
5.05
40
104
5.45
3. Measure the resistance of SS1 on/off solenoid.

If the resistance does not meet specications
in Figure 39, replace solenoid.
4. Measure the resistance of SS2 (C6 enable)
if 3700SP model. If the resistance does not
meet specications in Figure 39, replace
solenoid.
313

Figure 39. ON/OFF SolenoidsSS1 and SS2 (C6 Enable) in 7Speed Models
5. Measure the resistance of retarder air solenoid
SS2 (if equipped) If the resistance does not
meet specications in Figure 310, replace
solenoid.
314
Figure 310. Retarder Accumulator Air SolenoidSS2 in RetarderEquipped Transmissions

6. Measure the resistance of sump temperature
sensor. If the resistance does not meet
specications shown in Figure 311, replace
sump temperature sensor.
315

Figure 311. TransID Thermistor Characteristics

7. Measure the resistance of retarder
temperature sensor. If the resistance does
not meet specications shown in Figure 311,
replace retarder temperature sensor.
8. Measure the resistance of PS1 (diagnostic
switch) and PS2 switch (if equipped with
prognostics lter life switch), If the resistance
measures more than 4 ohms closed or less
than 20,000 ohms with the switch open then
replace the switch. PS1 and PS2 are normally
closed (NC switches).
For inspection and repair of electrical components,
refer to the Allison 4th Generation Controls
Troubleshooting Manual TS3989EN.
36.
ASSEMBLY PROCEDURES
a. Parts Lubrication. During nal assembly,

lubricate all moving parts with transmission uid.
The uid helps protect friction surfaces and ferrous
metals until the unit is in service.
316
b. Grease Used for Assembly. During assembly

use oilsoluble grease with a low melting point
(petrolatum) to temporarily retain parts, buttjoint
sealrings, scarfcut sealrings, and hooktype
sealrings.
c. Sealing Compounds and Nonsoluble
Greases. Do not use gaskettype sealing
compounds, brous greases, or nonsoluble
vegetablebased cooking compounds inside the
transmission, or where they could be ushed into
the transmission hydraulic system.
d. Clutches and Pistons.
1. Soak each frictionfaced clutch plate (two
minute minimum) in transmission uid before
nal assembly.
2. Apply a generous amount of transmission uid
to the piston cavity before nal assembly.
3. Assemble clutch plates so the cone of each
plate faces the same direction.

e. Threaded Plugs and Hydraulic Fittings.
CAUTION:
3. Using a feeler gauge, measure the end

clearance of the sealring. The end clearance
must not be less than specications allow.
Do not use Teon tape on threaded

parts. Slivers can cause the
transmission to malfunction.
4. If the end clearance is less than minimum

specications, bake the sealring at 93149C
(200300F) for 24 hours or get a new
sealring. Repeat 2 and 3.
Improperly installed plugs or ttings

can cause leakage and cracked
housings.
5. Pack the sealring and its groove with a liberal

amount of oilsoluble grease.
Threaded plugs in 3000 Product Families

transmissions are straightthread Oring type plugs.
Be sure the Oring is in likenew condition and
tighten all plugs to the torque values specied in
the assembly procedure or in disassembled views.
Tighten other ttings sufciently to prevent leakage.
f. Coated Threaded Fasteners. 3000 Product
Families control valve module bolts and 3700 SP
adapter housing bolts are being manufactured with
a band of thread sealant on the threads.
6. Roll up 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. 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.
g. LipType Seals.
1. When replacing liptype seals, make sure
the springloaded lip is toward the uid to be
sealed (toward the inside of the unit). Coat
the inside of the seal with high temperature
grease (MILG3545A 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 identication. Precoated
seals do not require any additional sealant
before installation.
h. ButtJoint Sealrings.
1. Buttjoint sealrings require special handling
during assembly. The sealrings contain
materials that absorb moisture from the
atmosphere causing the sealring to expand.
The sealrings are shipped in airtight packages.
Do not open the sealed package until the
buttjoint sealring is ready to be installed into
the transmission.
37.
REMOVING (OR INSTALLING)

TRANSMISSION (Figure 312,
Figure 313)
WARNING: Avoid contact with the hot uid
or the sump when draining transmission
uid. Direct contact with the hot uid or the
hot sump may result in bodily injury.

repairs, the Transmission Control Module
(TCM) must be RESET TO UNADAPTED
SHIFTS. This will cause the TCM to erase
previous adaptive information and begin
to adapt in Fast Adaptive Mode from the
base calibration. Use the Allison DOC
For PCService Tool (refer to the Allison
DOC For PCService Tool Users Guide
GN3433EN for instructions) to RESET TO
UNADAPTED SHIFTS.
2. Remove the sealring from its package and

place it in its operational position inside the
bore that it will be sealing.
317

a. Drain Fluid. Drain the transmission uid before
removing the transmission from the vehicle. The
transmission should be warm and the uid allowed
to drain overnight.
1. Remove the drain plug from the control
valve module. Examine the drained uid
and magnetic drain plug for evidence
of contamination (refer to 212. FLUID
CONTAMINATION). Install the drain plug
when uid draining is completed. If drain
plug threads are damaged, see 213. FLUID
AND FILTER CHANGE PROCEDURE for
corrective action.
2. Remove the transmission ll tube if it interferes
with transmission removal.
NOTE: A signicant amount of uid may
drain from a hydraulic hose when it is
disconnected from the transmission.
Figure 312. Disconnect Locations (Retarder

Equipped Models)
3. Disconnect all hydraulic hoses from the

transmission. Remove the hoses from the
vehicle if they interfere with the transmission
removal. Plug all openings to prevent dirt from
entering the hydraulic system.
4. 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 prevent dirt from entering the
cooling system.
318

2. For retarder models, disconnect the
transmission external harness from the
transmission feedthrough harness, the input
speed sensor, the output speed sensor, the
retarder temperature sensor, the retarder valve
body connector, and the PTO connector, if
present (refer to Figure 312 and Figure 313.
If used, disconnect the tachograph drive.
Cover the harness connectors to keep out dirt.
3. For transfer case models, disconnect the
feedthrough harness connector, the input
speed sensor, the transfer case connector,
and the PTO connector, if present (refer to
Figure 313. Cover the harness connectors
to keep out dirt.
c. Uncoupling From Driveline, Vehicle, And
Engine.
1. Disconnect the vehicle drive shaft from the
transmission output ange or yoke. Position
the disconnected shaft to avoid interference
with removing the transmission.
2. Transmissions with PTOs require uncoupling
one of the following:
PTO from the transmission
PTO drive shaft from the PTO
3. If the transmission supports the rear of the
engine, place a jack or other support under
the engine.
4. Securely support the transmission with a hoist,
jack, or other suitable removal equipment.
Figure 313. Disconnect Locations (3700)

b. Disconnecting Controls. Disconnect or
completely remove controls. If controls are not
removed from the transmission, position them so
that they do not interfere with transmission removal.
1. For nonretarder models, disconnect the
feedthrough harness connector, the input
speed sensor, the output speed sensor,
and the PTO connector, if present (refer to
Figure 312. Disconnect the tachograph
drive, if used.
5. Remove all bolts, nuts, washers, spacers, and

supports that attach the transmission to the
vehicle and to the engine or input driveline.
d. Removing the Transmission.
1. Move the transmission away from the engine
approximately 110 mm (4.33 inch) until it is
completely clear of the engine. Remove the
adapter ring (if used).
2. Raise or lower the transmission as necessary
to remove it from the vehicle.
319

38.
WEAR LIMITS
Refer to Table 71 for information covering parts

ts, clearances, and wear limits.
39.
SPRING SPECIFICATIONS
Refer to Table 72 for spring identication and

specications.
310. TORQUE SPECIFICATIONS

Assembly procedures in Section 5. MODULE
REBUILD and Section 6. TRANSMISSION
ASSEMBLY specify the torque requirements for
all plugs, bolts, and nuts. Torque values are also
presented with the foldout illustrations in the back
of this manual. Torque values specied are for dry
assembly, except when otherwise noted. Wash and
dry bolts and washers before assembly.
311.
ENGINE, TRANSMISSION
ADAPTATION REQUIREMENTS
You must make sure a new transmission installation

can be adapted to the vehicles engine. Use the
measurements described in this section to ensure
correct transmissiontoengine adaptation. Refer to
Figure 314 or Allison extranet Tech Data. Typical
arrangement of adaptation components is shown
in Figure 315.
320
Figure 314. 3000 Product Family Engine Adaptation
321

Figure 315. Arrangement of Adaptation Components

a. Measuring Equipment. The following
measuring equipment is required:
600 mm (24 inch) precision caliper
g. Crankshaft Hub Pilot or Adapter

Concentricity. The crankshaft hub pilot or the hub
adapter pilot concentricity cannot exceed 0.13 mm
(0.005 inch)TIR.
50100 mm (24 inch) telescoping gauge

2576 mm (13 inch) outside micrometer
Dial indicator and mounting
attachmentsbase, posts, and clamps
h. Flexplate Bolt Hole Flatness. Flexplate

atness in the area of the bolt holes is not a
measurement required for the 3000 and 4000
Product Families transmissions.
0150 mm (06 inch) depth micrometer

b. Flywheel Housing Pilot Bore Diameter. The
ywheel housing pilot bore diameter must measure
447.68447.81 mm (17.62517.630 inches).
c. Flywheel Housing Bore Runout. Flywheel
housing bore runout cannot exceed 0.51 mm (0.020
inch)TIR.
i. Torque Converter Axial Location. Using a

depth gauge, measure from the face of the torque
converter housing to the torque converter explate
adapter mounting face. The torque converter
axial location should measure 49.3650.38 mm
(1.9431.983 inches). See Figure 316.
d. Flywheel Housing Face Squareness. The

ywheel housing face cannot be outofsquare more
than 0.51 mm (0.020 inch)TIR.
e. Crankshaft Hub Pilot or Adapter Diameter.
The crankshaft hub pilot or hub adapter pilot
diameter must measure between 50.9450.99 mm
(2.0062.008 inches).
f. Crankshaft Hub Pilot or Adapter Squareness.
The crankshaft hub or hub adapter cannot be
outofsquare more than 0.13 mm (0.005 inch)TIR.
322
Figure 316. Converter Axial Location Measurement
312. CHECKING FLEXPLATE DRIVE

ASSEMBLY
313. CHASSIS AND DRIVELINE

INSPECTION
a. Flexplate Inspection. Check the explate for

cracks, distortion, or elongated bolt holes. Replace
a worn or damaged explate.
Inspect the chassis and driveline components

for the following conditions, and correct them as
appropriate:
b. Engine Crankshaft End Play. Make sure

engine crankshaft end play is within the engine
manufacturers specications.
NOTE: When assembling the explate to
the crankshaft hub or hub adapter, make
sure the outer explate bolt holes are
aligned.
Transmission mountsbroken or wornout

Bolts and other hardwaredamaged, missing,
or incorrect
Isolators (rubber mounts)damaged or
missing
Driveline anglesrunout, or balance which
does not conform to the manufacturers
recommendations
Driveline yoke slip joints:
c. Flexplate Assembly Installation. Install the

explate onto the engine crankshaft hub using the
bolts and torque values specied for that engine.
Refer to Figure 314 for the proper position of an
installed explate.
freedom of movement
damaged or wornout
correctly lubricated
correctly indexed
323

Driveline midship or hanger
bearingsdamaged or misaligned
Universal joints:
freedom of movement
damaged or wornout
correctly lubricated
correctly indexed
Vehicle differential backlashmanufacturers
specication
Universal joint couplingalignment and
differential damage
Crossframe members and rear support
memberscondition and location
PTOdriven equipment shafts and
couplingsdamaged or misaligned
Auxiliary transmission:
shaft alignment
alignment of yoke or ange
backlash
uid leaks
324
SECTION 4TRANSMISSION DISASSEMBLY

41.
SCOPE
42.
a. Section. This section covers disassembly of

3000 Product Families transmissions. Disassembly
procedures include Power Takeoff (PTO) provisions
and retarders. The disassembly sequence is
continuous and includes all models.
b. Procedures. When a procedure does not apply
to your specic 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 Section 3.
GENERAL OVERHAUL INFORMATION and
Section 7. WEAR LIMITS AND SPRING DATA for
general information as follows:
Paragraph
Title
32. TOOLS AND

EQUIPMENT
Tools and Equipment
33. REPLACEMENT
PARTS
Replacement Parts
34. CAREFUL
HANDLING
Careful Handling
35. CLEANING AND

INSPECTION
Cleaning and Inspection
37. REMOVING
(OR INSTALLING)
TRANSMISSION
(Figure 312,
Figure 313)
Removing Transmission
38. WEAR LIMITS
Wear Limits Data
72. SPRING DATA
Spring Data
DISASSEMBLY OF TRANSMISSION
a. Mounting Transmission on Repair Stand.

WARNING: 3000 Product Family
transmission dry weights are as follows:
Base Transmission
243 kg (535 lb)
With PTO Provision
261 kg (575 lb)
With Retarder
279 kg (610 lb)
With PTO and

Retarder
297 kg (655 lb)
With PTO, Retarder,

and Integral Sump
Cooler
336.5 kg (740 lb)
3700 SP
530 kg (1170 lb)
Use proper tools and lifting equipment

when installing or removing a
transmission from the repair stand.
1. Mount J 35926 holding xture onto the main
housing module.
2. Attach a hoist, making sure lifting attachments
are placed so transmission is properly
balanced, and raise the transmission to the
mounting face of the repair stand.
3. Secure the transmission holding xture to
J 29109 repair stand.
4. For a 3700 SP transmission model, follow
Step 1. In addition, install J 38572 xture
on the transfer case. Connect xtures J
35926 and J 38572 by installing four bolts (1)
(Figure 41). Secure the transmission holding
xtures to the repair stand.
e. Foldouts. Refer to Foldout 5 through

Foldout 192 for disassembled views and
Foldout 20 through Foldout 38 for the hydraulic
schematics.
41

inch) ID), and Oring (13) (brown, 66.3 mm
(2.610 inch) ID).
7. Remove ange (14) or yoke (15).
8. Inspect the journal diameter, on ange (14)
or yoke (15), for excessive wear. Minimum
allowable diameter for reuse is 89.78 mm
(3.535 inch). Inspect dust shield (16) for
damage. Replace if necessary.
9. If present, remove four M16 x 2 x 80 bolts (7)
and parking brake assembly (6).
10. If present, remove selftapping M8 screw and
harness bracket (3).
Figure 41. 3700 SP Repair Stand Brackets

b. Removal of Common ExternallyMounted
Parts (Figure 42).
1. Inspect transmission breather 1 for damage
or obstruction. Remove if necessary for
replacement or cleaning.
2. Remove selftapping M8 screw (23) retaining
ll tube bracket (24) to the main housing
module. Remove bracket (24), ll tube (22),
ll tube seal (21), and dipstick (25).
3. Remove expander plug (5) and ll tube seal
(4) from the other ll tube location on the
opposite side of the main housing module.
NOTE: Pry under the head of plug (5),
compress tangs and remove plug (5).
4. Remove six M10 x 1.5 x 35 bolts (17) retaining
remote cooler manifold (19), or cover (18),
to the main housing module. Remove cooler
manifold (19), or cover (18), and gasket (20).
5. If present, remove bolts (9) (3/824, length may
be 3/4 or 13/8) and brake drum (8).
NOTE: For 3700 SP transmission model, do
not remove yokes yet. Removal is covered
in 516. TRANSFER CASE MODULE.
6. Remove one M14 x 2 x 70 bolt (10), retainer
plug (11), Oring (12) (brown, 12.3 mm (0.484
42
TRANSMISSION DISASSEMBLY
Figure 42. Common ExternallyMounted Parts Removal

c. Removal of Speed Sensors.
1. If nonPTO model, remove M8 x 1.25 x 20
bolt (6) (Foldout 61), retainer (5), input speed
sensor assembly (3), and Oring (brown,
15.6 mm (0.614 inch) ID) from the converter
housing module.
2. If PTOequipped model, remove M8 x 1.25 x
20 bolt (21) (Foldout 62), retainer (20), input
speed sensor assembly (18), and 15.6 mm
(0.614 inch)ID Oring (brown) (19) from the
converter housing module.
3. For nonretarder model, remove M8 x 1.25
x 20 bolt (32) (Foldout 11B), retainer (31),
output speed sensor assembly (29), and 15.6
mm (0.614 inch)ID Oring (brown) (30) from
the rear cover module.
4. For retarder model, remove M8 x 1.25 x 20
bolt (42) (Foldout 11A), retainer (41), output
speed sensor assembly (39), and 15.6 mm
(0.614 inch)ID Oring (brown) (40) from the
retarder housing.
d. Removal of Integral Oil Cooler (Foldout 181).

1. Remove two M12 x 1.75 x 25 bolts (24) and
seventeen M10 x 1.5 x 35 bolts (25). Remove
cover (23), gasket (22), and two 42.4 mm
(1.661 inch)ID Orings (brown) (26).
2. Remove plate assembly (27) and four Orings
(28).
NOTE: Beginning with transmission
S/N 6510676916, S/N 6520056783,
S/N 6610199812 (7 Plate Cooler) and
S/N 6510676917, S/N 6520058810 (17
Plate Cooler), the integral oil cooler has
been redesigned to use one thick Oring
between the integral cooler and the cooler
housing. The current Oring cannot be
used with the former integral cooler design.
Current nonsump integral coolers now
utilize only one Oring instead of two. For
more information see SIL 13WT06.
43
SECTION 4TRANSMISSION DISASSEMBLY
Figure 43. Integral Oil Cooler

3. Remove nine M10 x 1.5 x 225 bolts (15)
and nine M10 washers (16). Remove cooler
housing (7) and gasket (5).
4. Remove three M12 x 1.75 x 230 bolts (13),
three M10 x 1.5 x 205 washers (14), bolt (12),
washer (11), six M10 x 1.5 x 225 bolts (15)
and six washers (16). Remove cooler housing
(7) and gasket (6).
e. Removing Integral Retarder Sump Oil Cooler

(Foldout 182).
1. If used and not already removed, remove the
retarder accumulator hose from the tting on
cooler manifold (16).
2. If not already removed, remove inlet and outlet
water hoses from the cooler manifold.
44
3. Support cooler (7) to prevent it from falling
from manifold (16).
4. Remove sixteen M10 x 1.5 x 60 bolts (1).
5. Remove six M8 x 1.25 x 25 bolts (5).
WARNING: To help avoid personal
injury, securely support the cooler before
removing the bolts retaining the cooler to
the manifold. The cooler weighs 29 kg (64
lb) use care when handling the cooler.
NOTE: The cooler plate assembly has a

provision to install two M12 eyebolts to allow
support during disassembly/assembly.
6. Remove cooler plate assembly (7) and two
gaskets (6) from the cooler manifold.
7. Remove inlet and outlet water hose adapters
from cooler manifold (16). Remove two
gaskets (3).
8. Remove plugs (11), (14), (25), (23), (20),
and (17) from cooler manifold. Remove and
discard plug Orings.
9. Rotate the transmission so that the retarder
is facing up.
g. Removal of Transfer Case Module 3700SP.

1. Remove hose (1) (Figure 44), ttings (2)
and (3), Orings (4) and (5), and screen (6).
Remove scavenge pump (7) by removing nine
M10 x 1.5 x 35 bolts (8). Remove gasket (9).
2. Separate J 35926 xture (Figure 45) and
the J 38572 transfer case lifting xture by
removing four bolts (6).
WARNING: The transfer case module
assembly weighs approximately 270 kg
(595 lb).
3. Attach a hoist, making sure that lifting
attachments are placed so that the transfer
case is properly balanced. Remove nineteen
bolts (2) and one bolt (7) to disconnect the
transfer case from the main transmission.
4. Raise the transfer case to the mounting face
of the repair stand.
5. Secure the transfer case holding xture to the
repair stand.
6. Remove gasket (4) and selective shim (1).
The selective shim is located inside shaft
adapter (5).
10. Remove eight M10 x 1.5 x 210 bolts (9) and

three M12 x 1.75 x 218 bolts (8).
11. Remove cooler manifold (16) and gasket (4).
f.
Removal of PTO(s) (Foldout 192).

NOTE: Each PTO has eight mounting
bolts, two studs, and a gasket. Removal
instructions are for a transmission with
a single rightside mounted PTO. If your
transmission has more than one PTO or the
PTO is mounted in a different location, use
the same procedure to remove the PTO(s).
1. Remove eight M8 x 1.5 x 35 PTO mounting
bolts (7) or M10 x 1.5 x 35 bolts (11). Carefully
remove PTO assembly (8) or (12) and gasket
(6) or (10).
2. Inspect two PTO studs (5) or (9) for damage
and remove them if necessary.
45

WARNING: The control valve module
assembly weighs approximately 25 kg (56
lb). Handle carefully to avoid personal
injury or control valve module damage. The
control valve module assembly used in a
3700 SP weighs approximately 29 kg (65
lb).
1. For a twoinch or seveninch sump, remove
thirtytwo M10 x 1.5 x 55 bolts (3) retaining
control valve module (1) to the main housing
module, including the bolts retaining the lter
covers.
2. For a fourinch sump, remove seven M10 x
1.5 x 55 bolts (3) and twentyve M10 x 1.5 x
100 bolts (4) retaining control valve module
(1) to the main housing module, including the
bolts retaining the lter covers.
Figure 44. 3700 SP Scavenge Pump Removal
3. Loosen control valve module (1) by applying

pressure at the reinforced tabs or use jack
bolts. Insert jack bolts into the control valve
module bolt holes that bottom against the
main housing module.
4. Remove control valve module assembly (1)
and gasket (2).
Figure 45. Transfer Case Module Removal

h. Removal of Control Valve Module
(Figure 46).
NOTE: The control valve module or lters
may contain residual transmission uid.
46
explate adapter bolt holes. Then place
a screwdriver at an angle to prevent
converter rotation (Figure 47, View C).
5. Remove M16 x 2 x 30 bolt (1) using
J 38564 converter bolt tool .
6. Remove shim (2) located under bolt (1)
(Figure 47, View A).
7. Attach a sling to the explate adapter by
positioning the adapter connections an equal
distance from each other. Using a chain hoist,
carefully lift torque converter module (3) out of
the converter housing (Figure 47, View A).
8. Place two wooden blocks on the workbench,
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.
Figure 46. Control Valve Module Removal

i. Removal of Torque Converter Module
(Figure 47).
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 47, View C).
3. Remove threaded plug (5) and Oring (4)
using a 3/4 inch Allen wrench.
4. Hold the turbine and turbine shaft stationary
by using one of the methods listed below:
a. Insert a screwdriver into the vanes on
the rotating clutch module (Figure 47,
View B).
b. If the control valve module is in place,
remove the plug(s), if present, from the
ll tube hole or from cooler ports before
applying lockup air pressure. Apply air
pressure through the lockup pressure
tap (Figure 47, View D) and use a heel
bar, screwdriver, and bolts. Insert the
heel bar into a torque converter housing
bolt hole. Insert two bolts into the
47

Figure 47. Torque Converter Module Removal

j. Removal of Converter Housing Module
(Figure 48).
NOTE: Three converter housing retaining
bolts (3) are removed from inside converter
housing (1). After loosening the bolts,
use mechanical ngers or a similar tool to
remove these bolts.
1. Remove twenty M10 x 1.5 x 35 bolts (3) that
retain converter housing (1) to main housing
module (4).
2. Lift straight up on converter housing module
(1), or remove it using the same sling used for
removing the converter module.
3. Remove main housing gasket (2) from
converter housing (1), or from main housing
module (4).
Figure 48. Converter Housing Module Removal

k. Removal of Retarder Module
(Foldout 11A and Figure 49).
1. Remove fourteen M12 x 1.75 x 130 bolts (2)
(Foldout 11A), three M10 x 1.5 x 90 bolts
(33), four bolts (3), four M10 x 1.5 x 182 bolts
(4), and nine M8 x 1.25 x 25 bolts (52) that
48
secure retarder module (2) (Figure 49) to
main housing (3).
WARNING: The retarder module assembly
weighs approximately 64 kg (141 lb). Use
care to prevent injury to personnel while
handling the retarder module assembly.
2. Thread an M10 eye bolt into the retarder
output shaft (7) (Foldout 11A) and lift the
retarder module (2) (Figure 49) from main
housing (3).
3. Remove retarder gasket (1) (Figure 49) from
main housing (3) or retarder housing (2).
Figure 410. Transfer Case Adapter

Housing Removal
m. Removal of Rear Cover Module (Figure 411).
1. Remove nineteen M12 x 1.75 x 45 bolts (3).
2. If used, remove the rear support bracket.
3. Attach a suitable sling and lift upward,
removing rear cover (2).
4. Remove rear cover gasket (1) from main
housing (4) or rear cover (2).
Figure 49. Retarder Module Removal

l. Removal of Transfer Case Adapter Housing
Module (Figure 410).
1. Remove adapter housing (3) by removing
fteen M12 x 1.75 x 45 bolts (8), three M10
x 1.5 x 100 bolts (6), three M12 x 1.75 x 60
bolts (5), four M10 x 1.5 x 70 bolts (4), and
two M10 x 1.5 x 40 bolts (7).
2. Remove gasket (2).
3. Remove P3 carrier assembly (1) (Foldout 172)
by sliding it up over the main shaft.
Figure 411. Rear Cover Module Removal
49

n. Removal of Main Shaft Module (Figure 412).
6. Lift P1 planetary module (1) (Figure 414)

from the main housing module.
1. Remove thrust bearing (3) and shim (2) from

the main shaft module.
2. Lift main shaft module (1) out of the
transmission.
Figure 413. P2 Module and C5 Clutch

Pack Removal
Figure 412. Main Shaft Module Removal

o. Removal of P2 Module, C5 Clutch Plates,
and P1 Module (Figure 413, Figure 414).
1. Lift P2 planetary module (1) (Figure 413)
from the main housing module.
2. Lift C5 clutch pack from the main housing
moduleseven friction plates (3) and eight
steel reaction plates (2).
3. Visually inspect all friction and steel reaction
plates for damage or excessive wear. If
friction plates or steel reaction plates have
perceivable wear or distortion, measure the
thickness of each friction plate (3). Minimum
allowable thickness for reuse is 2.90 mm
(0.114 inch). Measure the oil groove depth of
each friction plate. Minimum allowable groove
depth for reuse is 0.20 mm (0.008 inch).
4. Measure thickness of each steel reaction plate
(2). Minimum allowable thickness for reuse is
2.36 mm (0.093 inch).
5. Measure the cone of each plate. Maximum
allowable cone for reuse is 0.41 mm (0.016
inch). If plates do not meet specications,
replace as necessary.
410
Figure 414. P1 Module Removal

p. Removal of Front Support/Charging
Pump Module and Rotating Clutch Module
(Figure 415, Figure 416).
1. Remove six M10 x 1.5 x 60 bolts (1) and
ve M10 x 1.5 x 35 bolts (2) (Figure 415)
that retain front support and charging pump
module (3) to the main housing.
2. Lift front support and charging pump module
(3) away from the turbine shaft.
3. Using a hoist and a M16 eye bolt, lift
turbine shaft and rotating clutch module (1)
(Figure 416) from the main housing module.
q. Removal of C3/C4 Clutch Assembly From

Main Housing Module (Figure 417).
CAUTION: Make sure that the main
housing assembly is horizontal when
removing the C3/C4 clutch assembly.
1. Remove twelve M10 x 1.5 x 35 mm bolts 3
retaining C3/C4 clutch assembly (1) in main
housing module (2).
2. Remove C3/C4 clutch assembly (1) by
sliding it out of the input end of main housing
module (2).
3. Remove the main housing from the repair
stand for cleaning.
4. Inspect the main housing clutch plate splines.
Maximum allowable wear for reuse is 1.15
mm (0.045 inch).
Figure 415. Front Support/Oil Pump

Module Removal
CAUTION: Carefully place rotating clutch
module (1) (Figure 416) on the workbench
and prevent it from rolling off the bench.
Figure 417. C3/C4 Clutch Module Removal
Figure 416. Rotating Clutch Module Removal
411

NOTES
412
SECTION 5MODULE REBUILD

51.
SCOPE
53.
a. Section. This section covers the disassembly of

3000 Product Families transmissions. Disassembly
procedures include Power Takeoff ( PTO) provisions
and retarders. The disassembly sequence is
procedure.
d. Foldouts. Refer to Foldout 5 through
Foldout 192 for disassembled views and torque
specications.
52.
GENERAL INFORMATION FOR

MODULE REBUILD
Refer to Section 3. GENERAL OVERHAUL

INFORMATION and Section 7. WEAR LIMITS AND
SPRING DATA for general overhaul information as
follows:
Paragraph
Title
32. TOOLS AND

EQUIPMENT
Tools and Equipment
33. REPLACEMENT
PARTS
Replacement Parts
34. CAREFUL
HANDLING
Careful Handling
35. CLEANING AND

INSPECTION
37. REMOVING
(OR INSTALLING)
TRANSMISSION
(Figure 312, Figure 313)
71. WEAR LIMITS DATA
Wear Limits Data
72. SPRING DATA
Spring Data
TORQUE CONVERTER MODULE
a. Disassembly (Foldout 5).

1. Before disassembling the torque converter,
note balance marks (Figure 510) or mark a
line across the converter cover to the pump
assembly with a scribe. Aligning these marks
will make sure the torque converter is correctly
assembled and reduce balance problems.
2. Place torque converter module (3) on a
at surface with the oil pump drive tangs
downward. Support the converter assembly
on wooden blocks that keep the oil pump drive
tangs from contacting the workbench.
3. Remove thirtysix M8 x 1.25 nuts (4) from the
OD of torque converter cover assembly (5).
4. Carefully separate the torque converter cover
assembly (5) from the torque converter pump
assembly (31), avoiding damage to their
sealing surfaces.
5. Remove the large seal (30) used between the
cover assembly and pump assembly.
6. Remove turbine assembly (17). Remove
sealring (15) from the hub of the turbine
assembly. Measure the OD of the turbine
hub. Minimum allowable diameter for reuse is
61.34 mm (2.415 inch). Place sealring (15)
into the bore of torque converter cover (7)
where it is located during operation. Measure
the sealring ID. Maximum allowable sealring
ID for reuse is 56.75 mm (2.234 inch).
7. If replacement is necessary, remove
and inspect, per 35. CLEANING AND
INSPECTION, thrust bearing assembly 18
55 mm (2.165 inch)ID, and star washer (19).
8. Remove stator assembly (20).
9. Remove and inspect, per 35. CLEANING
AND INSPECTION, pump thrust bearing (29)
and 80 mm selective shim (28) from the back
of the stator.
10. Remove retaining ring (21).
11. Remove stator thrust plate (22) and measure
its thickness adjacent to the stator race.
Minimum allowable thickness for reuse is
11.68 mm (0.460 inch).
12. Remove and inspect stator thrust washer
(23). Maximum step wear allowed is 0.25 mm
51

(0.010 inch). Stator thrust washer may be
turned over or replaced if step wear exceeds
service limits.
13. Remove and inspect stator race (24), thirteen
springs (25) (refer to Table 72 for Spring
Chart), and rollers (26). Also inspect stator
thrust washer under cam (not shown).
Maximum step wear allowed is 0.25 mm
(0.010 inch). Stator thrust washer may be
turned over or replaced if step wear exceeds
service limits.
14. From converter cover and bushing assembly
(6), remove thirty M8 x 1.25 x 30 bolts (14)
retaining the lockup clutch backplate (13) to
converter cover (7).
15. Remove lockup clutch backplate (13).
Measure the thickness of the backplate wear
surface. Minimum allowable thickness for
reuse is 8.58 mm (0.338 inch). Measure the
cone of backplate (13). Maximum allowable
cone for reuse is 0.15 mm (0.006 inch).
16. Remove lockup clutch/damper (12) from
converter cover (7). Measure the thickness
across the lockup clutch friction surfaces.
Minimum allowable thickness for reuse is
0.625 mm (0.025 inch) per side. Check for
distortion of the lockup clutch friction surfaces.
Maximum allowable distortion for reuse is 0.51
mm (0.020 inch). Check spline wear between
the turbine and the lockup clutch damper.
Maximum allowable spline wear for reuse is
0.38 mm (0.015 inch).
17. Remove lockup clutch piston assembly (10)
by using air pressure or by lightly striking
the converter cover against a at surface.
Remove OD sealring (11) from the lockup
clutch piston. Measure the thickness of the
lockup clutch piston. Minimum allowable
thickness for reuse is 5.71 mm (0.225 inch).
21. If replacement is necessary, remove pump

thrust washer (32)ID80.15 mm (3.15 inch)
from the pump.
22. If bolt replacement is necessary, remove
damaged M8 x 1.25 x 25 Thead bolt(s) (34)
from the OD of torque converter pump (33).
23. Examine torque converter pump assembly
(31) for cracks, missing vanes, or a loose
torus ring.
24. Inspect stator washer in stator and cam
assembly (27) for visual damage or step
wear. Maximum allowable step wear of thrust
washer is 0.25 mm (0.010 inch).
b. Assembly (Foldout 5).
NOTE: Beginning with S/N 6510717281,
S/N 6520083093, S/N 6610220990,
S/N 6620005821, S/N 9370007661,
S/N 9320006231, S/N 9470006080, and
S/N 9420007560, the material of specic
seals has been modied to be compatible
with DEXRONVI uids. Transmissions
prior to the above serial numbers are not
compatible with DEXRONVI uids. Seal
compatibility can be identied by a "D6C" or
8 color marks on the face of the seal. See
SIL 6WT07 for more information.
1. Install stator race (24) into stator and cam
assembly (27)
2. Install thirteen springs (25) and rollers (26)
into stator and cam assembly (27). Be sure
springs and rollers are installed in the cam
pockets as shown in (Figure 51). Lubricate
the rollers.
18. Remove thrust bearing (16).

19. Visually inspect converter cover bushing (8).
Maximum allowable bushing ID for reuse is
61.51 mm (2.422 inch). Remove the bushing
using a hammer and chisel if visually damaged
or worn beyond service limits.
20. Remove inner lockup piston sealring (9) from
the hub of the converter cover (7).
52
MODULE REBUILD

S/N 6520083093, S/N 6610220990,
S/N 6620005821, S/N 9370007661,
S/N 9320006231, S/N 9470006080, and
Figure 51. Stator Roller/Spring Installation
9. Install lockup clutch/damper (12) (Figure 52),

with part number down (Figure 53) towards
lockup piston assembly, into torque converter
cover (7) (Figure 54).
3. Install stator thrust washer (23) and thrust

plate (22) onto stator and cam assembly (27).
4. Install retaining ring (21).
5. Lubricate star washer (19), and install it onto
the stator.
6. If removed in 53a. Disassembly (Foldout 5),
Step 19, press a new bushing (8) (61.45
mm (2.42 inch)ID) into the bore, ush to
0.040 below ush, of torque converter cover
(7) using J38566 Bushing Installer and
J8092 Drive Handle. Insert turbine assembly
(17) onto the new bushing and check for
freedom of rotation. After the trial t, remove
the turbine from the front cover.
7. Install thrust bearing (16)63.2 mm (2.48
inch)ID black side down against converter
cover and bushing assembly (6). See
Figure 34 for reference.
Figure 52. Lockup Clutch and Damper

Assembly
8. Install lockup piston seal ring (9), 86.9 mm ID,

color coded with green marks, on the hub of
torque converter cover (7) and lockup piston
sealring (11) on the OD of lockup clutch piston
assembly (10). Install the lockup clutch piston.
53

Figure 53. Lockup Clutch Part Number
Figure 55. Turbine

13. Install sealring (15) onto torque converter
turbine assembly (17) and install torque
converter turbine assembly (17) into torque
converter cover assembly (5) aligning
the balance mark on the turbine with the
balance mark on the lockup clutch damper
(Figure 56).
Figure 54. Torque Converter Cover and

Lockup Clutch
10. Install lockup clutch backplate (13).
11. Install thirty M8 x 1.25 x 30 bolts (14). Tighten
bolts to 3035 Nm (2226 lb ft).
Step 7, install stator thrust bearing assembly
(18) (55 mm (2.16 inch)ID) onto torque
converter turbine assembly (17) (Figure 55).
Figure 56. Turbine and Cover Balance Marks

14. Install stator assembly (20) onto turbine (17).
15. Install selective shim (28) (Figure 57)
removed in 53a. Disassembly (Foldout 5),
Step 9 and pump thrust bearing assembly
(29), 80 mm (3.14 inch)ID onto the stator
54
MODULE REBUILD
(Figure 58, Figure 59). See Figure 34 for
reference.
Figure 59. Stator and Thrust Bearing Assembly
Figure 57. Stator Shim
16. Be sure all thirtysix M8 x 1.25 x 25 Thead

bolts (34) are installed into torque converter
pump assembly (33) ange. If removed, install
thrust washer (32) into torque converter pump
assembly (31). Stake thrust washer (32) into
the converter. Stake at six equallyspaced
locations
17. Install 368 mm (14.48 inch) Oring (30) onto
torque converter cover (7). With balance
marks or scribe mark aligned (Figure 510),
install torque converter pump assembly (31)
on top of torque converter cover assembly (5).
Figure 58. Thrust Bearing
Figure 510. Torque Converter Balance Marks
55

18. Install four M8 x 1.25 nuts (4), onto four evenly
spaced M8 x 1.25 x 25 Thead bolts (34).
Tighten the nuts to 3035 Nm (2226 lb ft).
19. Using a depth micrometer, measure from the
top of the converter hub to the thrust surface
of torque converter turbine assembly (17).
This is dimension A (Figure 511).
Figure 511. Torque Converter Selective Shim Procedure

20. Insert J38548 into the converter cover and
place on a at surface. Repeat the same
measurement as in Step 19. This is dimension
B.
21. Subtract dimension B from dimension A to get
dimension C.
22. Refer to Table 51 for correct shim selection.
Table 51. Torque Converter Selective Shims
Dimension C
Use P/N
Shim Thickness
0.080.35 mm (0.0030.014 inch)
0.000 mm (0.00 inch) NO STEP
0.360.60 mm (0.0140.024 inch)
29502277
0.230.28 mm (0.0090.011 inch)
0.610.83 mm (0.0240.033 inch)
29502276
0.460.51 mm (0.0180.020 inch)
0.841.06 mm (0.0330.042 inch)
29502275
0.690.74 mm (0.0270.029 inch)
23. If dimension C does not equal the NO STEP

dimension of 0.080.35 mm (0.0030.014
inch), go back to 53a. Disassembly
(Foldout 5) and disassemble the converter
and install the correct shim at Step 15. Repeat
Steps 1623. If dimension C equals the NO
56
STEPdimension, clearance is correct, go on

to Step 24.
24. Install the remaining thirtytwo M8 x 1.25
nuts (4) onto converter pump M8 x 1.25 x 25
bolts (34) . Tighten all the nuts to 3035 Nm
(2226 lb ft).
MODULE REBUILD
54.
TORQUE CONVERTER HOUSING

MODULE (Models With PTO
Provision)
a. Module Disassembly (Foldout 62).

S/N 6510633307 and S/N 6520058755, the
input speed sensor has been redesigned.
See Figure 37 to identify former or current
found in SIL 5WT06.
1. If not previously removed, remove input speed
sensor M8 x 1.25 x 20 retaining bolt (21),
sensor retaining bracket (20), input speed
sensor assembly (18), and Oring (19)*.
Check input speed sensor resistance. Refer
to 35. CLEANING AND INSPECTION.
2. Remove and inspect breather assembly (28)
or breather adapter (29) using a thin 14 mm
wrench.
3. If present, remove Power Takeoff (PTO)
cover(s) (25) by removing ten M10 x 1.5 x
25 bolts (26) for each cover. Remove PTO
cover(s) (25) and gasket(s) (24).
4. Remove ten M10 x 1.5 x 35 bolts (2) holding
bearing retainer assembly (3) into converter
housing (22).
5. Remove bearing retainer assembly (3) and
PTO gear assembly (9). If necessary, use jack
bolts to loosen the bearing retainer assembly.
6. Inspect the bearing bore of converter housing
(22) for damage. Measure the bearing bore
maximum allowable ID for reuse is 140.06 mm
(5.514 inch).
b. Disassembly of the Bearing Retainer
Assembly.
1. Remove sealring (8) (178.8 mm) from bearing
retainer (7). Remove oil seal (4) using
J24171A Slide Hammer and Jaw Set.

S/N 6520083093, S/N 6610220990,
S/N 6620005821, S/N 9370007661,
S/N 9320006231, S/N 9470006080, and
S/N 9420007560, material of specic
2. Inspect bushing (6) for damage and wear.
Maximum allowable bushing ID for reuse
is 75.5 mm (2.97 inch). If replacement is
necessary, remove the bushing using a
hammer and chisel.
3. Inspect the bearing bore of bearing retainer
(7) for damage. Measure the bearing
boremaximum allowable ID for reuse is
140.06 mm (5.514 inch).
c. Disassembly of the PTO Gear Assembly.
1. Remove retaining ring (15). Remove 68 mm
oil pump drive hub (13) from PTO gear (12).
2. Inspect oil pump drive hub (13) for excessive
wear on the drive tangs. Maximum allowable
tang wear is 0.38 mm (0.015 inch).
3. Remove buttjoint sealrings (10) and (16) (88
mm ID). If replacement is required, inspect the
condition of 90 mm ID bearings (11) and (14)
per 35e. Inspecting Bearings. If bearings do
not meet service specication, remove them
from the PTO gear (12) using a bearing puller.
d. Assembly of the PTO Gear Assembly.
1. If removed, press 90 mm ID bearings (11)
and (14) onto shoulder of gear (12), using
J38565 Pump Gear, Torque Converter Cover
Bushing Installer.
2. Install 68 mm oil pump drive hub (13) into PTO
gear (12). Install retaining ring (15) onto oil
pump drive hub (13).
3. Refer to 36h. ButtJoint Sealrings. Insert
two buttjoint sealrings (10) and (16) into the
sealing bore of bearing retainer housing (7)
and measure the end gap with feeler gauges.
57

Maximum allowable sealring end gap for
reuse is 1.15 mm (0.045 inch)0.57 mm
(0.022 inch).
4. Remove the two buttjoint sealrings (10) and
(16) (88 mm ID) from the bearing retainer
housing and install them onto the PTO gear
(12) if they meet specication. Otherwise,
install new buttjoint sealrings on the PTO
gear (12).
e. Assembly of the Bearing Retainer Assembly.
housing (22). Tighten the bolts to 5161 Nm

(3845 lb ft).
4. If used, install PTO cover(s) (25) and gasket(s)
(24) using ten M10 x 1.5 x 25 bolts (26) in
each cover. Tighten the bolts to 5161 Nm
(3845 lb ft).
5. Install breather (28) or breather adapter (29).
Tighten the breather or breather adapter to
1216 Nm (912 lb ft) using a thin 14 mm
wrench.
55.
S/N 6520083093, S/N 6610220990,
S/N 6620005821, S/N 9370007661,
S/N 9320006231, S/N 9470006080, and
1. If removed, install bushing (6)75.5 mm (2.972
inches) using a press or soft mallet and
J359222 Oil Pump Body Bushing/Ground
Sleeve Bearing/P1 Sun Gear Bushing Installer
and J8092 Drive Handle. Press bushing
(6) ush to 0.25 mm (0.010 inch) below the
surface.
2. Install sealring (8) (178.8 mm). Install oil seal
(4) ush to 0.25 mm (0.010 inch) below the
surface using a press and J359213 Oil Pump
(Input) Seal Installer and J359211 Output
Bearing Installer/Drive Sleeve. Press sealring
(8) ush, to 0.25 mm (0.010 inch) below the
surface.
f.
TORQUE CONVERTER HOUSING

MODULE (Models Without PTO
Provision)

Refer to 35. CLEANING AND INSPECTION
S/N 6510630089 and S/N 520057820,
Figure 37 to identify former or current
found in SIL 5WT06.
1. If not previously removed, remove input
speed sensor retaining bolt (6) M8 x 1.25 x
20, sensor retaining bracket (5), input speed
sensor assembly (3), and Oring (4). Refer
to 54a. Module Disassembly (Foldout 62),
Step 1.
2. Remove breather assembly (9) using a thin 14
mm wrench.
Module Assembly.
1. With a mallet, lightly tap PTO gear assembly
(9) into converter housing (22) until the gear
assembly is seated.
2. Use guide bolts to install bearing retainer
assembly (3), rocking the retainer while
installing.
1. Be sure Oring (4), ID 15.6 mm, M8 x 1.25 x

20 is in place and install input speed sensor
assembly (3). Hold bracket (5) in place and
install retaining bolt (6). Tighten the bolt to
2429 Nm (1821 lb ft).
2. Install breather (9). Tighten the breather to
1216 Nm (912 lb ft).
3. Install ten M10 x 1.5 x 35 bolts (2) holding

bearing the retainer assembly (3) into the
58
MODULE REBUILD
56.
FRONT SUPPORT AND CHARGING

OIL PUMP MODULE
a. Module Disassembly (Foldout 71).

1. Remove three 88 mm ID seals (23) from the
front support hub.
2. Remove 104 mm ID thrust bearing (24).
3. Remove eight M10 x 1.5 x 65 bolts (6) that
retain pump housing assembly (7) to front
support assembly (15).
4. Remove pump housing assembly (7)
(Figure 512) and gear set (10).
Figure 513. Main Pressure Relief Spring

Compressor Attachment
Figure 512. Pump Housing Assembly

5. Compress pressure relief spring (26) using
J41462 Main Pressure Relief Spring
Compressor (Figure 514). Remove pin (25)
(Figure 515). Slowly release the pressure
on the spring and remove spring (26) and ball
(27) (Figure 516).
Figure 514. Compress Pressure Relief Spring
59

Figure 515. Pin Removal
Figure 517. Measuring GearCavity Depth

In The Pump Housing
8. Measure gearcavity diameter in the pump
housing (Figure 518). Maximum allowable ID
for reuse is 127.30 mm (5.012 inch).
Figure 516. Pump Housing Spring and Ball

6. On models without PTO, remove 4inch
ID Oring (4). Remove oil seal (5) using
J24171A Slide Hammer and Jaw Set.
7. Measure gearcavity depth in the pump
housing (Figure 517). Maximum allowable
Figure 518. Measuring GearCavity Diameter

In The Pump Housing
9. On nonPTO models only, inspect bushing
(8) inside pump housing (9) (Foldout 71) for
wear or damage. Measure the ID of the pump
bushing. Maximum allowable ID for reuse is
75.15 mm (2.95 inch). If worn or damaged,
remove bushing (8) from pump housing (9).
10. If pump housing (9) is worn or damaged,
replace the pump housing.
510
MODULE REBUILD
11. Measure the OD of the driven (outer) pump
gear. Minimum allowable OD is 126.95 mm
(4.998 inch).
12. Measure the width of the driven pump gear.
Minimum allowable width for reuse is 17.81
mm (0.701 inch ).
13. Inspect the bushing inside the drive (inner)
gear for wear or damage. Measure the ID of
the drive gear bushing. Maximum allowable
ID for reuse is 57.30 mm (2.256 inch). If worn
or damaged, remove the bushing (11) from
the drive gear.
14. Measure the width of the drive and driven
pump gears. Minimum allowable width for
reuse is 17.81 mm (0.701 inch).
15. Examine the tang slots in the drive pump gear.
Replace the gear if the slots have step wear.
16. Install gear set (10) into pump housing
(9). Measure pump gear side clearance
(Figure 519). Maximum allowable clearance
Figure 519. Measuring Gear Side Clearance

In The Pump Housing
17. Measure gear tooth tip clearance
(Figure 520). Maximum allowable
clearance for reuse is 0.20 mm (0.008 inch).
Figure 520. Measuring Gear Tooth Tip

Clearance In The Pump Housing
18. Measure driven geartopump housing
(diametrical) clearance (Figure 521).
Maximum allowable clearance for reuse is
0.36 mm (0.014 inch).
Figure 521. Measuring Driven Gear Clearance

In The Pump Housing
19. If any measurement is out of specication,
replace the pump housing and/or gear set (10)
and repeat Steps 11 through 18.
20. Remove ten M10 x 1.5 x 25 bolts (12)
(Foldout 71) retaining stiffening plate (13), if
present, and wear plate (14) attached to front
support assembly (15). Remove stiffening
511

plate (13), if present, and wear plate (14).
Inspect wear plate (14) for surface damage
and distortion. Measure the thickness of the
wear plate. Minimum allowable wear plate
CAUTION: Be sure to use the correct
length bolts when installing the front support
or transmission damage will occur. The ten
bolts (12) used when the stiffening plate is
present are 5 mm (0.197 inch) longer, (M10
x 1.5 x 30) than the bolts used when the
stiffening plate is not present.
21. Inspect 63 mm OD bearing (22) in front support
assembly (15). If bearing (22) does not meet
guidelines in 35e. Inspecting Bearings,
remove bearing with J24171A Slide
Hammer and Jaw Set.
22. Measure the OD of front support sleeve (20).
Minimum allowable OD is 98.83 mm (3.891
inch). If damaged, replace front support (21).
23. If damaged, remove dowel pin(s) (19) from
front support (21).
24. Measure the OD of ground sleeve (16) or (17)
(Figure 524) at the journal for the oil pump
gear set bushing. Minimum allowable OD for
reuse is 57.04 mm (2.246 inch). If journal is
damaged or worn beyond service limits then
replace the ground sleeve.
25. If worn or damaged, remove ground sleeve
(16) or (17) by pressing ground sleeve from
front support (21).
NOTE: 63 mm OD bearing (22) must be
removed when removing ground sleeve
(16) or (17) from front support (21).
b. Assembly of the Front Support.

NOTE: To avoid front support distortion, the
ground sleeve and front support must both
be at room temperature while pressing the
ground sleeve in the front support.
1. If removed, install ground sleeve (16) or (17)
(Foldout 71 and Figure 524). Place front
support (21) on press bed with front support
resting on hub. The machined at at the base
of the ground sleeve must align with the cast
arrow on the front support (Figure 524, View
C). Press ground sleeve (16) or (17) into front
support (21) to the shoulder. After installation,
total runout may not exceed 0.30 mm (0.012
inch) See (Figure 524, View A).
2. If removed, install dowel pin(s) (19). Press the
pin(s) to a height of 14.5 mm (0.57 inch) from
the surface (Figure 524, View A).
CAUTION: Be sure to use the correct
length bolts when installing the front support
or transmission damage will occur. The ten
bolts (12) used when the stiffening plate is
present are 5 mm (0.197 inch) longer (M10
x 1.5 x 30) than the bolts used when the
stiffening plate is not present.
3. Install stiffening plate (13), if present, and
wear plate (14) (Foldout 71). Secure with ten
M10 x 1.5 x 25 bolts (12). Tighten the bolts to
5161 Nm (3845 lb ft).
4. Install 63 mm OD bearing (22) using a
press and J359222 Oil Pump Body
Bushing/Ground Sleeve Bearing/P1 Sun Gear
Bushing Installer and J8092 Drive Handle.
Press bearing (22) ush to 0.25 mm (0.010
inch) below the surface.
NOTE: To keep from distorting front

support, do not use blocks to space up
the support while pressing a new ground
sleeve.
512
MODULE REBUILD
c. Assembly of the Pump Housing (Foldout 71).

S/N 6520083093, S/N 6610220990,
S/N 6620005821, S/N 9370007661,
S/N 9320006231, S/N 9470006080, and
Figure 522. Pump Housing Spring and Ball
NOTE:
For models without PTO, proceed
with Step 1.
For models with PTO, skip to Step 4.
1. If old bushing was removed, install new
bushing (8) 75.15 mm ID (Foldout 71) into
pump housing (9) using a press and tools
J359222 Oil Pump Body Bushing/Ground
Sleeve Bearing/P1 Sun Gear Bushing Installer
and J8092 Drive Handle.
2. Install oil seal (5) using a press and
J359213 Oil Pump (Input) Seal Installer
and J359211 Output Bearing Installer/Drive
Sleeve.
3. Install a 4.4 inch ID Oring (4).
4. Install pressure relief ball (27) and pressure
relief spring (26) into pump housing
(Figure 522). Using tool J41462 Main
Pressure Relief Spring Compressor, compress
spring (26). Install pin (25) to retain spring and
ball (Figure 523).
Figure 523. Compress Pressure Relief Spring
513

Figure 524. Ground Sleeve Removal and Installation

5. Lubricate pump gear set (10) to prevent
damage and install the gear set in pump
housing (9).
6. Attach the pump housing to the front support
using the two locating pins, with eight M10 x
1.5 x 65 bolts (6). Tighten the bolts to 5161
Nm (3845 lb ft).
7. Install 104 mm ID thrust bearing (24) onto front
support (21) (Figure 525). When installing
thrust bearings, take care to orient the thrust
bearing consistent to Figure 34 shown in
35e. Inspecting Bearings.
514
MODULE REBUILD
3. Inspect and measure the ID of sun gear
bushing (43). Maximum allowable ID for
reuse is 68.22 mm (2.685 inch). Remove the
bushing with a hammer and chisel if visually
damaged or worn beyond service limits.
4. Remove 298 mm ID retaining ring (44).
5. Remove C2 clutch pressure plate (39).
6. Measure the thickness of C2 clutch pressure
plate (39). Minimum allowable thickness for
reuse is 6.25 mm (0.246 inch). Check atness
of the C2 clutch pressure plate (39). Maximum
allowable distortion for reuse is 0.45 mm
(0.018 inch).
7. Remove six C2 clutch pack friction plates (38)
and six steel reaction plates (37).
Figure 525. Thrust Bearing Installed
on Front Support
8. Insert three 88 mm ID buttjoint sealrings (23)
into the sealing bore of the rotating clutch hub
and measure the end gap with feeler gauges.
Maximum allowable sealring end gap for
9. Remove three buttjoint sealrings (23) from
the rotating clutch hub and install them onto
the hub of front support (21). If any do not
meet specications, replace all three buttjoint
sealrings.
57.
ROTATING CLUTCH MODULE

S/N 6520083093, S/N 6610220990,S/
N 6620005821, S/N 9370007661,
S/N 9320006231,S/N 9470006080,S/
N 9420007560, material of specic seals
has been modied to be compatible with
DEXRON VI uids. Transmissions
compatible with DEXRON VI uids. Seal
1. Remove 298 mm ID retaining ring (40).
2. Remove P1 sun gear assembly (41).
8. Visually inspect each friction plate for damage

or excessive wear. If any plate has perceivable
wear or distortion, measure the thickness of
each friction plate (38). Minimum allowable
Measure the oil groove depth and cone of
each friction plate. Minimum allowable groove
Maximum allowable cone for reuse is 0.40
mm (0.016 inch).
9. Visually inspect each steel reaction plate for
damage or excessive wear. If any plate has
thickness and cone of each steel reaction
reuse is 2.36 mm (0.093 inch). Maximum
inch).
10. Remove C2 drive hub (36), including two 74
mm ID thrust bearings (35) . Inspect thrust
bearings (35) using guidelines from 35e.
Inspecting Bearings. Replace any thrust
bearing that does not meet specications.
Inspect the splines of the C2 drive hub.
0.38 mm (0.015 inch).
11. Remove C1 drive hub (34). Inspect the splines
of the C1 drive hub. Maximum allowable
spline wear for reuse is 0.38 mm (0.015 inch).
12. Remove 104 mm ID retaining ring (33), C1
backing plate (32), six C1 apply plates (29),
six C1 friction plates (30), and ve steel
reaction plates (31).
515

13. Visually inspect each C1 friction plate (30) for
(0.087 inch). Measure the oil groove depth
and cone of each friction plate. Minimum
allowable groove depth for reuse is 0.20 mm
(0.008 inch). Maximum allowable cone for
14. Visually inspect each steel reaction plate (31)
for damage or excessive wear. If any plate
has perceivable wear or distortion, measure
the thickness and cone of each steel reaction
reuse is 2.36 mm (0.093 inch). Maximum
inch).
Figure 526. Measure Wear Surface Thickness
15. Measure the wear surface thickness of the

C1 apply plate (29). Minimum allowable
Check atness of the apply plate. Maximum
allowable distortion for reuse is 0.15 mm
(0.006 inch).
16. Measure the wear surface thickness of the C1
backing plate (32) (Figure 526). Minimum
(0.323 inch). Check atness of the backing
plate. Maximum allowable distortion for reuse
is 0.15 mm (0.006 inch). Measure wear from
the friction plate side to the top of the spline
tooth (Figure 527, Figure 528).
Figure 527. Proper Placement of

Micrometer A
516
MODULE REBUILD
C1 return spring assembly (25). Remove
retaining ring (28). Remove J 359231 Piston
Spring Compressor (C1).
S/N 6520083093, S/N S/N 6610220990,
S/N 6620005821, S/N 9370007661,
S/N 9320006231, S/N 9470006080, and
with Dexron VI uids. Transmissions
compatible with DexronVI uids. Seal
Figure 528. Proper Placement of
Micrometer B
17. Remove 74 mm ID thrust bearing (15) from
rotating clutch hub assembly (12). Inspect
thrust bearing (15) using guidelines from
18. Remove 48 mm ID retaining ring (16) from
turbine shaft assembly (5) or (8).
19. Inspect turbine shaft bushing (7) inside the
end of turbine shaft (5) or (8). Measure the
ID of the turbine shaft bushing. Maximum
allowable ID for reuse is 20.19 mm (0.795
inch). Remove with hammer and chisel if
visually damaged or worn beyond service
limits.
20. Remove three 51 mm OD buttjoint sealrings
(10) from turbine shaft assembly (5) or (8).
21. Remove Oring (4) from turbine shaft
assembly (5) or (8).
WARNING: Piston springs are highly
compressed. Be extremely careful during
disassembly. Personal injury can occur if
the spring force is not controlled.
22. Place rotating clutch on J 359234 Compressor
Base so rotating drum is supported by tool
tangs (Figure 532, View C). Install
J 359231 Piston Spring Compressor (C1)
(Figure 532, View A), bearing, washer, and
J 2846734 Handle. Tighten tool, compressing
C1 balance piston (26) (Foldout 72) and
23. Remove balance piston (26), (with yellow

markings) sealring (27), and C1 spring
assembly (25).
24. Install J 359234 Compressor Base,
and J 359232 Piston Spring Compressor
(C5) (Figure 532, View B), bearing, washer,
and handle J 2846734 Handle. Tighten tool
and remove 298 mm ID retaining ring (22)
(Foldout 72). Remove tools J 359232 Piston
Spring Compressor (C5) and J 359233 Piston
Spring Compressor (C2) .
25. Remove C2 spring assembly (21).
26. Remove assembly from
J 359234 Compressor Base. Then
remove rotating clutch drum (11) from the rest
of the assembly. Inspect the clutch splines of
the rotating drum. Maximum allowable spline
wear is 0.38 mm (0.015 inch).
NOTE: Do not use pliers or vise grips to
remove or disassemble C1/C2 assembly
in step 27 and step 30. Parts may be
damaged.
27. Remove C1 and C2 pistons (20) and (24)
as an assembly from hub assembly (12)
by rocking the pistons from sidetoside
(Figure 529, Figure 530, and Figure 531).
517

Figure 529. Piston Removal A
Figure 531. Piston Removal C

28. Inspect rotating clutch hub bushing (13).
Maximum allowable bushing ID is 99.25 mm
(3.907 inch). Remove the bushing from hub
assembly (12) if replacement is necessary.
Avoid damaging the bushing bore.
29. Remove 116 mm ID (with pink marks) C2
piston sealring (17), and 101 mm ID (with
light blue marks) C1 piston sealring (18) from
rotating clutch hub assembly (12).
30. Separate C1 piston (24) from C2 piston
(20) by tapping lightly on the C1 piston (24).
Remove 179 mm (7.039)ID (with orange
marks) C1 piston sealring (23) from C1 piston
(24). Remove C2 piston sealring (19) from C2
piston (20).
Figure 530. Piston Removal B
518
MODULE REBUILD
Figure 532. Rotating Clutch Assembly/Disassembly
519

hub assembly (14). Lightly tap until it is fully

seated.

S/N 6520083093, S/N 6610220990,
S/N 6620005821, S/N 9370007661,
S/N 9320006231, S/N 9470006080, and
with DexronVI uids. Transmissions
1. If removed during disassembly, install 99.15
mm ID bushing (13) into rotating clutch
hub (14) using J 359222 Oil Pump Body
Bushing Installer and J 8092 Drive Handle.
NOTE: For all ush mount bushings align
the bushing with its bore and press or drive
the bushing until it seats. The top of the
bushing must be ush with the top of the
bore or no more than 0.25 mm (0.010 inch)
below the bore top.

S/N 6520083093, S/N 6610220990,
S/N 6620005821, S/N 9370007661,
S/N 9320006231, S/N 9470006080,
2. Install 116 mm ID (with pink marks) C2 piston
sealring (17) and 101 mm ID (with light blue
marks) C1 piston sealring (18) into rotating
clutch hub assembly (12). Lube sealrings.
3. Lubricate the C2 piston OD and ID. Install a
new C2 piston sealring (19) on C2 piston (20).
Install C2 piston (20) into the rotating clutch
520
4. Lubricate the C1 piston OD and ID. Install

a new 179 mm ID (with orange marks) C1
piston sealring (18) on C1 piston (24). Lube
the inside bore and OD sealring on the C1
piston (24). Aligning slot in C1 piston (24)
(Figure 532, View D) with any lube orice on
the rotating clutch hub, install C1 piston (24)
into the center of C2 piston (20). With a soft
mallet, lightly tap C1 piston (24) until it is fully
seated at the bottom of C2 piston (20).
S/N 6520083093, S/N 6610220990,
S/N 6620005821, S/N 9370007661,
S/N 9320006231, S/N 9470006080,
5. Place this assembly on J 359234 Compressor
Base. Install C1 spring assembly (25).
6. Install a new 202 mm ID (with yellow marks)
balance piston sealring (27) on balance piston
(26). Lube the sealring.
7. Place balance piston (26) on rotating clutch
assembly (14), aligning the notch on C1 piston
(24) with the cast bump on balance piston (26)
(Figure 532 View D).
8. Prestage snap ring (28). Install tool
oriented to compress C1 spring assembly
(25), washer, and handle. Thread the handle
down and compress C1 spring assembly (25).
9. Install 104 mm ID external retaining ring (28)
in groove closest to balance piston (26) of
rotating clutch hub assembly (14).
10. Carefully release C1 spring (25) and remove
all tools from the assembly.
11. Install C1/C2 assembly into rotating clutch
drum (11).
MODULE REBUILD
12. Install C2 spring assembly (21) with the inner
locating ring down in the rotating clutch drum
(11) (Figure 533). Make sure the spring
assembly properly aligns with the rotating
clutch drum (11) and C2 piston splines.
36h. ButtJoint Sealrings for method and

procedure.
17. Install turbine shaft assembly (5) or (8) in
rotating clutch assembly (3) so turbine shaft
(5) or (8) is pointing towards torque converter.
Install the 48 mm ID retaining ring (16) in
turbine shaft retaining ring groove located
closest to buttjoint sealrings (10).
18. Install 74 mm ID thrust bearing (15) onto
the end of rotating clutch hub assembly
(12). When installing thrust bearings, take
care to orient the thrust bearing consistent
to Figure 34 shown in 35e. Inspecting
Bearings. Position the assembly with the
turbine shaft downward.
19. Install C1 apply plate (29) on turbine shaft
(5) or (8).
20. Starting with a C1 friction plate (30), alternately
install six C1 friction plates (30) and ve C1
reaction plates (31).
Figure 533. Spring Assembly Installation

13. Place the assembly on J 359234 Compressor
Base so that the rotating clutch drum (11) is
supported by tool tangs (Figure 532, View
C). Install tools J 359233 Piston Spring
Compressor (C2) and J 359232 Piston Spring
Compressor (C5) (Figure 532, View B),
bearing, washer, and handle. Compress C2
spring assembly (21) and install 298 mm ID
retaining ring (22) in retaining ring groove
(Foldout 72). Remove J 359233 Piston
Spring Compressor (C2) and J 359232 Piston
Spring Compressor (C5).
install 20 mm ID bushing (7) into turbine shaft
(6) or (9) using tools J 359221 Piston Spring
Compressor (C1) and J 8092 Drive Handle.
15. Install 25.1 mm ID (brown) Oring (4) on the
converter end of the turbine shaft (6) or (9).
16. Insert three buttjoint sealrings (10) into the
sealing bore of ground sleeve (16) or (17)
(Foldout 71) and measure the end gap
with feeler gauges. Maximum allowable
sealring gap for reuse is 0.46 mm (0.018
inch). Remove sealrings from the ground
sleeve bore and install them on turbine shaft
assembly (5) or (8) (Foldout 72). Refer to
NOTE: Friction plates should be soaked

in clean transmission uid as discussed
in 36d. Clutches and Pistons prior to
assembly.
21. Install C1 backing plate (32), beveled edge
up, on last installed C1 friction plate (30).
22. Install 104 mm ID external retaining ring (33)
in retaining ring groove of rotating clutch hub
(14).
23. Install C1 drive hub (34) over C1 clutch pack.
Using C1 drive hub (36), align and locate each
friction and reaction plate inside the C1 drive
hub (36) until the C1 drive hub (36) seats
completely down to the C1 clutch apply plate
(29).
24. When installing thrust bearings, take care
to orient the thrust bearing consistent to
Figure 34 shown in 35e. Inspecting
Bearings. Install one 74 mm ID thrust bearing
(35) on each side of C2 drive hub (36), and
install this assembly over C1 drive hub (34).
25. Starting with a C2 reaction plate (37),
alternately install six C2 reaction plates and
six C2 friction plates (38) inside rotating drum
(11).
521

assembly.
26. Install C2 backing plate (39). Install 298 mm
ID C2 retaining ring (40) in rotating drum
retaining ring groove closest to the C2 backing
plate (39).
27. If removed in 57a. Disassembly
(Foldout 72), install 68.164 mm ID bushing
(43). Using J 359222 Oil Pump Body
Bushing Installer and J 8092 Drive Handle,
drive bushing (43) until J 359222 Oil Pump
Body Bushing/Ground Sleeve Bearing/P1 Sun
Gear Bushing Installer is ush against the P1
sun gear. The bushing should be 5.7 mm to
6.3 mm below the P1 sun gear face.
28. Install P1 sun gear drive hub assembly
(41). Install 298 mm ID retaining ring (44) in
retaining ring groove of rotating clutch drum
(11) above the P1 sungear drive hub (42).
58.
C3/C4 AND MAIN HOUSING

MODULE

NOTE: When replacing a nameplate,
keep the original nameplate. Stamp
the information recorded on the original
nameplate onto the replacement nameplate.
1. If nameplate (24) is damaged, remove
nameplate retaining rivet or screw (25) and
nameplate (24).
2. Inspect the C5 clutch splines inside the main
housing (22). Refer to 35j. Inspecting
Splined Parts for specications and service
limits.
3. Remove twelve bolts (2) (M10 x 1.5 x 90)
of C3/C4 clutch assembly (1). Remove
C3 backplate assembly (3) from C3 clutch
housing (11).
excessive wear. If any plate has perceivable

wear or distortion, measure the wear plates
at the contact surface. Minimum allowable
Check atness of backplate (3) and the wear
plates. Maximum allowable distortion for
reuse is 0.15 mm (0.006 inch). Remove each
wear plate by gently prying the wear plate
from the backplate.
5. Remove P1 ring gear (6). Inspect splines of
the P1 ring gear. Maximum allowable spline
wear for reuse is 0.38 mm (0.015 inch).
6. Remove C3 clutch packve friction plates
(7) and ve steel reaction plates (8).
7. Visually inspect each friction plate (7) for
8. Measure the oil groove depth of each friction
plate. Minimum allowable groove depth for
slot erosion of each friction plate. Maximum
allowable slot erosion for reuse is 4.00 mm
(0.157 inch).
9. Visually inspect each steel reaction plate 8
for damage or excessive wear. If any plate
has perceivable wear or distortion, measure
the thickness of each steel reaction plate 8.
Minimum allowable thickness for reuse is 3.20
mm (0.126 inch). Maximum allowable cone
10. Remove piston return plate (9) with four return
spring assemblies attached. Visually inspect
piston return plate (9) for damage or distortion.
If it has perceivable damage or distortion,
replace.
11. Remove C3 clutch housing assembly (13).
12. Remove C3 clutch piston (10) from C3 clutch
housing (13).
13. Inspect C3 clutch housing (13).
4. Visually inspect three wear plates (5) on C3

clutch backplate assembly (3) for damage or
522
MODULE REBUILD
NOTE: Recommend manual parts cleaner

used for C3/C4 housings to avoid caustic
solution in automatic cleaners damaging
piston seal surfaces.
14. Visually inspect each wear plate (12) in clutch
housing (13) for damage or excessive wear. If
any plate has perceivable wear or distortion,
measure the wear plates at the contact
surface. Minimum allowable thickness for
reuse is 2.81 mm (0.111 inch). If replacement
is necessary remove the wear plates by gently
prying the wear plate from the backplate. .
15. Visually inspect the backplate for damage or
excessive wear. If the plate has perceivable
wear or distortion, measure for step wear of
backplate (3), maximum allowable step wear
for reuse is 0.13 mm (0.005 inch). Measure
the cone of C3 backplate (3). Maximum
allowable cone of C3 backplate for reuse
is 0.15 mm (0.006 inch). If replacement is
necessary, remove the wear plates by gently
prying the wear plate from the backplate.
16. Remove C4 clutch packve friction plates
(14) and six steel reaction plates (15).
17. Visually inspect each friction plate (19) for
reuse is 0.40 mm (0.016 inch) .
18. Measure the oil groove depth of each friction
plate. Minimum allowable groove depth for
slot erosion of each friction plate. Maximum
allowable slot erosion for reuse is 4.00 mm
(0.157 inch).
19. Measure the thickness and cone of each
steel reaction plate 14. Minimum allowable
thickness for reuse is3.20 mm (0.126 inch).
Maximum allowable cone for reuse is 0.40
mm (0.016 inch).
20. Remove piston return plate (16) with four
return spring assemblies attached. Visually
inspect piston return plate (16) for damage
or distortion. If it has perceivable damage or
distortion, replace.
21. Remove C4 piston (17) from the C4 clutch

housing (18).
22. Inspect C4 clutch housing (18) for damage.
S/N 6520083093, S/N 6610220990,
S/N 6620005821, S/N 9370007661,
S/N 9320006231, S/N 9470006080, and
1. Install piston (17) into C4 housing (18).
2. Install piston return plate (16).
3. Install C4 clutch pack. Starting with a steel
reaction plate, alternately install six steel
reaction plates (14), and six friction plates
(15).
assembly.
4. If required, install new C3 housing wear plates
(12), position the C3 housing (13) on the bed
of an arbor press with the piston side of the C3
clutch housing (13) facing up (Figure 536).
5. Align the post on the back of a wear plate with
one of three chamfered wear plate mounting
holes in the C3 clutch housing (13).
6. Lightly press the wear plate until it is ush to
0.070 mm (0.0027 inch) above ush.
7. Repeat Steps 4 through 6, for each of the two
remaining wear plates.
8. Lube seal surfaces of C3 clutch piston (10),
and install the C3 clutch piston into C3 clutch
housing (13).
9. Install C3 clutch housing assembly (13) with
clutch piston (10) on top of the assembled C4
clutch housing (items (14)(18), Figure 534).
523

Make sure the index tangs on the clutch
housings are aligned (Figure 535) and piston
return springs locate in C4 housing packets.

assembly.
13. To install new C3 backplate wear plates,
position the C3 backplate on the bed of an
arbor press with the C3 clutch piston side
facing up.
14. Align the post on the back of a wear plate with
one of three chamfered wear plate mounting
holes in the C3 backplate.
15. Lightly press the wear plate until it is ush to
0.070 mm (0.003 inch) above ush.
16. Repeat Steps 12 through 14, for each of the
two remaining wear plates.
Figure 534. C3/C4 Clutch Housing Assembly
17. Install C3 backplate assembly (3). Backplate

(3) must be indexed with C3 and C4 housings
in order to correctly insert the assembly into
main housing (21).
18. Install twelve M10 x 1.5 x 90 retaining bolts (2)
through the C3 backplate assembly (3) and
into the C4 clutch housing (18). Tighten the
19. If removed, install nameplate (24) and screw
(25) to main housing (21).
Figure 535. C3/C4 Clutch Housing Assembly

Index Tangs Aligned
10. Install piston return plate spring retainer
assembly (9).
11. Install P1 ring gear (6) so it is located on C3
wear plates.
12. Install C3 clutch pack. Starting with a steel
reaction plate, alternately install ve reaction
plates (8), and ve friction plates (7).
524
MODULE REBUILD
59.
MAIN SHAFT MODULE

NOTE:
For 3000 Product Family models,
except 3500, and 3700 SP models,
proceed to 59a. Disassembly (3000
Product Family Models, Except 3500
and 3700 SP Models) (Foldout 82)
For 3500 model proceed to
59c. Module Disassembly(3500
Transmission Model) (Foldout 91).
For the 3700 SP model, proceed to
59e. Module Disassembly (3700 SP
Transmission Model) (Foldout 92).
a. Disassembly (3000 Product Family Models,

Except 3500 and 3700 SP Models) (Foldout 82).
1. Remove spiral retaining ring (4) (48 mm ID).
2. Remove P2 sun gear (6).
3. Remove thrust bearing (5) (55 mm ID) and
inspect as per 35e. Inspecting Bearings.
Replace if necessary.
4. Remove bearing spacer (7).
5. Remove selective shim (1), if not previously
removed.
6. Remove thrust bearing (2) (78.5 mm ID), if not
previously removed, and inspect per 35e.
Inspecting Bearings. Replace if necessary.
7. Remove P3 sun gear (8) from main shaft (9).
Figure 536. Installing Wear Plates
8. Inspect and measure main shaft pilots.

Minimum allowable pilot OD for reuse is 19.98
mm (0.787 inch). Inspect and measure main
shaft journal OD for the P2 planetary bushing.
Minimum allowable main shaft journal OD for
9. Inspect for main shaft spline wear. Refer
to 35j. Inspecting Splined Parts for
specications and service limits.
525

b. Assembly (3000 Product Family Models,
Except 3500, 3700 SP Models) (Foldout 82).
NOTE: Do not install thrust bearing (2) or
selective shim (1) until nal transmission
assembly. Measurement for selective shim
(1) is performed during nal buildup.
1. Install P3 sun gear (8) onto main shaft (9).
2. Install bearing spacer (7).
3. Install thrust bearing (5) (55 mm ID).
When installing thrust bearings, take care
Bearings.
4. Install P2 sun gear (6).
5. Install spiral retaining ring (4) (48 mm ID).
Compress the spiral retaining ring to lock it
into place on main shaft 9.
6. Proceed to 510. P1 PLANETARY MODULE.
d. Module Assembly (3500 Transmission

Model) (Foldout 91).
NOTE: Do not install thrust bearing (2) or
selective shim (1) until nal transmission
assembly. Measurement for selective shim
(1) is performed during nal buildup.
1. Install spacer (7) and thrust bearing 6 (67
mm ID). When installing thrust bearings, take
care to orient the thrust bearing consistent
to Figure 34 shown in 35e. Inspecting
Bearings.
2. Install P2 sun gear (5) and spiral retaining
ring (4) (43.5 mm ID). Compress the spiral
retaining ring to lock it into place on main shaft
(8).
3. Proceed to 510. P1 PLANETARY MODULE.
e. Module Disassembly (3700 SP Transmission
1. Remove spiral retaining ring (3) (48 mm ID).
c. Module Disassembly(3500 Transmission

2. Remove P2 sun gear (5) and thrust bearing

(4) (55 mm ID).
1. Remove spiral retaining ring (4) (43.5 mm ID)

from main shaft (8).
3. Remove spacer (6).
3. Remove thrust bearing (6) (67 mm ID) and

inspect per 35e. Inspecting Bearings.
Replace if necessary.
5. Remove thrust bearing (1) (96.36 mm OD).
4. Remove spacer (7).

5. Inspect and measure main shaft pilots.
Minimum allowable pilot OD for reuse is 19.98
shaft journal OD for P2 planetary bushing.
Minimum allowable main shaft journal OD for
6. Inspect C6 bushing journal OD on main shaft

8. Minimum allowable OD for reuse is 35.92
mm (1.414 inch). Inspect P3 bushing journal
OD. Minimum allowable OD for reuse is 52.98
mm (2.086 inch).
7. Measure the front main shaft pilot. Minimum
allowable pilot OD permitted for reuse is 19.98
shaft journal OD for P2 planetary bushing.
Minimum allowable journal OD for reuse is
42.97 mm (1.692 inch).
f. Module Assembly (3700 SP Transmission
1. Install thrust bearing (1) (96.36 mm OD).
When installing thrust bearings, take care
526
MODULE REBUILD
Bearings.
2. Install P3 sun gear (7).
allowable step wear for reuse is 0.12 mm

(0.005 inch).
8. Remove thrust bearings (3) and (13) from
each side of P1 planetary carrier (8).
3. Install spacer (6).

4. Install P2 sun gear (5) and thrust bearing
(4) (55 mm ID). When installing thrust
bearings, take care to orient the thrust bearing
consistent to Figure 34 shown in 35e.
Inspecting Bearings.
9. Inspect spline wear of P1 planetary carrier (8)

and P2 planetary ring gear (14). Refer to 35j.
Inspecting Splined Parts for specications and
service limits.
5. Install spiral retaining ring (3) (48 mm ID).

Compress the spiral retaining ring to lock into
place on main shaft (8).
510. P1 PLANETARY MODULE

1. Remove retaining ring (2) (190.2 mm OD)
from P2 ring gear (14).
Figure 537. Carrier Indexing Ring Wear

2. Remove P2 ring gear (14).

3. Measure the P1 planetary pinion end play
in P1 carrier assembly (4). When end play
exceeds 0.94 mm (0.037 inch) for P1, P2,
or P3 pinions, review Section 3. GENERAL
OVERHAUL INFORMATION for inspection
criteria of pinion gears, thrust washers, and
carriers. Replace any parts that do not meet
inspection guidelines or service specications
in this section or Table 71. Measure all six
pinion gears.
1. Install two roller bearing assemblies (11) into

the center of a pinion gear (10) (Figure 538).
Install thrust washers (9) and (12) inside P1
planetary carrier (8). Align thrust washer tangs
with the slots in the carrier and retain them
with oilsoluble grease (Figure 540). Slide
the pinion gear and bearing sets into the side
of the P1 planetary carrier, between the thrust
washers (Figure 541). Repeat the procedure
with the ve remaining pinion gears.
4. Remove retaining ring (5) (159.2 mm OD) and

indexing ring (6). Inspect indexing ring (6) for
step wear, ip over indexing ring and reuse
if step wear is minor. Replace the indexing
ring if wear is excessive (Figure 537). If both
sides of the indexing ring have step wear,
replace the indexing ring.
5. Remove six spindles (7) from P1 carrier (8).
6. Slide out each pinion gear (10), thrust washers
(9) (14.5 mm ID) and (12) (21.5 mm OD), and
two roller bearings (11) from the P1 planetary
carrier assembly (8). Repeat the procedure
with the ve remaining pinion gears.
7. Measure the thickness of all thrust washers
(14.5 mm ID) and (12) (21.5 mm OD).
Minimum thrust washer thickness permitted
the step wear of each thrust washer. Maximum
Figure 538. Pinion Gear Bearing Installation
527

Figure 539. Pinion Gear and Bearing

Assembled
Figure 541. Pinion Gear Installation

2. Install six spindles (7) so the lower step is
positioned for proper installation of indexing
ring (6) (Figure 542).
Figure 540. Proper Thrust Washer Orientation

Figure 542. Spindle Installation
3. Install indexing ring (6) (Figure 543) and
retaining ring (5) (159.2 mm OD).
528
MODULE REBUILD
P2 or P3 pinions, review Section 3. GENERAL
criteria of pinion gears, thrust washers, and
carriers. Replace any parts that do not meet
in this section or Table 71. Measure end play
of all four pinion gears.
4. Remove retaining ring (13) (159.2 mm OD).
Remove indexing ring (12). Remove four
pinion spindles (11) from P2 carrier (3).
Inspect indexing ring (12) for step wear.
Indexing rings may be ipped over and reused
if corners are not abnormally worn (see
Figure 537).
Figure 543. Indexing Ring Installation

4. If components were replaced, check pinion
end play. When end play exceeds 0.94
mm (0.037 inch) for P1, P2 or P3 pinions,
review Section 3. GENERAL OVERHAUL
INFORMATION for inspection criteria of
pinion gears, thrust washers, and carriers.
Replace any parts that do not meet inspection
guidelines or service specications in this
section or Table 71. Check all six pinion
gears.
5. Install P1 planetary carrier assembly (4) on
P2 ring gear (14).
6. Install retaining ring (2) (190.2 mm ID) in
groove of P2 ring gear (14) for retaining P1
planetary carrier assembly (4) to the planetary
ring gear.
7. Install two thrust bearings (3) (74.25 mm ID)
and (13) (74.25 mm ID) one on each side of P1
planetary carrier assembly (4). When installing
thrust bearings, take care to orient the thrust
bearing consistent to Figure 34 shown in
511.
P2 PLANETARY MODULE

1. Remove retaining ring (2) (190.2 mm OD).
5. Slide out each pinion gear (9), thrust washers

(7) (14.5 mm ID) and (10) (21.5 mm OD), and
two roller bearings (8) (16 mm ID) from the
P2 planetary carrier assembly (5). Repeat
the procedure with the three remaining pinion
gears.
(7) (14.5 mm ID) and (10) (21.5 mm OD).
Minimum thrust washer thickness permitted for
step wear of each thrust washer. Maximum
(0.005 inch).
7. Inspect bushing (6) inside P2 planetary carrier
(5) for wear or damage. Maximum allowable
bushing ID is 43.20 mm (1.701 inch). Remove
with hammer and chisel if visually damaged or
worn beyond service limits.
8. Check spline wear between P2 planetary
carrier (5) and P3 planetary ring gear (14).
0.38 mm (0.015 inch).
1. If replacement is necessary, press bushing
(6) (43.104 mm ID), using installer
J 359221 Turbine Shaft/Output Shaft/P2
Planetary Bushing Installer and driver
J 8092 Drive Handle, until J 359221 Turbine
Shaft/Output Shaft/P2 Planetary Bushing
Installer seats against the P2 carrier hub
(Figure 544).
2. Remove P3 ring gear (14).

3. Measure P2 planetary pinion end play. When
end play exceeds 0.94 mm (0.037 inch) for P1,
529

Figure 544. Bushing Installation
Figure 546. Pinion Gear Bearing Assembly
2. Install two bearing sets (8) (16 mm ID/24

mm OD) into the center of pinion gear (9)
(Figure 545). Install thrust washers (7)
and (10) in P2 planetary carrier (5), align
thrust washer tangs with slots in the carrier
(5), and retain them with oilsoluble grease
(Figure 547). Slide the pinion gear and
two bearing sets into the side of the P2
planetary carrier between the thrust washers
(Figure 548). Repeat the procedure with the
three remaining pinion gears.
Figure 547. Proper Thrust Washer Orientation
530
MODULE REBUILD
3. Install four spindles (11) so the lower step is

positioned for proper installation of indexing
ring (12) (Figure 549).
5. If components were replaced, check pinion

end play. Pinion end play should not exceed
0.94 mm (0.037 inch). Check all four pinion
gears.
6. Install P2 carrier (3) into P3 ring gear (14).
7. Install retaining ring (2) (190.2 mm OD) into
P3 ring gear (14), retaining P2 planetary
carrier assembly (4).
NOTE:
For models without retarder and
without transfer case, skip 512.
RETARDER MODULE and proceed
to 513. REAR COVER MODULE.
For models with transfer case, skip
512. RETARDER MODULE and
513. REAR COVER MODULE and
proceed to 514. ADAPTER
HOUSING AND P3 OVERHAUL.
Figure 549. Spindle Installation

4. Install indexing ring (12) (159.2 mm OD,
Figure 550) and retaining ring (13).
512. RETARDER MODULE

a. Disassembly of Retarder Valve Body
(Foldout 11A).
1. Remove nine M8 x 1.25 x 65 bolts (81) and
one plug assembly (82) retaining the retarder
control body assembly (64) to retarder housing
subassembly (46) and remove retarder control
body assembly (64).
531

2. Remove separator plate (63).
3. Remove plug (70) (16.4 mm ID), Oring (69),
relay valve (66), and spring (67).
4. Remove plug (72) (16.4 mm ID), Oring (73),
spring (74), and regulator valve (75).
5. Remove retaining pin (76). Remove solenoid
with connector (77) assembly. Remove
Orings (79) (29 mm ID) and (80) (28 mm ID
Brown) from solenoid assembly (77).
6. Check the resistance of (PCS5) retarder
variable bleed solenoid (78). Resistance must
be within the range shown on Figure 38.
b. Disassembly of Retarder Housing
(Foldout 11A).
1. Remove four M10 x 1.5 x 30 bolts (89)
retaining either the remote manifold (88) or
the retarder housing (46).
2. Remove remote manifold (88) and gasket
(86).
3. If not already removed, remove output speed
sensor bolt (42) (15.6 mm ID Brown), retainer
(41), output speed sensor assembly (39), and
Oring (40) from the retarder housing. Check
output speed sensor resistance. Refer to
35r. Inspecting Electrical Components.
4. If not already removed, remove M8 x 1.25
x 20 temperature sensor retaining bolt (38)
(7.6 mm ID Brown), bracket (37), temperature
sensor assembly (35), and Oring (36) from
the retarder housing. Check the resistance
of the temperature sensor and replace the
sensor if it is defective (Figure 38).
5. Remove nine M8 x 1.25 x 25 bolts (52),
cover (51) and gasket (50) from the bottom of
retarder housing (49).
6. Remove plug (47) and washer (48) from
retarder housing (49).
7. Remove retaining ring (43) (1.668 inch OD)
and ow valve plug (44).
8. Thread the J42048 Retarder Flow Valve
Spring Compressor into the accumulator port
as far as it will go and still allow the handle
to be aligned with the plug (57). Compress
the plug (57) to relieve the spring load on
the retaining ring (58) (1.668 inch OD).
Remove retaining ring (58). Carefully release
532
the spring load by turning the tool handle

counterclockwise. Remove J42048 Retarder
Flow Valve Spring Compressor, plug (57),
Oring (56) (34.6 mm ID), spring (55), retarder
valve (54), and pin (53).
9. If not previously removed, remove oil seal
assembly (59), using J24171A. Seal
Removal tool.
10. Remove bearing retainer (60) using
J359252 Spanner Nut Wrench and
J47347 Output Shaft Holding Tool. Remove
Belleville spring washer (61).
11. Support retarder housing (49) so the P3
planetary carrier assembly (6) can be
removed from the retarder housing. Place
J47347 Output Shaft Holding Tool against the
threaded shoulder of the P3 planetary carrier
(12). Drive J47347 Output Shaft Holding
Tool on with a hydraulic press or a mallet until
the P3 planetary carrier is separated from the
retarder housing.
12. Remove roller bearing (62) (75 mm ID) from
the retarder housing.
13. Remove three M10 x 1.5 x 90 bolts (33) to
allow removal of retarder stator assembly (20)
from the retarder housing (49). Remove the
gasket (30) which provides a seal between the
retarder stator (27) and the retarder housing
(49).
14. Remove rotor (31). Inspect rotor hub splines
for wear. Refer to 35j. Inspecting Splined
Parts.
15. Remove sealring (32) (103.98 min ID). Insert
hooktype sealrings (29) and (32) into their
mating bores and measure the ID of each
sealring. Replace the sealrings if the ID
exceeds 95.67 mm (3.767 inch).
16. Remove bearing cup (45) using
J3940 Bearing Race Remover if bearing is
not being reused.
c. Disassembly of P3 Planetary Carrier
Assembly (Foldout 11A).
1. Remove retaining ring (14) (52 mm ID).
Remove output shaft assembly (7). Inspect
bushing (8) (20 mm ID) inside the output shaft
(9) for wear or damage. Measure the ID of the
MODULE REBUILD
output shaft bushing. Maximum allowable ID
2. If replacement is necessary, remove tapered
bearing (13) (75 mm ID) from P3 carrier (12)
with bearing puller.
3. Measure pinion end play of all four pinions.
Pinion end play should not exceed 0.94 mm
(0.037 inch).
NOTE: The spindles and pinions do not
need to be removed before removing the
output shaft assembly (7).
4. Remove retaining ring (10) (159 mm OD).
pinion spindles (15).
5. Slide pinion gear (17), thrust washers (16)
and (19), and two bearings (18) (28 mm ID,
38.025 mm OD) from the side of P3 planetary
carrier (12). Repeat the procedure with the
three remaining pinion gears.
6. Inspect indexing ring (11) for minor wear.
They may be ipped over and reused if corner
is not abnormally worn (see Figure 537).
(16) and (19). Minimum allowable thickness
the step wear of each thrust washer. Maximum
(0.005 inch).
d. Disassembly of Retarder Stator Assembly
(Foldout 11A).
1. Remove Oring (28) (297.1 mm ID) from stator
assembly (20).
compressed. Be extremely careful
during removal and installation. Personal
injury can occur if the spring force is not
controlled.
2. Compress retainer and spring assembly (22)
using J359232 Piston Spring Compressor.
Remove retaining ring (21) (128 mm ID) from
stator (27) and slowly release the spring
tension. Remove C5 clutch piston (23) from
retarder stator (27).
3. Remove outer piston sealring (24) (258.7 mm

ID color coded with yellow marks.) from C5
clutch piston (23).
S/N 6520083093, S/N 6610220990,
S/N 6620005821, S/N 9370007661,
S/N 9320006231, S/N 9470006080, and
4. Remove inner piston sealring (25) (140.3 mm
OD) from C5 clutch piston (23).
5. If bearing cup (26) does not meet guidelines
listed in Section 3. GENERAL OVERHAUL
INFORMATION, remove by pressing out
towards the C5 piston side of stator housing
assembly (20) using J3940 Bearing Race
Remover.
6. Replace any parts that do not meet general
inspection guidelines listed in Section 3.
GENERAL OVERHAUL INFORMATION.
e. Assembly of Retarder Stator (Foldout 11A).
1. If bearing cup (26) was removed,
install a new bearing cup in the stator
housing assembly (20). To install, place
J359223 Output Bearing Cup Installer
on J35922 Bearing/Bushing Installer with
handle J8092 Drive Handle. Place stator
housing assembly (20) so the retarder side of
the assembly is down. Install bearing cup (26)
on J359223 Output Bearing Cup Installer so
the side of the bearing cup with the larger ID
is oriented toward the C5 piston side of the
stator housing assembly (20) after installation.
Press the bearing cup (26) into the stator
housing assembly (20) until it contacts the
shoulder in the housing bore.
2. Install inner sealring (25) (140.3 mm OD) onto
C5 clutch piston (23).
533

S/N 6520083093, S/N 6610220990,
S/N 6620005821, S/N 9370007661,
S/N 9320006231, S/N 9470006080, and
3. Install outer piston sealring (24) (258.7 mm ID
color coded with yellow marks) onto C5 clutch
piston (23). Lube sealrings on the piston and
seal bore areas in the retarder stator.
4. Align the tab on the back of the C5 clutch
piston with the notch in the retarder stator
housing. Lightly seat the C5 clutch piston (23)
into retarder stator (27).
installation. Personal injury can occur if the
spring force is not controlled.
CAUTION: Use care when compressing

spring assembly not to allow the assembly
to catch in and damage the retaining ring
groove.
5. Align the tab on the C5 return spring assembly
(22) with the notch in the stator housing (27).
Compress the C5 return spring assembly (22)
using J359232 Piston Spring Compressor.
Install retaining ring (21) (128 mm ID) so
the ends clear the tab of the assembly, and
slowly release the spring force. Remove the
J359232 Piston Spring Compressor.
6. Install Oring seal (28) (291.7 mm ID) on
retarder stator (27).
(13) so that it centers on the carrier with

the rollers facing up. Press the bearing
down until it contacts the shoulder on the P3
carrier (12) using J359211 Output Bearing
Installer/Drive Sleeve.
2. If removed, drive or press bushing (8) into
the output shaft (9) with J359221 Turbine
Shaft/Output Shaft/P2 Planetary Bushing
Installer , and J8092 Drive Handle, until
J359221 Turbine Shaft/Output Shaft/P2
Planetary Bushing Installer seats against
output shaft (9).
3. Install output shaft assembly (7) into P3
planetary carrier (12).
4. Install retaining ring (14) (52 mm ID).
5. Install two roller bearings (18) (28 mm ID,
38.025 mm OD) inside the pinion gear (17)
bores. Install thrust washers (16) and (19) in
P3 planetary carrier (12). Align thrust washer
tangs with the slots in the carrier, and retain
them with oilsoluble grease. Slide the pinion
gear with roller bearings into the side of the P3
planetary carrier between the thrust washers.
Repeat the procedure with the three remaining
pinion gears.
6. Install four pinion spindles (15) so the lower
step is positioned for proper installation of
indexing ring (11).
7. Install indexing ring (11) (159 mm OD). Install
retaining ring (10).
8. If components were replaced, measure pinion
end play. Maximum allowable pinion end
play for reuse is 0.942 mm (0.037 inch).
Measure all four pinion gears. When end play
exceeds 0.942 mm (0.037 inch) for P1, P2
and P2 pinions review Section 3. GENERAL
criteria of pinion gears, thrust washers and
carriers. Replace any part that does not meet
in this section or Table 71.
f. Assembly of P3 Planetary Carrier Assembly

(Foldout 11A).
1. If removed, install a new bearing (13) on
the P3 carrier. Position the carrier so the
output shaft end is facing up. Place bearing
534
MODULE REBUILD
g. Assembly of Retarder Housing Assembly
(Foldout 11A).
S/N 6520083093, S/N 6610220990,
S/N 6620005821, S/N 9370007661,
S/N 9320006231, S/N 9470006080, and
with DEXRON VI uids. Transmissions
compatible with DEXRON VI uids. Seal
6. Install Belleville spring washer (61) by tilting

the washer slightly, and with convex side of
the washer towards yoke/ange, engage the
tang in indexing hole of P3 carrier.
1. If bearing cup (45) was removed, install

new a bearing cup in the retarder housing
(46). To install, place J359223 Bearing
Tool on J35922 Bearing/Bushing Installers
and J8092 Drive Handle. Place retarder
housing so rotor cavity side is down. Install
bearing cup (45) on J359223 Bearing Tool
so the side with the larger outside diameter
is positioned towards the output yoke/ange
side of the retarder housing after its installed.
Press the bearing cup (45) into the rotor
housing assembly (46) until the bearing cup
has contacted the shoulder inside the bearing
bore of the housing.
2. Place the P3 carrier assembly (6) on the
work table (output shaft up) and place stator
assembly (20) over the output shaft so bearing
(13) sits in bearing cup (26).
3. Install rotating sealrings (29) and (32) onto
rotor (31) and hook them. Install the rotor
assembly on the output shaft.
4. Install gasket (30) between the stator
assembly (20) and retarder housing (49).
Place the retarder housing over the output
shaft and align the holes of the housing with
the holes of the stator assembly. Install three
M10 x 1.5 x 90 bolts (33). Tighten the bolts to
5161 Nm (3845 lb ft).
5. Install roller bearing (62) using
J359211 Output Bearing Installer/Drive
Sleeve so roller side is down towards the
bearing cup (45) and press into the retarder
housing (49) while rotating the retarder
housing.
535

Figure 551. Retaining Ring to P3 Carrier Assembly
CAUTION: Overtightening bearing retainer

nut (60) will damage bearing rollers and
cone (13) and (62). If the torque wrench and
breaker bar positions in Figure 552 are
reversed, the output spanner nut will
be overtorqued. Be sure wrenches are
positioned ONLY as shown in Figure 552.
7. Lubricate bearing retainer nut (60) with clean
transmission uid. Install and tighten bearing
retainer nut (60) using J47347 Output Shaft
Holding Tool and J359252 Spanner Nut
536
Wrench. Place the torque wrench and a

breaker bar as shown in Figure 552. Rotate
the torque wrench in a counterclockwise
direction and tighten the nut to 145155
Nm (107114 lb ft). If the retarder module
is installed on a transmission, see Section
6. TRANSMISSION ASSEMBLY assembly
instructions for correct torque specications.
NOTE: Delay installing output oil seal (59)
until nal assembly of the transmission.
MODULE REBUILD
8. Support retarder housing (49) so that turning
torque of P3 carrier assembly (6) can be
checked after installation of bearing retainer
nut (60) (Figure 552). Maximum allowable
drag is 3 Nm (26 lb in).
Figure 552. Tightening Output Spanner Nut
Figure 553. P3 Carrier Turning Torque CheckRetarder Equipped Models

9. Install ow valve plug (44) and retaining ring
(43).
10. Thread the J42048 Retarder Flow Valve
Spring Compressor spring compressor tool
into the accumulator port as far as it will
go and still allow the handle to be aligned
with the retarder valve bore. Rotate the tool
counterclockwise to provide clear access to

the retarder valve bore.
11. If removed, install pin (53) into retarder valve
(54) and insert the valve roll pin into the
bore. Install spring (55), Oring (56) (34.6 mm
ID), and plug (57). Spring (55) must remain
uncompressed until J42048 Retarder Flow
537

Valve Spring Compressor is used to safely
compress it.
12. Align J42048 Retarder Flow Valve Spring
Compressor with the retarder valve bore and
rotate the tool handle clockwise to contact the
center of the plug (57). Continue turning the
tool handle clockwise to compress the spring
(55) until plug (57) is below the groove for
retaining ring (58). Install retaining ring (58)
(1.668 inch ID).
13. Turn the tool handle counterclockwise to
allow plug (57) to contact retaining ring (58)
(1.668 inch ID) and to allow removal of the
tool. Remove the J42048 Retarder Flow
Valve Spring Compressor compressor tool
from the accumulator bore by rotating it
counterclockwise.
14. Be sure Oring (40) (15.6 mm ID) is in place
and install output speed sensor assembly
(39). Hold retainer (41) in place and install M8
x 1.25 x 20 retaining bolt (42). Tighten the bolt
to 2429 Nm (1821 lb ft).
15. Install Oring (36) (7.6 mm ID) on the
temperature sensor (35) and install the
temperature sensor assembly (35) into the
retarder housing.
16. Install temperature sensor bracket (37) and
M8 x 1.25 x 20 temperature sensor retaining
bolt (38). Tighten bolt to 2429 Nm (1821
lb ft ).
17. Install plug (47), washer (48). Tighten plug
(47) to 6067 Nm (4449 lb ft).
18. Install gasket (50), cover (51), and nine M8 x
1.25 x 25 bolts (52). Tighten bolts to 2429
Nm (1821 lb ft ).
19. Install remote manifold (88) or jumper manifold
(87) and four M10 x 1.5 x 30 bolts (89).
Tighten bolts to 5161 Nm (3845 lb ft).
h. Assembly and Installation of Retarder
Control Body Assembly (Foldout 11A).
1. Install and lube Orings (79) and (80) onto
solenoid connector assembly (77). Insert
connector assembly (77), through the bore
at the top of valve body (65), align solenoid
groove with hole for solenoid retaining pin
(76), push down to seat Orings. An audible
538
click will be heard and the top of the solenoid

will be ush with retarder valve body (65).
2. Install Oring seal (84) and pressure tap plug
(83). Tighten plug to 1013 Nm (710 lb ft).
3. Install valve (75), spring (74), lubed Oring
(73), and plug (72). Tighten plug to 2429
Nm (1821 lb ft).
4. Install valve (66), spring (67), lubed Oring
(69), and plug (70). Tighten plug to 2429
Nm (1821 lb ft).
5. Install solenoid separator plate (63) on
retarder control body (65).
6. Install the retarder control body assembly (64)
to the retarder housing assembly (46). Install
nine M8 x 1.25 x 65 bolts (81) and tighten
513. REAR COVER MODULE

a. Disassembly (Foldout 11B).
1. If not previously removed, remove retaining
bolt (32), retainer (31), output speed sensor
assembly (29), and Oring (30). Resistance
must be within specications. Refer to 35r.
Inspecting Electrical Components.
2. If not previously removed, remove oil seal
assembly (38) using seal removal tool
J24171A Slide Hammer and Jaw Set. If
present, remove plug (39) and washer (40).
3. Remove bearing retainer nut (37) using
J359252 Spanner Nut Wrench and
J47347 Output Shaft Holding Tool.
4. Remove Belleville spring washer (36).
5. Place blocks under rear cover (28) or (41)
so the P3 carrier assembly is far enough
above the work surface to allow removal from
the rear cover. Place J47347 Output Shaft
Holding Tool against the threaded shoulder of
the P3 carrier assembly. Drive or press the
carrier out with J47347 Output Shaft Holding
Tool until the P3 carrier assembly separates
from the rear cover (28) or (41).
6. Remove roller bearing (35) and output speed
signal wheel (33) from rear cover (28) or (41).
7. If tapered bearing is going to be replaced,
Press the bearing cup (34) out towards
MODULE REBUILD
yoke/ange side using J3940 Bearing Race
Remover.
8. Replace any parts that do not meet the
general inspection guidelines listed in Section
3. GENERAL OVERHAUL INFORMATION of
this manual.
b. Disassembly of the P3 Planetary Carrier
Assembly (Foldout 11B).
1. Remove pin (11) if damaged or if removing the
bearing assembly (13) or replacing the output
speed signal wheel (33).
2. If replacement is necessary, remove bearing
assembly (13) with bearing puller.
3. Measure the pinion end play of all four pinion
gears. If pinion end play exceeds 0.94
section or Table 71.
the ID of the output shaft bushing. Maximum

allowable inside diameter for reuse is 20.19
mm (0.795 inch).
c. Disassembly of the Rear Cover Assembly
(Foldout 11B).
removal. Personal injury can occur if the
1. Remove the C5 clutch piston (24) from the
rear cover (28) or (41) by compressing the
retainer and spring assembly (23) (128 mm ID)
using J359232 Piston Spring Compressor
(C5) (Figure 554). Remove retaining ring
(22) with snapring pliers and slowly release
the spring force.
NOTE: Spindles and pinions do not need

to be removed to remove output shaft
assembly (6).
4. Remove retaining ring (9) (159 mm OD).
planetary spindles (16).
5. Slide pinion gear (18), thrust washers (17)
and (20), and two bearings (19), from the
side of P3 planetary carrier (12). Repeat the
procedure with the three remaining pinion
gears.
6. Measure the thickness of thrust washers (17)
and (20). Minimum thickness allowable for
(0.005 inch).
Figure 554. Compressing Retainer and

Spring Assembly
2. Remove outer sealring (25) (258.7 mm ID
color coded with yellow marks) from the C5
clutch piston (24).
7. Remove retaining ring (15) (50.8 mm ID) and

spacer (14).
8. If not done previously, remove output shaft
assembly (6).
9. Inspect the bushing (7) inside the end of the
output shaft (8) for replacement. Measure
539

S/N 6520083093, S/N 6610220990,
S/N 6620005821, S/N 9370007661,
S/N 9320006231, S/N 9470006080, and
3. Remove inner sealring (26) (140.3 mm OD)
from C5 clutch piston (24).
4. If the bearing cup (27) does not meet the
guidelines listed in Section 3. GENERAL
OVERHAUL INFORMATION, remove the
bearing cup (27) by pressing out towards the
C5 piston side of rear cover (28) or (41) using
J3940 Bearing Race Remover.
5. Replace any parts that do not meet the
general inspection guidelines listed in Section
3. GENERAL OVERHAUL INFORMATION of
this manual.
d. Assembly of Rear Cover (Foldout 11B).
S/N 6520083093, S/N 6610220990,
S/N 6620005821, S/N 9370007661,
S/N 9320006231, S/N 9470006080, and
1. If bearing cup (27) was removed, install a new
bearing cup (27) in rear cover (28) or (41). To
install, place J359223 Output Bearing Cup
Installer on J35922 Bearing/Bushing Installer
and fasten to J8092 Drive Handle. Place rear
cover piston side up. Install bearing cup (27)
on J359223 Output Bearing Cup Installer so
the largest ID of the cup is positioned towards
the C5 piston side of the rear cover after
540
installation. Press bearing cup (27) into the

rear cover until it contacts the shoulder.
2. Install inner sealring (26) (140.3 mm OD) onto
C5 clutch piston (24). Install outer sealring
(25) (258.7 mm ID color coded with yellow
marks) onto C5 clutch piston (24).
3. Before installing the C5 clutch piston (24) into
the rear cover (28) or (41), align the tab on the
back of the C5 clutch piston with the notch for
the piston tab in the rear cover.
4. Install the C5 clutch piston (24) into rear cover
(28) or (41).
installation. Personal injury can occur if the
CAUTION: Use care when compressing

spring assembly not to allow the assembly
to catch in and damage the retaining ring
groove.
5. Align the tab on the spring retainer assembly
(23) with the notch in the rear cover. Compress
the spring assembly (23) (128 mm ID) and
retainer using piston spring compressor
J 359232 Piston Spring Compressor (C5).
Install the retaining ring (22) so the ends
clear the tab in the spring retainer, and slowly
release the spring force.
e. Assembly of the P3 Planetary Carrier
Assembly (Foldout 11B).
1. If removed, install a new bearing (13) (75
mm ID) on the P3 carrier. Position the carrier
so the output shaft end is facing up. Place
bearing (13) so that it centers on the carrier
and the rollers are facing up. Press the
bearing down until it contacts the shoulder on
the P3 carrier (12) using J359211 Output
Bearing Installer/Drive Sleeve.
2. Install a 12 mm (0.47 inch) roll pin (11) to a
height of 2.352.95 mm (0.0930.116 inch)
above the carrier shaft.
3. If removed, press bushing (7) (20 mm ID)
inside the end of the output shaft (8) using
J359221 Turbine Shaft/Output Shaft/P2
MODULE REBUILD
Planetary Bushing Installer and J8092 Drive
Handle until J359211 Output Bearing
Installer/Drive Sleeve seats against output
shaft (8).
4. Install output shaft assembly (6) into P3
planetary carrier 12.
5. Install retaining ring (15) (50.8 mm ID,
Figure 555).
Figure 555. Retaining Ring Installation

6. Install two bearings (19) (28 mm ID) inside
the pinion gear (18) (Figure 556). Install
thrust washers (17) and (20) in P3 planetary
carrier (12). Align the thrust washer tangs
with the slot in the carrier and retain them
with oilsoluble grease (Figure 558). Slide
the pinion gear with bearings into the side of
the P3 planetary carrier between the thrust
washers (Figure 559). Repeat the procedure
with the three remaining pinion gears.
Figure 557. Pinion Gear with Bearings Installed
541

Figure 558. Thrust Washer Installation
Figure 560. Pinion Spindle Installation

8. Install indexing ring (10) (159 mm OD),
(Figure 561). Install retaining ring (9).

7. Install the four pinion spindles (16) so the
lower step is positioned for proper installation
of the indexing ring (10) (Figure 560).
542

INFORMATION for inspection criteria of pinion
gears, thrust washers, and carriers.
MODULE REBUILD
NOTE: When end play exceeds 0.94 mm

(0.037 inch) for P1, P2 or P3 pinions,
INFORMATION for inspection criteria
of pinion gears, thrust washers, and
carriers. Replace any parts that do not
meet inspection guidelines or service
specications in this section or Table 71.
10. Align the slot in output speed signal wheel (33)
with spring pin (11). Using J 359211 Output
Bearing Installer/Drive Sleeve, press output
speed signal wheel (33) to full depth on P3
carrier assembly (5) (Figure 562).
f. Completion of the Rear Cover Module

(Foldout 11B).
S/N 6520083093, S/N 6610220990,
S/N 6620005821, S/N 9370007661,
S/N 9320006231, S/N 9470006080, and
1. If the bearing cup (34) was removed, install
a new bearing cup in rear cover (28) or (41).
To install, fasten J8092 Drive Handle to
J35922 Bearing/Bushing Installers and place
J359223 Output Bearing Cup Installer to
J35922 Bearing/Bushing Installers. Place
rear cover (28) or (41) C5 piston side down.
Install bearing cup (34) on J359223 Output
Bearing Cup Installer positioned so when
installation is complete the larger ID of the cup
points up to the yoke/ange side of the rear
cover (28) or (41). Press the bearing cup (34)
into the rear cover (28) or (41) until it contacts
the shoulder inside the bore.
2. Place the P3 carrier assembly (5) on the work
table (with the output shaft up) and place rear
cover (28) or (41) over the output shaft.
Figure 562. Output Speed Signal Wheel

Installation
3. Using J359211 Output Bearing

Installer/Drive Sleeve, press roller bearing
(35) (75 mm ID) into rear cover (28) or (41),
while rotating the cover assembly.
4. Locate Belleville springs washer (36), so the
convex side is on the yoke/ange side, and tilt
the washer to engage its tang to the indexing
hole of the P3 carrier.
CAUTION: Overtightening bearing retainer
nut (37) will damage bearing rollers and
cone (13) and (35). If the torque wrench and
breaker bar positions in Figure 552 are
reversed, the output spanner nut will
be overtorqued. Be sure wrenches are
positioned ONLY as shown in Figure 552.
543

Figure 563. Retaining Ring to P3 Carrier Assembly

5. Lubricate bearing retainer nut (37) with clean
transmission uid, then install and tighten
bearing retainer nut using J47347 Output
Shaft Holding Tool and J359252 Spanner
Nut Wrench. Place the torque wrench and a
breaker bar as shown in Figure 552. Rotate
the torque wrench in the counterclockwise
direction and tighten the nut to 7488 Nm
(5565 lb ft).
6. Support rear cover (28) or (41) so the turning
torque of the P3 carrier assembly (5) can be
measured after installation of bearing retainer
nut (37) (Figure 553). Maximum allowable
544
drag is 3 Nm (26 lb inch). Measure the torque

on bearing retainer nut (37) (Step 5above). If
torque is correct, measure drag torque. If both
torque values meet specication, proceed to
Step 8.
7. Install output shaft oil seal (38) using
J39928A Output Seal Installer
(models with nondrum parking brake)
or J359214B Output Seal Installer Adapter
(models with parking brake) (models with
drum parking brake).
8. Be sure Oring (30) (15.6 mm ID) is in place
and install output speed sensor assembly
MODULE REBUILD
(29). Hold bracket (31) in place and install M8
x 1.25 x 20 retaining bolt (32). Tighten the bolt
to 2429 Nm (1821 lb ft).
9. When rear cover (41) is used, be sure to
install plug (39) and washer (40). Torque plug
(39)to 6067 Nm (4450 lb ft).
Figure 565. P3 Carrier Turning Torque

CheckModels Without Retarder
6. Remove C5 piston from adapter housing (20).
7. Remove C5 piston sealring (18) (258.7 mm
ID. Color Coded With Yellow Marks) and
inside liptype sealring (19) (140.3 mm OD)
from the piston.
Figure 564. P3 Carrier Turning Torque
CheckModels Without Retarder
514. ADAPTER HOUSING AND P3

OVERHAUL
1. Place adapter housing assembly (14) on
J359234 Compressor Base with output end
down.
2. Install J359232 Piston Spring Compressor
(C5) along with its washer, bearing, and
handle.
3. Thread the handle down to compress C5
return spring assembly (16).
4. Remove retaining ring (15) (50.8 mm ID).
5. Remove J359232 Piston Spring Compressor
(C5), Remove C5 return spring assembly (16).
CAUTION: Make sure that the C5 return
spring assembly does not catch in the
retaining ring groove.
8. Remove plug (22) from the lower left side of

the housing.
9. Remove Oring (23) (19.2 mm ID) from the
plug.
10. Remove lter screen (24) from housing (20).
This screen lters main sump uid before it
enters the transfer case lube pump.
11. Measure pinion end play of all four pinion
gears. When end play exceeds 0.94 mm
(0.037 inch) for P1, P2 or P3 pinions,
section or 71. WEAR LIMITS DATA.
12. Remove retaining ring (2) and indexing ring
(3). Inspect indexing ring (12) (159 mm OD)
for step wear. Indexing rings may be ipped
over and reused if corners are not abnormally
worn (Figure 537). If both areas of the
indexing at are worn, replace the indexing
ring.
545

13. Slide pinion gear (9) , thrust washers (8) (24
mm ID, 36.725 mm OD) and (11), and two
bearings (10), from the side of P3 planetary
carrier (5). Repeat the procedure with three
remaining pinion gears.
14. Measure the thickness of thrust washers (8)
and (11). Minimum allowable thickness for
(0.005 inch).
15. Inspect bushing (6) inside carrier (5). Measure
the ID of bushing (6). Maximum allowable
inside diameter for reuse is 53.22 mm (2.095
inch). Remove bushing (6) with a hammer
and chisel if replacement is needed.
S/N 6520083093, S/N 6610220990,
S/N 6620005821, S/N 9370007661,
S/N 9320006231, S/N 9470006080, and
1. If removed, use J38569 P3 Carrier/C6/C7
Housing Bushing Installer and J8092 Drive
Handle to press bushing (6) (53.12 mm ID)
into carrier (5) until J38569 P3 Carrier/C6/C7
Housing Bushing Installer contacts carrier.
2. Install two bearings (10) (24 mm ID, 36.725
mm OD) inside pinion gear (9). Install thrust
washers (8) and (11) in P3 planetary carrier
(5). Align the thrust washer tangs with the slot
in the carrier and retain them with oilsoluble
grease. Slide the pinion gear and bearing
sets into the side of the P3 planetary carrier
between the thrust washers. Repeat the
procedure with the three remaining pinion
gears.
3. Install four pinion spindles (7) so the lower
step is positioned for proper installation of
indexing ring (3).
546
CAUTION: Be sure that the planetary

spindles cannot rotate after the indexing
ring has been installed or lube ow to the
pinion bearings may be blocked. When the
indexing ring slots are worn on one corner
(Figure 537), ip the plate over to obtain a
new unworn contact surface. If both contact
areas are worn, replace the indexing ring.
4. Install indexing ring (3) (159 mm OD). Install
retaining ring (2).
section or 71. WEAR LIMITS DATA.
6. Install a new lter screen (24). Make sure
the round metal boss properly indexes in the
housing.
7. Install a new Oring (23) (19.2 mm ID) on plug
(22), and then install the plug in the housing.
Tighten the plug to 3447 Nm (2535 lb ft).
8. Install C5 piston sealring (19) (140.3 mm OD)
and C5 piston sealring (18) (258.7 mm ID.
Color Coded With Yellow Marks) on C5 piston.
Lube the sealrings.
9. Install C5 piston (17), aligning the cast tab
on the piston with the notch in the adapter
housing. Lightly seat the piston into adapter
housing (20) using a soft face mallet.
10. Install C5 return spring assembly (16).,
aligning the notch in the housing with the tab
on the retainer.
11. Place adapter housing (20) on the base of
J359234 Compressor Base with input side
up.
12. Install J359232 Piston Spring Compressor
(C5). Tighten the handle to compress C5
return spring assembly (16). Make sure that
spring retainer tab indexes with the notch in
the housing.
13. Install retaining ring (15) (128 mm ID).
MODULE REBUILD
14. Release spring force and remove
J359232 Piston Spring Compressor
(C5) and J359234 Compressor Base.
17. Measure the pump body gear cavity depth

(Figure 566). Maximum allowable depth for
515. SCAVENGE PUMP OVERHAUL

1. Remove retaining pin (2) from pump housing
(3).
2. Remove shaft (4).
3. Remove Orings (5) (12.4 mm ID) and (6)
(12.4 mm ID) from shaft (4).
4. Remove three M8 x 1.25 x 30 bolts (7) from
pump housing (3).
5. Remove driven gear assembly (8) and pump
assembly (13) from pump housing (3).
6. Remove thrust washer (12) from pump
housing (3).
7. Measure the thickness of thrust washer (12).
mm (0.097 in).
8. If thrust washer (12) is worn, damaged, or
does not meet specications, replace thrust
washer (12).
Figure 566. Measuring Scavenge Pump

Body Gear Cavity Depth
18. Measure the pump body gear cavity diameter
(Figure 567). Maximum allowable ID for
9. Remove gasket (18) from pump housing (3).

10. Inspect for damaged bearings (9) and (10) in
driven gear (11). Remove damaged bearings
using J24171A Slide Hammer and Jaw Set.
11. Remove four M8 x 1.25 x 20 bolts (19) from
pump assembly (13).
12. Remove pump cover (14), gear set (15), and
thrust washer (16) from pump body (17).
13. Measure the thickness of thrust washer (16).
mm (0.097 inch).
14. If thrust washer (16) is worn, damaged, or
does not meet specications, replace the
thrust washer (16).
15. Measure the thickness of pump cover (14).
mm (0.265 inch).

Body Gear Cavity Diameter
16. If pump cover (14) is worn, damaged, or does

not meet specications, replace pump cover
(14).
19. If the pump body gear cavity is worn,

damaged, or does not meet specications,
replace the pump body (17).
547

20. Measure the OD of the outer pump gear of
gear set (15). Minimum allowable OD for
21. Measure the width of the drive and driven
pump gears. Minimum allowable width for
22. Install gear set (15) into pump body (17).
Measure the pump gear side clearance
(Figure 568). Maximum allowable side

Gear Tooth Tip Clearance
24. Measure driven gear (11) to pump body
(17) (diametrical) clearance (Figure 570).
Maximum allowable diametrical clearance for

Body Gear Side Clearance
23. Measure gear tooth tip clearance
(Figure 569). Maximum allowable
Figure 570. Measuring Scavenge Pump Driven

Gear To Pump Body Diametrical Clearance
25. Remove gear set (15) from pump body (17).
26. If any measurement does not meet
specications, replace gear set (15) or pump
body (17) and repeat measurements in Steps
16 through 24.
548
MODULE REBUILD
1. If removed, install new bearings (9) and
(10) into driven gear (11) using a press and
J47028 Scavenge Pump Bearing Installer
and J8092 Drive Handle. Install bearing with
driver against numbered bearing cage.
2. Install bearings (9) and (10) to a depth of 3
mm (0.118 inch).
3. Install new Orings (5) (12.4 mm ID) and (6)
(12.4 mm ID) onto shaft (4).
4. Install thrust washer (16) into pump body (17).
5. Lubricate gear set (15) and install the gear set
into pump body (17).
6. Position pump cover (14) on pump body (17)
and install four M8 x 1.25 x 20 bolts (19).
Tighten bolts (19) to 2429 Nm (1821 lb ft).
7. Align the ats on the driven gear hub with the
ats on the inner gear set. Slide driven gear
assembly (8) into pump assembly (13).
8. Install a new gasket (18), pump assembly
(13), and driven gear assembly (8) into pump
housing (3).
9. Secure the pump assembly (13) to the pump
housing (3) with three M8 x 1.25 x 30 bolts
(7). Tighten the bolts (7) to 2429 Nm (1821
lb ft).
10. Install thrust washer (12) into pump housing
(3).
11. Insert shaft (4) into pump housing (3) with the
hole in the shaft (4) aligned with the hole in
the pump housing (3).
12. Install retaining pin (2) into pump housing (3)
through the hole in shaft (4).
shaft (57). Loosen the nut by installing a large

reaction tool (for leverage) and an impact
wrench. Leave the nut installed on the front
output shaft.
2. Remove fteen M10 x 1.5 x 40 bolts (45).
Remove front output housing (49) by lifting
with a chain hoist and eye bolts in output yoke
(44). Remove gasket (50).
3. Remove C7 clutch housing assembly (58).
4. Rotate the xture so the rear output end is
facing up.
NOTE: Refer to Foldout 14 for Steps
5 through 11.
5. Loosen rear output shaft nut (81) by following
the same procedure explained in Step 1.
Leave the nut installed on the rear output
shaft.
6. Remove six M10 x 1.5 x 40 bolts (75) and
nine M10 x 1.5 x 100 bolts (82). Remove rear
output housing (74) by lifting with a chain hoist
and eye bolts. Remove gasket (73).
7. Remove P4 carrier assembly (57).
8. Remove fteen bolts (23) and two bolts (24).
Remove C6 clutch housing assembly (17).
Remove C6 clutch housing gasket (22). Note
where the different length bolts were removed
so reassembly will be correct.
9. Remove ve M10 x 1.5 x 40 bolts (50), holding
rear idler cover (49) onto the transfer case.
Remove rear idler cover (49), gasket (47), and
Oring (48). Use small pry bars at locations
provided in order to remove the cover.
516. TRANSFER CASE MODULE
10. Remove ten M8 x 1.25 x 30 bolts (44).

Remove controls cover (43). Remove gasket
(42). Removing the controls cover provides
access to the control valve body (29) and its
wiring.
a. Disassembly of Transfer Case Module

(Foldout 122, Foldout 13, Foldout 14).
11. Remove the bolts securing the rear transfer

case to the J38572 Transfer Case Holding
Fixture.
13. Press retaining pin (2) ush to 0.25 mm (0.010

inch) below the pump housing gasket surface.
1. If not previously done, install transfer case

assembly (1) on the transmission overhaul
stand. Position the transfer case so the front
output is facing up. Begin the transfer case
disassembly by loosening the front output
shaft nut (42) installed on the front output
NOTE: Refer to Foldout 122 for Steps

12 through 14.
549

12. Remove the fteen M10 x 1.5 x 100 bolts (17)
securing the rear transfer case cover (8) to the
front transfer case housing (7).
13. Thread an eye bolt in the center of the rear
transfer case cover (8), to lift it.
14. Use a soft face mallet to separate the rear and
front transfer cases. Pry points at opposite
ends of the case halves are also provided to
accomplish separation.
15. Lift and remove the rear transfer case.
Removal of the rear transfer case exposes
the drive gear (19) (Foldout 13), idler gear
(39), driven gear (80), and control valve
body (29) (Foldout 14). Remove gasket (16)
(Foldout 13) and replace it during assembly.
16. Remove the output speed sensor and solenoid
wiring harness connectors. Remove two M8 x
1.25 x 25 bolts (46) and output speed sensor
(45) (Foldout 14).
17. Remove control valve assembly (29) after
removing six M8 x 1.25 x 50 bolts (41)
securing the control valve body to the transfer
case.
18. Remove driven gear (80), idler gear (39), and
drive gear (19) (Foldout 13).
19. Rotate the remaining assembly, front output
end facing up.
20. Remove eight M10 x 1.5 x 35 bolts (4), and
then remove lube charging pump (5).
21. Remove shim pack A and keep it intact for
assembly. Shim pack A is critical to drive gear
end play.
22. Remove eight M10 x 1.5 x 35 bolts (71) and
manifold assembly (72).
23. Remove shim pack C and keep it intact for
assembly. Shim pack C is used to set up
driven gear end play.
24. Remove ve M10 x 1.5 x 40 bolts (22), then
remove front idler cover (23), Oring (24), shim
pack B (keeping it intact), and gasket (28).
Use pry bars as in removal of rear idler cover.
25. Remove the nut (88) securing the electrical
harness connector (31) to the connector plate
(29). Remove the four M8 x 1.25 x 25 bolts
(32) securing the connector plate (29) to the
transfer case. Remove connector plate (29),
followed by the harness and gasket (30).
550
26. Remove the suction hose tting (not shown)

from the transfer case. The tting is sealed
with an Oring, and provides a pilot for the
screen which lters the uid returning to the
main transmission sump from the transfer
case sump. Replace the lter screen during
the overhaul.
27. Inspect bearing cups (17), (37), and (78)
on the front transfer case (14) for wear and
damage likewise, inspect bearing cups (21),
(41), and (82) (Foldout 13) on the rear transfer
case (2) (Foldout 14).
28. If the bearing cups must be replaced, use a
hammer and drift to drive them out.
29. During the bearing cup installation, temporarily
install the lube charging pump or the manifold
with the appropriate shim pack to locate the
bearing cup in the housing. Since the bearing
cup does not have an actual seat in the
housing, locating the bearing cup correctly is
essential for proper gear end play.
30. Install the bearing cups in the housing. For
the drive and driven gear bearing cups, use
J385681 Drive/Driven Bearing Cup Installer
and J359211 Output Bearing Installer/Drive
Sleeve. For the idler gear bearing cup, use
J385682 Idler Bearing Cup Installer and
J8092 Drive Handle.
31. Remove the two lube passage plugs (33)
(Foldout 13). Removing the lube plugs
provides access to orice plugs (34).
32. Remove two orice plugs (34). Inspect the
lube orices for obstructions and remove any
obstructions that are found.
33. Install orice plugs (34), and lube passage
plugs (33). Tighten the orice plugs to 1214
Nm (910 lb ft). Tighten lube passage plugs
to 2429 Nm (1821 lb ft).
34. Remove lube passage plug (25) (Foldout 14)
and orice plug (26). Inspect lube orice for
obstructions and remove any obstructions that
are found.
35. Install orice plug (26) and tighten to 1214
Nm (910 lb ft). Install lube passage plug
(25) and tighten to 2429 Nm (1821 lb ft).
MODULE REBUILD
b. Disassembly of C6 Clutch (Foldout 14).
1. Remove retaining ring (6) (244.5 mm OD)
holding C6 clutch plates (10) and (11) and C6
clutch hub (7) in the C6 clutch housing.
2. Remove C6 clutch hub (7) by lifting it out along
with ve C6 clutch friction plates (10), four C6
clutch steel reaction plates (11), and backplate
(9). One steel reaction plate (11) will remain
in the C6 clutch housing (19). Inspect clutch
hub splines for wear and damage. Replace
hub (7) if it is damaged.
3. Remove the remaining steel reaction plate
(11) from the C6 clutch housing (19).
4. Separate backplate (9), ve friction plates
(10), and ve reaction plates (11).
5. Visually inspect the friction plates (10) for
damage or excessive wear. If a plate has
perceivable wear or distortion, measure for
step wear of friction plate (10), maximum
(0.005 inch). Measure the cone of friction
plates (10). Maximum allowable cone of
friction plate for reuse is 0.4 mm (0.016 inch).
If replacement is necessary, remove the
friction plates by gently prying them from the
backplate.
6. Inspect steel reaction plates (11) for wear,
damage, and the following specications:
minimum thickness allowed: 2.36 mm (0.093
inch), maximum allowable cone 0.40 mm
(0.016 inch) if any of the above specications
are not met, replace the part.
7. Inspect backplate (9) for burrs, wear, damage,
atness, and the following specications:
minimum thickness 7.9 mm (0.311 inch), and
maximum cone 0.40 mm (0.016 inch).
8. Remove retaining ring (12) after using
J38573 C6 Spring Compressor to compress
the C6 piston spring retainer assembly (13).
9. Release the piston spring force, remove
the special tool and check sealring bores
in housing (19) for wear, nicks, and other
damage. Remove spring retainer assembly
(13).
10. Remove piston (14) by rmly striking the
housing against a at surface. Remove
sealrings (15) and (16) from piston (14).
11. Inspect thrust bearing (8) for wear and

damage. If damaged, remove thrust bearing
(8) from the C6 housing.
12. Measure the C6 clutch housing bushing (21)
by using a telescope gauge and an outside
micrometer. The maximum allowable ID is
36.18 mm (1.424 inch). If C6 clutch housing
bushing (21) is worn or damaged, remove it
from the C6 housing.
c. Assembly of C6 Clutch (Foldout 14).
1. Inspect C6 clutch housing (19) for groove
wear. Maximum allowable groove wear for
2. If removed, install C6 clutch housing bushing
(21) using J38569 P3 Carrier/C6/C7 Housing
Bushing Installer and J8092 Drive Handle.
3. If removed, install thrust bearing (8) over C6
housing sleeve. Machined tangs on the thrust
bearing help make sure the bearing is installed
in the proper direction. See Figure 34.
4. Inspect piston (14) for sealring groove
damage. Correct the damage with crocus
cloth or soft stone. Replace the part if damage
cannot be corrected.
CAUTION: Incorrect liptype sealring
installation can cause improper
transmission operation or failure.
5. Install a new external sealring (15) and internal
sealring (16) in piston (14). For internal
sealring (16), use proper lip position. Lube
internal and external sealring bores in the C6
clutch housing (19), and the sealrings on the
piston.
NOTE: DEXRON VI uids are not
approved by Allison Transmission for use in
the 3700SP model transmission.
6. Install piston (14) into C6 clutch housing (19)
using a soft face mallet to seat the piston.
7. Inspect spring retainer assembly (13) for
missing or broken springs. Refer to Section
7. WEAR LIMITS AND SPRING DATA for the
spring specications. Replace spring retainer
assembly (13) if specications are not met.
551

8. Install spring retainer assembly (13).
9. Install retaining ring (12) after using
J385731 and J385733 to compress the
spring retainer assembly (13). Remove
special tools.
10. Install C6 clutch hub (7) into the C6 housing.
11. Install ve reaction plates (11), and ve friction
plates (10) alternately, starting with a reaction
plate (11), and nishing with a friction plate
(10).
assembly.
12. Install backplate (9).
d. Disassembly of C7 Clutch (Foldout 13).
1. Remove retaining ring (60).
2. Remove the C7 clutch hub (59) along with
C7 clutch pack. The C7 clutch pack consists
of a backplate (61), ve friction plates (62),
and ve steel reaction plates (63) stacked in
alternating order.
3. Inspect C7 friction plates (62) for minimum
allowable thickness2.06 mm (0.081 inch),
minimum oil groove depth allowed0.20 mm
(0.008 inch), and maximum cone permitted
0.25 mm (0.010 inch).
4. Inspect C7 reaction plates (63). Minimum
(0.083 inch), maximum allowable cone
permitted for reuse is 0.25 mm (0.010 inch).
5. Inspect backplate (61) for wear, atness, and
damage. Minimum allowable thickness for
6. Remove C7 piston (64). Remove internal and
external sealrings (66) and (65) from piston
(64).
7. Measure the C7 clutch housing bushing ID
and replace bushing (68) if required. The
maximum allowable ID for reuse is 47.26 mm
(1.861 inch).
552
8. Inspect pressure relief ball (69) and make

sure the ball moves freely minimum required
movement is 1.00 mm (0.040 inch).
9. Remove three sealrings (70) from C7 clutch
housing (67).
e. Assembly of C7 Clutch Housing (Foldout 13).
1. Inspect C7 clutch housing (67) for damage to
sealring groove and piston seal surfaces, and
housing spline wear. Replace the C7 clutch
housing if it is damaged.
2. Install three new sealrings (70) into C7 clutch
housing (67).
3. If bushing (68) was removed, install the
bushing using J38569 P3 Carrier/C6/C7
Housing Bushing Installer and J8092 Drive
Handle.
4. Install pressure relief ball (69) if it was
removed. Make sure that it moves freely.
5. Inspect piston (64) for sealring groove damage
and burrs.
CAUTION: Incorrect liptype sealring
installation can cause improper
transmission operation or failure.
6. Install new sealrings (65) and (66) into C7
piston (64). Be sure that sealring lips are
properly positioned. Lube the sealring areas
on the piston, and seal bore areas in C7 clutch
housing (67).
NOTE: DEXRON VI uids are not
approved by Allison Transmission for use in
the 3700SP model transmission.
7. Install piston (64) into C7 clutch housing (67).
Be sure it is properly seated.
8. Inspect C7 clutch hub (59) splines for wear
and damage. Replace hub if damage is not
repairable. Install C7 clutch hub (59) into C7
clutch housing (67).
9. Install ve friction plates (62) and ve reaction
plates (63) into housing (67) in alternating
order, starting with a reaction plate (63) and
nishing with a friction plate (62).
MODULE REBUILD
9. Install pressure relief valve (6), and spring (7)
into bore in the pump housing.

assembly.
10. Install backplate (61) into C7 clutch housing
(67).
10. Install a new washer onto plug (8), then install

the plug and tighten it to 1214 Nm (910 lb
ft).
h. Disassembly of P4 Carrier (Foldout 14).
1. Remove P4 sun gear (63) by lifting it out of
the P4 carrier assembly (56).
11. Install retaining ring (60) into C7 clutch

housing (67).
f.
2. Remove one set screw (58) by using an Allen

wrench or socket.
Disassembly of Oil Pump (Foldout 13).

1. Remove pressure relief valve plug (8).
3. Push spindle (59) out from the P4 carrier.
2. Remove spring (7), and then remove pressure

relief valve (6).
4. Remove pinion gear (61), along with upper

and lower thrust washers (62), and uncaged
needle bearings (60).
3. Remove locating pins (9) from front cover (83)

by driving them out using a small punch and
a hammer.
4. Separate front cover (83) from the rest of the
pump assembly.
5. Remove drive gear (84) from housing (87),
then remove driven gear (85) and reversing
ring (86). Note the orientation of drive and
driven gears.
g. Assembly of Oil Pump (Foldout 13).
1. Use a depth gauge to measure pump cavity
depth in pump rear cover (87).
2. Using an outside micrometer, measure the
driven gear width and the drive gear width.
3. Determine each gear side clearance by
subtracting the gear width from the pump
cavity depth. The specied side clearance is
0.125 mm (0.005 inch).
4. If not within the specication, replace
components as required.
5. Repeat Steps 2 through 4 to remove the

remaining two pinion gears (61).
i.
Assembly of P4 Carrier (Foldout 14).

1. Inspect thrust surfaces on each of three pinion
gears (61) for wear and damage. Also inspect
inside bore and gear tooth areas.
2. Inspect three upper and three lower thrust
washers (62) for wear and damage.
3. Install three lower thrust washers (62) into
each of three pinion slots in P4 carrier (57).
Each washer has a machined tang which
indexes with the notch in the P4 carrier
housing.
4. Apply a generous amount of lubricant to the
inside bore of each pinion gear. Install needle
bearings (60) into each of three pinions (61).
Use the spindle to make sure the needle
bearings are properly aligned.
5. Install reversing gear (86).
5. Install pinion (61) and needle bearing (60)

assembly into P4 carrier (57) with lower thrust
washer (62) already in place.
6. Install driven and drive gears (85) and (84) in

the same orientation as they were removed to
match wear pattern in rear pump cover (87).
6. Install upper thrust washer (62), aligning the

washer indexing tab with the notch in P4
carrier (57).
7. The groove in reversing ring (86) indexes with

the notch in the pump front cover (83).
7. Inspect spindle (59) for wear and damage.

Make sure the uid holes are free of
obstructions.
8. Install pump front cover (83), aligning the

holes with the locating pins in housing (87).
Drive locating pins (9) into the cover from the
back of the pump housing. Use a small punch
to slightly countersink the pins.
8. Install spindle (59) into P4 carrier (57), aligning

the set screw pilot on the spindle with the hole
in the housing.
553

9. Install one of three set screws (58), and
tighten to 2535 Nm (1826 lb ft). Using a
chisel and a hammer, swage set screw bore.
10. Repeat Steps 6 through 9 to install the
remaining two pinion gears (61).
11. Install sun gear (63) into P4 carrier assembly
(57).
j. Disassembly of Drive, Idler, and Driven
Gears (Foldout 13).
1. Inspect bearings (18), (20), (38), (40), (79),
and (81) per guidelines explained in 35e.
Inspecting Bearings. If any of bearings (18)
and (20) installed on drive gear (19), bearings
(38) and (40) installed on idler gear (39), or
bearings (79) and (81) installed on driven gear
(80) require replacement, use the procedure
in the next step.
2. To remove bearing (18) from drive gear
(19), install a large split bearing puller on
the bearing. Using appropriate tool(s) and
xture(s), remove the bearing by pressing out
the gear.
3. To remove bearings (20), (38), (40), (79), or
(81), follow the procedure in Step 2.
k. Assembly of Drive, Idler, and Driven Gears
(Foldout 13).
1. Inspect drive gear (19), idler gear (39), and
driven gear (80) for tooth wear and damage.
Refer to 35i. Inspecting Gears for gear
inspection guidelines.
2. If removed, install bearing (18) on drive
gear (19) using J385791 Drive/Driven
Bearing Installer and press. Repeat the same
procedure to install bearing (20) on drive gear
(19), or bearings (79) and (81) on driven gear
(80).
3. If removed, install bearing (38) on idler gear
(39) using J385792 Fwd/Rear Output and
Idler Bearing Installer and appropriate press.
Repeat the same procedure to install bearing
(40) on idler gear (39).
l. Disassembly of the Front Output Housing
and Front Output Shaft (Foldout 13).
1. Remove front output shaft nut (42) and at
washer (43).
554
2. Press front output shaft (57) out of front output

yoke (44).
3. Remove output seal (46) by using a hammer
and a chisel or J24171A Slide Hammer and
Jaw Set. Be careful not to damage the seal
bore area.
4. Remove output shaft bearing (47).
5. Inspect bearing cups (48) and (55) for pitting,
scoring, and damage. If the bearing cup(s)
needs replacement, remove it using a hammer
and a drift or a hammer and J3940 Bearing
Race Remover.
6. Remove shims (51), (52), or (53), and output
bearing spacer (54) from output shaft (57).
7. If bearing (56) on output shaft (57) is damaged,
remove bearing (56). To remove bearing (56),
install a split bearing puller on the bearing,
and position the bearing and the puller on a
press table. Press the output shaft out using
an appropriate press.
m. Assembly of the Front Output Housing and
Front Output Shaft (Foldout 13).
1. Inspect output housing (49) for scoring and
burrs
2. If removed, install new bearing cups (48)
and (55). To install the bearing cups, use
J385683 Fwd/Rear Output Bearing Cup
Installer and a press. Press each bearing cup
until it bottoms in the output housing (49).
3. Position bearing (47) in output housing (49).
4. Install output seal (46) in the output housing
using J 38547 Front And Rear Output Seal
Installer (MD 3070) and J359211 Output
Bearing Installer/Drive Sleeve.
5. Inspect output yoke (44) for scoring of seal
surface. Minimum allowable seal surface
diameter for reuse is 76.20 mm (3.00 inch).
If the yoke does not meet the required
specication, replace the yoke.
6. Inspect output shaft (57) for spline damage
and scoring. If necessary, replace the output
shaft.
7. If removed, install bearing (56) on output
shaft (57). To install the bearing, use
J385792 Fwd/Rear Output and Idler
Bearing Installer. Position the bearing and
MODULE REBUILD
J385792 Fwd/Rear Output and Idler Bearing
Installer on the press table, and then carefully
press the output shaft (57) into the bearing
until it is fully seated.
8. Place front yoke assembly (44) on a press
table.
9. Position output housing (49) on the yoke.
10. Place bearing spacer (54) and shims (51),
(52), or (53) on output shaft (57) the number
of shims could be one or more.
11. Install output shaft (57) into front output
housing (49) through bearing (47), output
seal (46), and into yoke (44). Once all the
components are properly aligned, press front
output shaft (57). Rotate output housing (49)
during this procedure to help the shaft and its
related components seat properly.
12. Install at washer (43) and front output shaft
nut (42).
13. Perform the bearing preload procedure as
explained in 516p. Output Housing Bearing
Preload Procedure (Foldout 14) which uses
the rear output housing as an example.
n. Disassembly of the Rear Output Housing
(Foldout 14).
1. Remove retaining ring (64) to remove P4 ring
gear (65).
9. Remove shims (70), (71), or (72), and bearing

spacer (69) from rear output shaft (66).
10. If bearing (67) on rear output shaft (66) is
damaged, replace it. To remove bearing (67),
position the bearing on the press table and
install split bearing puller. Using a press,
press out rear output shaft (66).
o. Assembly of the Rear Output Housing
(Foldout 14).
1. Inspect output housing (74) for scoring and
burrs.
2. If removed, install bearing cups (76) and
(68) into rear output housing (74) by using
J3940 Bearing Race Remover or a hammer
and a drift.
3. Position bearing (77) into the output housing.
4. Install output seal (78) into the output housing
using J38547 Front And Rear Output Seal
Installer (MD 3070) and J359211 Output
Bearing Installer/Drive Sleeve. See 36g.
LipType Seals for seal lubrication information.
5. Inspect output yoke (79) seal area for nicks,
burrs, and damage. Measure yoke seal
surface minimum allowable seal journal OD
is 76.20 mm (3.00 inch). If the yoke does not
meet the required specication, replace the
yoke.
2. Remove P4 ring gear (65) from rear output

housing (74).
6. Place output yoke (79) on a press table.
3. Remove output nut (81) and washer (80).
8. Inspect rear output shaft (66) for spline

damage and scoring, and if required, replace
the rear output shaft
4. Remove rear output shaft (66) by pressing it

out of rear output yoke (79).
5. Remove yoke (79). Check yoke sealing area
for nicks, burrs, or damage.
6. Remove output seal (78) by using
J24171A Slide Hammer and Jaw Set. Be
careful not to damage the seal bore areas.
7. Remove output shaft bearing (77) if it is
damaged.
8. Inspect bearing cups (76) and (68) for pitting,
scoring, and damage. If the bearing cups
need replacement, remove each bearing cup
by using J3940 Bearing Race Remover or
a hammer and a drift.
7. Position output housing (74) on the yoke.
9. If removed, install new bearing (67) on rear

output shaft (66). To install bearing (67),
use J385792. Position the bearing and
J385792 Fwd/Rear Output and Idler Bearing
Installer on the press table, and carefully
press rear output shaft (66) into the bearing
until it is fully seated.
10. Install bearing spacer (69) and shims (70),
(71), or (72) onto rear output shaft (66).
11. Press rear output shaft (66) into rear yoke
assembly (79) passing through bearing (77)
and output seal (78), making sure the output
housing (74) spins freely.
555

12. Install washer (80) and output shaft nut (81)
but do not tighten.
13. Place P4 ring gear (65) in output housing (74).
q. Disassembly of C7 Control Valve Body

(Foldout 14).
15. Follow the bearing preload procedure

explained in 516p. Output Housing Bearing
Preload Procedure (Foldout 14).
1. Begin C7 control valve body disassembly by

removing pins (34) and (40) securing the C7
signal valve solenoid (35) and C7 valve (31)
in control valve body (30). Remove the pins
by driving them out from the top toward the
bottom (machined face).
p. Output Housing Bearing Preload Procedure

(Foldout 14).
2. Remove stop (33), spring (32), and valve (31)

from control valve body (30).
1. Install output housing (74) on the rear transfer

case half (2).
3. Remove solenoid (35) and Orings (36) and

(37).
2. Remove output shaft nut (81).
4. Remove solenoid regulator valve (38).
3. Install washer (80) on the output shaft after

coating both sides with sealant.
5. Check the valves and bores for wear, scoring,

and damage.
4. Lube the threads on the output shaft.

5. Install output shaft nut (81) and tighten to
610 815 Nm (450600 lb ft).
6. Install a dial indicator to read up and down
shaft movements.
NOTE: You may need to place a shim or a
smooth washer on the output shaft to get
true readings.
7. Bottom the output shaft by applying downward
force while slightly rotating the output yoke.
8. The shaft is bottomed when the dial indicator
shows no more down movement. Zero the
dial indicator at this point.
9. Using a chain hoist and a scale, apply an
upward force of 734778 N (165175 lbs)
on the output shaft. While force is applied,
slightly rotate the yoke.
10. Check the dial indicator for movement.
11. If the indicator readings are not within the
specied limits, add or remove shims and
check preload again. End play must be
0.0250.127 mm (0.0010.005 inch).
12. If the indicator readings are within the
specied limits, coat both sides of the washer
(80) with sealant and install the washer.
Repeat Step 5 from above.
556
r. Assembly of C7 Control Valve Body

Assembly (Foldout 14).
1. Insert solenoid regulator valve (38) in the
bore of body (30) and inspect for smooth
movement.
2. Inspect solenoid lter screen for damage or
debris.
3. Replace solenoid Orings (36) and (37) during
overhaul.
4. Insert solenoid (35) into control valve body
(30).
5. Insert valve (31), followed by spring (32) and
stop (33).
6. Push in on stop (33) to compress spring (32)
and insert a small cylindrical punch through
the top hole in the body (30) to hold these
parts in position.
7. Install pin (34) by starting it in the hole opposite
where the punch has been inserted. Tap the
pin into position. The punch is displaced as
the pin is installed.
8. Install pin (40) which retains solenoid (35).
Insert the smooth end of the pin into the
mating hole at the bottom face of body (30).
Tap the pin into position ush with the bottom
of body (30). Use a small diameter punch to
slightly countersink pin (40).
MODULE REBUILD
s. Assembly of Transfer Case Module
(Foldout 122, Foldout 13, Foldout 14).
14. Install guide pins to facilitate the installation of

shims (10), (11), and (12) (Foldout 14).
1. Lube bearing cups (17), (37), and (78)

(Foldout 13) installed in front transfer case
housing (14).
15. Install shims (10), (11), and (12) shim pack A

there may be more than or fewer than three
shims.
2. One side of drive gear (19) has a shorter

shoulder than the other side. Install drive gear
(19) so the side with the shorter shoulder is
toward the front of the transmission.
16. Install lube charging pump (5) and the eight

M10 x 1.5 x 35 bolts (4) securing the pump
to the case. Tighten bolts (4) to 5161 Nm
(3845 lb ft).
3. Install idler gear (39) with its threaded hole

toward the front of the transmission.
17. Install guide pins into the two manifold bolt

holes in the front transfer case housing (14).
4. Install driven gear (80) into front transfer case

housing (14) in the same orientation as it was
removed.
18. Install manifold shims (75), (76), and (77)

shim pack C.
5. Install output speed sensor (45) (Foldout 14).
20. Install eight M10 x 1.5 x 35 bolts (71) and

tighten to 5161 Nm (3845 lb ft). Two bolts
will replace guide pins.
6. Install two M8 x 1.25 x 25 bolts (46) and

tighten them to 2429 Nm (1821 lb ft).
7. Install C7 control valve body assembly (29).
8. Install six M8 x 1.25 x 50 bolts (41), and
9. Install new transfer case gasket (16)
(Foldout 13).
10. Install rear transfer case cover (2) (Foldout 14)
onto the front transfer case. If necessary, use
soft face mallet to seat the case half.
11. Install fteen M10 x 1.5 x 100 bolts (17)
(Foldout 122). Tighten the bolts to 5161 Nm
(3845 lb ft).
NOTE: Follow Steps 12 through 27 for drive
gear bearing preload procedure. Perform
the procedure with all casetocase bolts
installed, but with the C6 housing and the
rear output housing removed.
12. Install test xtures where C6 housing and rear
output housing would normally be installed. In
place of the C6 housing, use a plate as the test
xture with the same hole pattern, size and
diameter as the C6 housing. In place of the
rear output housing, use a plate with the same
diameter, hole pattern and size. When special
xture plates are not available, use washers
or spacers under the bolt heads retaining the
C6 housing and rear output housing.
19. Install manifold (73) (Foldout 13).
21. Rotate the transfer case assembly so the rear

side is facing up.
22. Install J39623 Bearing End Play Checker
into drive gear (19).
23. Install a dial indicator, making sure the end
of the indicator rests squarely on the raised
center area of the tool.
24. Bottom the assembly by applying downward
force and rotating tool J39623 Bearing End
Play Checker.
25. Zero the dial indicator when there is no more
downward movement.
26. Using a hoist and a scale, apply 734778 N
(165175 lbs) of upward force.
27. Record the dial indicator reading and add
or remove shims if the reading is not within
the specied limits the allowable end play is
0.0250.127 mm (0.0010.005 inch).
NOTE: Follow Steps 28 through 34 for
driven gear bearing preload procedure.
28. Install J39623 Bearing End Play Checker
into driven gear assembly (80) (Foldout 13).
29. Install a dial indicator, making sure the end of
the indicator rests on the raised center area
of the tool.
13. Rotate the assembly so the front side of the

transfer case is facing up.
557

30. Bottom the assembly by applying downward
force and rotating J39623 Bearing End Play
Checker.
45. Install ve M10 x 1.5 x 40 bolts (22) and

tighten them to 5161 Nm (3845 lb ft). Two
bolts replace the guide pins.
31. Zero the dial indicator when there is no more

downward movement.
46. Remove front idler cover bolts (22), idler cover

(23), shim pack B, and gasket (28) to start the
idler gear bearing preload check.
32. Using a hoist and a scale, apply 734778 N

33. Record the dial indicator reading and add
or remove shims if the reading is not within
the specied limits the allowable end play is
0.0250.127 mm (0.0010.005 inch).
34. If the preload reading is not within the specied
limit, add or remove the shims, and recheck
the preload.
NOTE: Follow Steps 35 through 53 for idler
gear bearing preload procedure.
NOTE: Both idler covers must be installed

and tightened to establish the idler gear
position before bearing preload is checked.
47. Install the handle of J39623 Bearing End

Play Checker into the threaded hole of idler
gear (39).
48. Mount the dial indicator.
49. Bottom the idler gear assembly by slightly
rotatingJ39623 Bearing End Play Checker
while applying downward force.
50. Zero the dial indicator.
51. Use a chain hoist and apply 734778 N
52. Read dial indicator to determine bearing
preload.
53. If preload is not within the specied limits, add
or remove shims and repeat Steps 41 through
53. The allowable end play is 0.0250.127
mm (0.0010.005 inch).
35. Install guide pins in two rear idler cover bolt

holes.
54. When preload is within the specied limits,

remove the special tools.
36. Install new gasket (47) (Foldout 14) over guide

pins. Install new Oring (48) on idler cover
(49).
55. Install guide pins to ease installation of the

front idler cover.
37. Lube Oring and install idler cover (49) over

guide pins. Install ve M10 x 1.5 x 40 bolts
(50) and tighten them to 5161 Nm (3845 lb
ft). Two bolts replace the guide pins.
38. Rotate the transfer case assembly so the front
side is facing up.
56. Install a new gasket (28) over the guide pins

and onto the transfer case.
57. Install shims (25), (26), and (27) (shim pack
B).
58. Lube Oring (24).
59. Install Oring (24) on idler cover (23).
39. Install guide pins to ease installation of the

front idler cover.
60. Install idler cover (23), and tap it lightly for

installation.
40. Install a new gasket (28) (Foldout 13) over the

guide pins and onto the transfer case.
61. Install ve M10 x 1.5 x 40 bolts (22) and

bolts replace the guide pins.
41. Install shims (25), (26), and (27) (shim pack

B) over the guide pins.
42. Lube a new Oring (24).
43. Install Oring (24) on idler cover (23).
44. Install idler cover (23) and tap it lightly with a
softfaced mallet to seat it in position.
558
62. Install a new Oring onto the main wiring

harness connector (31).
63. Install electrical connector assembly (31) onto
the connector plate (29) and tighten nut (88)
to 2.734.09 Nm (2436 lb inch).
64. Place a new gasket (30) on the connector
plate, carefully rotating wiring harness through
the gasket.
MODULE REBUILD
65. Position the wiring harness connector through
the transfer case and the connector plate.
66. Install four M8 x 1.25 x 25 bolts (32) and
67. Lube and Install a new Oring (5) on suction
hose tting (2). (Figure 571).
75. Install fteen bolts M10 x 1.5 x 40 (45) and

bolts will replace guide pins.
76. Rotate the assembly so the rear side is facing
up.
77. Reconnect main electrical connector assembly
(31) to speed sensor (45) (Foldout 14) and
solenoid (35), making sure each connector
locks in place.
78. Install a new control valve cover gasket (42).
79. Install control valve cover (43).
80. Install ten M8 x 1.25 x 30 bolts (44), and
81. If not previously done, remove the test xtures
installed during drive and driven gear bearing
preload.
82. Position P4 carrier assembly (56) on the
transfer case.
83. Install two guide bolts to facilitate installation
of rear output housing (74).
84. Install a new gasket (73).
85. Carefully install rear output housing assembly
(74) onto the transfer case.
86. Install six M10 x 1.5 x 40 bolts (75) and nine
M10 x 1.5 x 100 bolts (82). Tighten them to
5161 Nm (3845 lb ft). Two bolts will replace
guide bolts.
87. Install guide bolts in two C6 cover bolt holes.
Figure 571. Transfer Case Fitting And

Screen Installation
68. Lube the metal boss of the lter screen (6)
and position it in the tting (2).
69. Carefully thread the tting into the transfer
case.
70. Tighten the jam nut on tting (2) to 100120
Nm (7489 lb ft).
71. Install C7 clutch assembly (58) (Foldout 13)
into the transfer case.

89. Position C6 clutch housing assembly (5) on
the transfer case.
90. Install fteen bolts (23) and two bolts (24).
Tighten them to 5161 Nm (3845 lb ft). Two
bolts will replace guide bolts.
91. Perform selective shim measurement before
installing the transfer case into the main
transmission as explained in 62n. Installation
of Transfer Case Module (Figure 613).
72. Install guide pins in two front output housing

bolt holes.
73. Install a new output housing gasket (50).
74. Position front output housing (49) on the
transfer case.
559

517. CONTROL VALVE MODULE
(Foldout 151, Foldout 152)
CAUTION:
To help prevent transmission damage,
protect control valve module parts
during removal, cleaning, 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
removed and use Valve Tray Set
J33163 Valve Body Parts Tray
Set to simplify correct valve body
reassembly.
Control valve module parts t
together closely and have specic
operating clearances. They can bind
if damaged. These parts depend
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.
b. Removal of Electrical Components and

Sensors.
NOTE: Refer to Troubleshooting Manual
TS3989EN (Allison 4th Generation
Controls) for the complete inspection
and repair procedures of all electrical
components used in the transmission
controls, such as for the connectors,
pins wire harnesses, sensors, solenoids,
switches, etc.

S/N 6510630089 and S/N 6520057820,
Table 32 for specications of current and
former sensors. Refer to SIL 5WT06 Rev
A.
NOTE: Refer to SIL 18TR98 for detailed

service information regarding suspected
contamination from water or ethylene
glycol. The presence of water and/or
ethylene glycol coolant in the transmission
oil is detrimental to the internal components.
Contaminated oil has a deteriorating effect
on transmission components.
a. Removal of Filters.
1. If not previously removed, remove two lter
covers (158) (Foldout 151, Foldout 152), two
gaskets (159), two Orings (160), two Orings
(161), and two lters (162).
2. Remove three bolts (3) and face seal (6).
Remove suction lter (5) and gasket (7).
Discard suction lter (5) and gasket (7) if
damaged.
560
MODULE REBUILD
Figure 572. Connector Removal

1. Remove two bolts (93) and turbine speed
sensor (94). Measure turbine speed sensor
resistance.
2. If present, remove two bolts (136) and Oil
Level Sensor (OLS ) assembly (137). Clean
the OLS with a soft cloth. Refer to 35r.
Inspecting Electrical Components and/or
TS3989EN for sensor operation.
3. Remove three bolts (46) from feedthrough
connector. Disconnect all connectors.
Release connectors in the wire harness
by pushing in the center tab with a small
screwdriver as shown in Figure 572.
4. Remove twelve bolts (57) and pressure switch
assembly bracket (56). Maximum resistance
of pressure switch assembly (54) (closed)
must not exceed 4 Ohms. Minimum resistance
of pressure switch assembly (54) (open) must
be at least 20,000 Ohms. The switch should
close between 159255 kPa (2337 psi).
c. Disassembly of the Control Valve Body
(Foldout 151, Foldout 152).
1. Remove two bolts (48).
2. Remove bracket (47).
3. Lift control valve body (118) and separator
plate (96) from control valve body (118) being
careful not to lose the four springs (50) and
(53) and accumulators (51) and (52). Set the
control valve body (118) on a at work surface.

(74). Remove valves (75) and spring (76).
(69). Remove valve (70) and spring (71).
7. Remove solenoid (62), Orings (63) and (64),
valve (65) and spring (66).
8. Insert J47942 Valve Spring Compressor
into slot to push in diagnostic valve (78) and
release clip (77), remove spring (79) and valve
(78).
9. Remove solenoid (80), two Orings (81) and
(82), valve (83) and spring (84).
10. Remove solenoid (85), two Orings (86) and
(87), valve (88) and spring (89).
11. Remove solenoid (90) and two Orings (91)
and (92).
d. Disassembly of Filter Life Valve Body
(Figure 573).
NOTE: Filter Life Valve Body is only on
models equipped with Prognostics.
Beginning July 2008 and with
S/N 6510822005, and S/N 6520099957,
MY09 prognostics was added to 3000 family
transmissions. Refer to SIL 11WT08.
NOTE: Special Tools Required:

J 47942 Valve Spring Compressor
4. Remove three face seals (49).

561

is found. Repair or replace the connector
as required. See 35r. Inspecting Electrical
Components.
e. Disassembly of C6 Control Valve Body
1. Remove four bolts (185) and remove C6 valve
body bracket (168), spring (178), accumulator
valve (172) and valve body (175).
2. Remove pin (176) for solenoid (175). Remove
nut (167), plate (168), solenoid (169), two
Orings (170) and (171), valve (172), and
spring (173).
3. Remove screw (185) and bracket (186).
Remove solenoid (180), Orings (181) and
(181), valve (179) and spring (178).
4. Inspect both valves and bores for nicks, wear,
and damage.
f. Disassembly of Control Valve Body
Figure 573. Filter Life Valve Body Assembly

Disassembled View
1. Disconnect internal wiring harness connector
(1) from the lter life valve body assembly.
2. Remove four M6 x 1.0 x 45 bolts (2) retaining
valve body (4) and pressure switch (3) to the
channel plate.
3. Remove valve body (4).
4. Remove pressure switch (3).
5. Place lter life valve body assembly (4) on the
work surface with the machinedside up.
6. Using J 47942 Valve Spring Compressor,
compress valve spring (6) enough to remove
valve retaining clip (8).
1. Remove two bolts (95) and control valve body

assembly (118).
2. Lift control valve body (118) and set on at
work space.
3. Remove solenoid retention pin (114) from
bottom of control valve body assembly (118).
4. Remove solenoid (115) with Orings (116) and
(117). Measure the resistance of the solenoid
by using the chart in Figure 38.
5. Remove valve retention pin (98).
6. Remove stop (101), spring (100), and lockup
relay valve (99).
8. Remove stop (105), spring (104), and lube
regulator valve (103).
7. Remove valve retaining clip (8).

8. Remove valve stop (7), spring (6), and valve
(5).
9. Inspect all parts for wear, damage, or burrs.
Replace parts that are worn or damaged.
10. Measure resistance and inspect pressure
switch (3) and its wiring leads for damage
or wear. Inspect pressure switch connector
(1) for damage or loose pins. Replace the
pressure switch if excessive wear or damage
562
WARNING: Springs (108) and (112) are

highly compressed. Be extremely careful
during disassembly. Personal injury can
occur if the spring force is not controlled.
9. Install J35924 Main Pressure Spring
Remover/Installer (Figure 574). Compress
spring (108), remove valve retention pin (106),
and carefully remove J 35924 Main Pressure
MODULE REBUILD
Spring Remover/Installer after turning handle
counterclockwise to release spring force.
2. Remove drain plug (155) and Oring (154) or

drain plug (149) and Oring (148).
3. Remove eight pressure tap plug assemblies
(156) with Orings (157) or nine plugs (145)
with Orings (146).
4. Remove Orings from all plugs.
h. Assembly of the Channel Plate (Foldout 151,
Foldout 152).
1. Install new Orings on all plugs.
2. Install eight pressure tap plugs (156) or nine
plugs (145). Tighten plugs to 1013 Nm
(710 lb ft).
3. Install drain plug (153) or (147). Tighten plug
to 2532 Nm (1824 lb ft).
4. If removed, install two dowel pins (151) or
(143).
Figure 574. Use of Tool to Release

MainPressure Valve Spring Force
10. Remove stop (109), spring (108), and main
regulator valve (107).
5. Install gasket (165), separator plate (139), and

channel gasket (140).
i. Assembly of the Main Valve Body
1. Install converter regulator valve (133), spring

(134), and stop (135).
12. Remove clip (113), spring (112), and control

main valve (111).
2. Install valve retention pin (132).
3. Install C1 latch valve (129), spring (130), and

stop (131).
14. Remove stop (124), spring (123), and C2 latch

valve (122).
5. Install exhaust back valve (126), spring (127),

and stop (128).
16. Remove stop (128), spring (127), and exhaust

back valve (126).
7. Install C2 latch valve (122), spring (123), and

stop (124).
18. Remove stop (131), spring (130), and C1

latching valve (129).
9. Install control main valve (111), spring (112),

and clip (113).
20. Remove stop (135), spring (134), and

converter regulator valve 133. Inspect stop
135 for battering and replace if it is battered.
Remove gasket (165), separator plate (139),
and channel plate gasket (140).
g. Disassembly of the Channel Plate
1. If damaged, remove the two dowel pins (151)
or (143).

11. Install main regulator valve (107), spring
(108), and stop (109).
12. Install J35924 Main Pressure Spring
Remover/Installer (Figure 574). Compress
spring (108), install valve retention pin
(106), and remove J35924 Main Pressure
Spring Remover/Installer after turning handle
563

counterclockwise until the tool clears pin
(106).
13. Install lube regulator valve (103), spring (104),
and stop (105).
body so that the pressure switch assembly bolt

holes align with three valve body bolt holes.
6. Install four M6 x 1.0 x 45 bolts (2) retaining

the pressure switch and valve body. Tighten
four bolts ngertight.
15. Install lockup relay valve (99), spring (100),

and stop (101).
7. Tighten four M6 x 1.0 x 45 bolts (2) to 1013

Nm (710 lb ft).
8. Connect the internal wiring to the pressure

switch connector.
17. Install Orings (116) and (117) on solenoid

(115) and install solenoid.
18. Install solenoid retention pin (114) through
bottom of control valve body assembly (118).
19. Install solenoid separator plate (96) on top of
control valve body assembly (118).
j. Assembly of C6 Control Valve Body
1. Install spring (175), valve (174), two Orings
(170) and (171), C6 enable solenoid (169),
nut (167) and solenoid retention pin (176) into
C6 valve body (175).
2. Install spring (178), valve (180), two Orings
(182) and (181), solenoid (180), and bracket
(186). Secure to C6 valve body (175) with
screw (185).
3. Install spring (177) and accumulator (179) into
valve body (175). Install bracket (168) and
four bolts (167). Tighten the bolts to 1013
Nm (710 lb ft).
k. Assembly of Filter Life Valve Body
(Figure 573).
1. With lter life valve body machined side up on
the work surface, install valve (5), spring (6),
and valve stop (7).
2. Using J 47942 Valve Spring Compressor,
compress spring (6) far enough to install
retaining clip (8).
3. Install retaining clip (8) so that the clip is below
the machined surface.
4. Position valve body assembly (4) on channel
plate assembly so that four bolt holes align
with their threaded holes in the channel plate.
5. Install pressure switch (3) assembly, wire
leads up, onto the machined area of the valve
l. Assembly of the Solenoid Valve Body

1. Install solenoid (90), two Orings (91) and (92).
2. Install spring (89), valve (88), Orings (86) and
(87) and solenoid (85).
3. Install spring (84), valve (83), two Orings (81)
and (82), and solenoid (80).
4. Install valve (78), and spring (79). Insert
J47942 Valve Spring Compressor into slot to
push in valve and install clip (77).
5. Install spring (66), valve (65), and solenoid
(62) with two Orings (63) and (64).
(67) with two Orings (68) and (69).
(72) with Orings (73) and (74).
8. Install three face seals (49).
9. Install accumulator plugs (51) and (52) and
springs (54) and (57).
10. Install separator plate (96) on bottoms of
solenoid valve body and place the solenoid
valve body on top of main valve body (118).
11. Install bracket (47).
12. Install bracket (56) with diagnostic pressure
switch (55).
13. Install twelve bolts (57). Install two bolts (48).
m. Installation of Electrical Components and
Sensors (Foldout 151, Foldout 152).
1. Install 24way internal connector feedthrough
connector (13) with wire harness assembly (8).
Secure connector assembly (13) with three
bolts (50). Connect all connectors. Tighten
bolts 50 to 1.32.7 Nm (1224 lb inch).
2. Reconnect all connectors.
564
MODULE REBUILD
3. If present, install two bolts (136) and OLS
assembly (137). Tighten bolts to 1013 Nm
(710 lb ft).
4. Install the turbine speed sensor (94), and the
bolt (93). Tighten bolt to 1013 Nm (710
lb ft).
n. Installation of Filters (Foldout 151,
Foldout 152).
1. Install suction lter (5), gasket (7) and face
seal (6). Install three bolts (3). Tighten bolts to
1013 Nm (710 lb ft).
2. Install two lters (162), two Orings (161), two
Orings (160), two gaskets (159), and two lter
covers (158).
3. If present and not previously installed, install
OLS assembly (161) and two bolts (160).
Tighten bolts to 1013 Nm (710 lb ft).
565

NOTES
566
SECTION 6TRANSMISSION ASSEMBLY

61.
SCOPE
2. Attach a hoist and lift the xture and main

housing.
a. Section. This section covers the assembly of

3000 Product Families transmissions. Assembly
procedures include Power Takeoff (PTO) provisions
and retarders. The assembly sequence is
procedure.
d. General Information. Refer to Section 3.
GENERAL OVERHAUL INFORMATION and
Section 7. WEAR LIMITS AND SPRING DATA for
general information as follows:
Paragraph
Title
32. TOOLS AND

EQUIPMENT
Tools and Equipment
33. REPLACEMENT
PARTS
Replacement Parts
34. CAREFUL
HANDLING
Careful Handling
35. CLEANING AND

INSPECTION
37. REMOVING
(OR INSTALLING)
TRANSMISSION
(Figure 312,
Figure 313)
38. WEAR LIMITS
Wear Limits Data
72. SPRING DATA
Spring Data
e. Foldouts. Refer to Foldout 5 through

Foldout 192 for disassembled views and
Foldout 20 through Foldout 38 for the hydraulic
schematics.
62.
ASSEMBLY OF TRANSMISSION
3. Mount the xture and main housing on the

repair stand J29109. Make sure the main
housing centerline is horizontal.
4. Install C3/C4 clutch assembly (1) (Figure 61)
through the input end of the main housing (2),
aligning the tabs on the clutch assembly with
the slot in the main housing.
5. Install two M10 X 1.5 X 35 mm bolts (3),
180 degrees from each other, to hold clutch
assembly (1) in place.
6. Rotate the repair stand so the transmission
housing output end is up and install the
remaining ten M10 X 1.5 X 35 mm bolts (3).
Tighten all bolts to 5161 Nm (3845 lb ft).
Figure 61. C3/C4 Clutch Module Installation

b. Installation of the Rotating Clutch Module
(Figure 62).
1. Rotate the repair stand so the input end of the
main housing is up.
2. Using a hoist and an M16 eye bolt, insert
rotating clutch module (1) in the front of the
main housing.
a. Assembly of C3/C4 Clutch.

1. Mount holding xture J35926 onto the main
housing.
61

d. Installation of the P1 Planetary Module
(Figure 64).
1. Rotate the repair stand so the rear of the main
housing is up.
2. Install P1 planetary module (1) consisting of
the P1 carrier and P2 ring gear.
3. Mesh the P1 pinion gears with the P1 ring
gear inside the C3/C4 clutch assembly.
Figure 62. Rotating Clutch Module Installation

c. Installation of the Front Support/Charging
Pump Module (Figure 63).
1. Lower the front support and charging pump
module (3) over the top of the turbine shaft.
2. Align the bolt holes in the front support (3) with
the threaded holes in the main housing.
3. Install six M10 X 1.5 X 60 mm bolts (1) and
ve M10 X 1.5 X 35 mm bolts (2). Tighten
Figure 64. P1 Planetary Module Installation

e. Installation of the P2 Planetary Module
(Figure 65).
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
during installation.
f. Installation of the C5 Clutch Pack
(Figure 65). Install the C5 clutch pack in the main
housingeight steel reaction plates (2) and seven
friction plates (3), stacked alternately, starting with a
steel reaction plate. Stack all plates so plate cone
faces the same direction. Steel plates mesh with
the main housing and reaction plates mesh with the
P3 ring gear.
Figure 63. Front Support/Oil Pump

Module Installation
62
TRANSMISSION ASSEMBLY
h. Main Shaft Selective Shim Measurement For
Close Ratio Models (Figure 67).
1. Place a straightedge across the retarder
or rear cover mounting surface of the main
housing.
2. Measure dimension A, from the top of the
straightedge to the selective shim thrust
surface on the main shaft bearing spacer.
3. Measure dimension B, thickness of
straightedge. Subtract dimension B from
dimension 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
mounting surface and place a straightedge
across the P3 planetary carrier.
Figure 65. P2 Planetary Module and C5
Clutch Pack Installation
assembly.
g. Installation of the Main Shaft (Figure 66).
Install main shaft (1) as assembled in Section 5.
MODULE REBUILD, without selective shim (2)
and thrust bearing (3) (does not apply to 3700 SP
models).
5. Measure dimension D, from the top of the

straightedge to the mounting 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
thrust bearing.
Figure 66. Main Shaft Installation
63

Figure 67. Main Shaft Selective Shim Measurement (Close Ratio Models)
3000 Product Family Except 3700 SP
i. Main Shaft Selective Shim Measurement
(Wide Ratio Models) (Figure 68).
1. Place a straightedge across the retarder
or rear cover mounting surface of the main
housing.
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
straightedge across the P3 planetary carrier.
2. Measure dimension A, from the top of the

straightedge to the selective shim thrust
surface on the main shaft bearing spacer.
5. Measure dimension D from top of the

straightedge to the rear cover mounting
gasket.
3. Measure dimension B, thickness of

straightedge. Subtract dimension B from
dimension A the remainder is dimension C.

straightedge to the thrust bearing contact
surface on the P3 planetary carrier. Subtract
64
dimensions E from dimension D the
remainder is dimension F.
7. Dimension G is the remainder of C minus F
shim.
8. Install the proper thickness selective shim and
thrust bearing.
Figure 68. Main Shaft Selective Shim Measurement (Wide Ratio)3500 Model
j. Main Shaft Selective Shim Measurement For
3700 SP (Figure 69).
(gasket removed). Also, be sure that there is

no selective shim in place at this time.
1. Place a straightedge across the transfer case

mounting surface of the adapter housing
65

2. Measure dimension A from the top of the
straightedge to the shoulder where the
selective shim will rest.
3. Measure dimension B, from the top of the
straightedge to the face where the gasket
rests. Subtract dimension B from dimension
A the remainder is dimension C.
4. Place transfer case rear output end down
(facing the bench top). Install a NEW gasket
on the front main transfer case mounting
surface and place a straightedge across the
transmission shaft adapter.
5. Measure dimension D from the top of the
straightedge to the transfer case mounting
gasket.
straightedge to the step inside the adapter
coupling. Subtract dimension E from
dimension D the remainder is dimension F.
7. Dimension G is the remainder of C minus F,
shim.
8. Coat the selected shim with a generous
coating of lube (petrolatum) and insert the
shim inside the transmission shaft adapter.
66
Figure 69. Main Shaft Selective Shim Measurement 3700 SP

k. Installation Retarder Module.
WARNING: The retarder module assembly
weighs approximately 64 kg (141 lb). Use
care to prevent injury to personnel while
handling the retarder module assembly.
Also four M10 x 1.5 x 192 mm bolts, gasket

(94), jumper manifold (95) or manifold (96)
(Foldout 11A). Tighten M10 bolts to 5161
Nm (3845 lb ft).
2. Lubricate and install output shaft oil seal (59)
using J39928A.
1. Install fourteen M12 x 1.75 x 130 mm bolts

marked A (Figure 610). Install four M12 x
1.75 x 190 mm marked C. Tighten eighteen
M12 bolts to 90110 Nm (6681 lb ft). Install
four M10 x 1.5 x 182 mm bolts marked B.
Tighten M10 bolts to 5161 Nm (3845 lb ft).
67

Figure 610. Retarder Module Bolts

l. Installation of Rear Cover Module
(Figure 611).
1. Install a new rear cover gasket (1) on main
housing (4).
2. Install guide bolts to ease rear cover (2)
installation and keep gasket (1) in place.
3. Place rear cover (2) on main housing (4) using
a hoist and sling as a lifting xture. Install rear
support bracket (3) (Foldout 11B) if used.
4. Install nineteen M12 x 1.75 x 45 bolts (3).
Tighten bolts to 90110 Nm (6681 lb).
5. Lubricate and install output yoke/ange oil
seal (5) using J39928A. Use J359214B for
parking brake rear cover models.
68
Figure 611. Rear Cover Module Installation

m. Installation of Transfer Case Adapter
Housing (Figure 612).
1. Install a new adapter housing gasket (2).
2. Inspect adapter housing (3) for cracks, nicks,
or burrs. Remove the burrs and nicks with
crocus cloth or soft stone.
3. Install adapter housing (3) by installing fteen
M12 x 1.75 x 45 bolts (8) and three M12 x
1.75 x 60 bolts (5). Torque bolts to 90110
Nm (6681 lb ft).
4. Install three M10 x 1.5 x 100 bolts (6), two
M10 x 1.5 x 40 bolts (7), and four M10 x 1.5
x 70 bolts (4). Torque bolts to 5161 Nm
(3845 lb ft).
Figure 612. Transfer Case Adapter

Housing Installation
n. Installation of Transfer Case Module
(Figure 613).
2. Be sure that selective shim (1) is located
inside shaft adapter (5).
3. Mount J38572 on transfer case (3).
WARNING: The transfer case module
assembly weights approximately 270 kg
(595 lb).
4. Use hoist and J38572 to lift transfer case (3).
5. Install transmission shaft adapter (5) into
transfer case (3).
6. Install transfer case (3) into the main
transmission, and install nineteen M10 x 1.5 x
55 bolts (2).
Figure 613. Transfer Case Module Installation

o. Installation of the Converter Housing Module
(Figure 614).
1. Place transmission input end up. Install a new
converter housing gasket (2) on main housing
module (4).
2. Install guide bolts to ease converter housing
(1) installation and keep gasket (2) in place.
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. Start by installing three M10 x 1.5 x 35 bolts
(3) into the inside of converter housing (1).
Use mechanical ngers, or a similar tool,
when installing these bolts.
5. Remove the two guide bolts and install the
remaining seventeen M10 x 1.5 x 35 bolts (3).
Tighten all bolts to 5161 Nm (3845 lb ft).
7. Install bolt (27) or (28) (Foldout 172, bolt

(7) in ) passing through C6 housing into the
adapter housing. Tighten bolt (27) or (28) to
5161 Nm (3845 lb ft) .
8. Torque nineteen bolts (2) to 5161 Nm
(3845 lb ft).
69

If the control valve module is in place,
remove the plug(s), if present, from the
ll tube hole or from cooler ports before
applying lockup air pressure. Apply air
pressure through the lockup pressure
tap (Figure 47, View D) and use a heel
bar, screwdriver, and bolts. Insert the
heel bar into a torque converter housing
bolt hole. Insert two bolts into the
explate adapter bolt holes. Then place
a screwdriver at an angle to prevent
converter rotation (Figure 615, View C).
6. Install J38548 Converter End Play Gauge
and tighten the attaching bolt to 2734 Nm
(2025 lb ft).
Figure 614. Converter Housing Module

Installation
p. Installation of the Torque Converter Module
(Figure 615).
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
race. 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 seal ring.
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 tangs or the PTO oil pump
drive hub.
3. Using a hoist and sling, install torque converter
module (6) into the converter housing module
7. Measure from top of J38548 Converter End

Play Gauge to face of turbine shaft and record
it as dimension B. Subtract dimension B from
dimension A dimension A is the height of
J38548 Converter End Play Gauge , 100.00
mm (3.937 inch) to determine dimension
CFigure 615, View D).
8. Use Dimension C and Table 61 to determine
proper selective shim part number. Remove
J38548 Converter End Play Gauge and
continue with installation of the torque
converter.
9. Install selective shim (5) with the shim step
side toward the turbine shaft. Install bolt (4)
and J38564 Converter Bolt Tightening Tool
NOTE: Dimension C shown in
Table 61 includes a correction due
to internal deection caused by the 2734
Nm (2025 lb ft) bolt torque applied to
gauge P/N J 38548. Accurate torque value
is critical to selection of the proper shim.
4. Make sure the torque converter is properly

seated. If PTO equipped, rotate the PTO gear
to engage the pump hub with the charging
pump.
5. Hold the turbine and turbine shaft stationary
by using one of the methods listed below:
Insert a screwdriver into the vanes on
the rotating clutch module (Figure 615,
View B).
610
Figure 615. Torque Converter Module Installation and Selective Shim Measurement
Table 61. Torque Converter Selective Shims
Dimension C
Use P/N
Shim Step Dimension
0.40930.6597 mm (0.01610.0260 in.)
29505688
0.000 mm (0.000 in) NO STEP
0.65980.8377 mm (0.02610.0330 in.)
29505681
0.1780.228 mm (0.0070.009 in.)
0.83781.0157 mm (0.03310.0400 in.)
29505682
0.3560.406 mm (0.0140.016 in.)
1.01581.1937 mm (0.04010.0470 in.)
29505683
0.5340.584 mm (0.0210.023 in.)
1.19381.3707 mm (0.04710.0540 in.)
29505684
0.7110.761 mm (0.0280.030 in.)
1.37081.5487 mm (0.05410.0610 in.)
29505685
0.8890.939 mm (0.0350.037 in.)
1.54881.6823 mm (0.06110.0662 in.)
29505686
1.0671.117 mm (0.0420.044 in.)
611

10. Prevent turbine shaft rotation as in Step 5.
Tighten M16 x 2 x 30 bolt (4) to 100120 Nm
(7489 lb ft) (Foldout 182) .
NOTE: Main and lube lters are

interchangeable. However, the lters for a
two inch sump are a different length than
those for a four inch sump. The lters in the
seven inch sump are the same as in the
two inch sump.
11. Remove J38564 Converter Bolt Tightening

Tool. Install Oring (8) on threaded converter
end plug (7). Use a 3/4 inch Allen socket to
install threaded converter end plug (7) and
tighten it to 5060 Nm (3744 lb ft).
12. Install converter shipping brackets (12)
(Foldout 81), or equivalent, to retain the
torque converter to the transmission. Tighten
the shipping bracket bolts to 5161 Nm
(3845 lb ft).
q. Installation of the Control Valve Module
(Figure 616).
WARNING: Transmissions installed in
overhaul stands must be positioned
vertically before installing control valve
module. Failure to do so could result in
personal injury.
1. Position transmission in overhaul stand
vertically.
WARNING: The control valve module
assembly weighs approximately 25 kg (56
lb). Handle carefully to avoid personal
injury or control valve module damage. The
control valve module assembly used in a
3700 SP weighs approximately 29 kg (65
lb).
Figure 616. Control Valve Module Installation

r.
2. Install a new control valve module gasket (2)

over the dowel pins on control valve module
(1).
3. Guide control valve module (1) onto the main
housing using the dowel pins. Install one bolt
(163) (Foldout 151) in the top center bolt hole.
Installation of Power Takeoff(s) (Figure 617).

1. If removed, install PTO studs (4).
2. Install PTO gasket (3) and PTO assembly (2).
Insert bolt (1) into each of the 6 oclock and
12 oclock positions. Install the remaining six
bolts. Tighten bolts to 5161 Nm (3845 lb ft).
4. Install two lter covers (158) (Foldout 151),

two gaskets (159), two Orings (160), two
Orings (161), and two lters (162). Install
remaining thirtyone M10 x 1.5 x 55 bolts (163)
and/or M10 x 1.5 x 100 bolts (164). Tighten all
612
Figure 617. Power Takeoff(s) Installation

s. Installation of Integral Oil Cooler
(Foldout 181).
ft) and three M12 x 1.75 x 230 bolts (13) to

100120 Nm (7489 lf ft).
5. Lubricate and install the Orings (28) onto
cooler plate assembly (27).
NOTE:
For units without retarder, go to
Step 1.
For units with retarder, skip Steps
15 and go to Step 6.
1. Install the two M10 guide studs at rear of main
housing where the cooler housing attaches.
Install the gasket (5) and the cooler housing
(7) onto the guide bolts. Be sure the housing
and gasket are properly aligned.
2. Install the ve M10 x 1.5 x 205 bolts (12) with
new washers (11).
3. Remove the two M10 guide studs and install
the remaining two or four M10 x 1.5 x 205
bolts (12) with new washers (11).
4. Install the three M12 x 1.75 x 230 bolts (13)
with new washers (14). Tighten the M10 x
1.5 x 205 bolts (12) to 5161 Nm (3845 lb
NOTE: Beginning with transmission

serial numbers S/N 6510676916,
S/N 6520056783 (7 Plate Cooler),
S/N 6510676917, S/N 6520058810 (17
Plate Cooler), the integral oil cooler has
been redesigned to use one thick Oring
between the integral cooler and the cooler
housing. The current Oring cannot be
used with the former integral cooler design.
Current nonsump integral coolers now use
only one Oring instead of two.
6. Install cooler plate assembly (27) into cooler
housing (7).
7. Lubricate and install Orings (26). Install two
M10 guide studs at rear of cooler housing
where cover (23) attaches. Slide the gasket
(22) and the cover (23) into position over the
guide bolts.
613

8. Install the two bolts (24) handtighten at this
time and the fteen bolts (25) (handtighten
at this time).
the remaining two bolts (25).
10. Tighten the seventeen bolts (25) to 5161
Nm (3845 lb ft). Tighten the two bolts (24)
to 90110 Nm (6681 lb ft).
11. Install the gasket (8), the coolant ports (9) or
(21) and the eight M10 x 1.5 x 35 bolts (10).
Tighten the eight M10 x 1.5 x 35 bolts (10) to
5161 Nm (3845 lb ft).
12. Lubricate and install the Orings (26) onto the
pressure taps (18).
13. Install the pressure taps (17) into cooler
housing (7). Tighten the pressure taps to
1013 Nm (710 lb ft).
t. Installation of Integral Retarder Sump Oil
Cooler (Foldout 182).
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 140 kg (64 lb), use care when
handling the cooler.
11. Install cooler plate assembly (7) to cooler
manifold (16) and retain with six M10 x 1.5 x
60 bolts (1). Tighten bolts ngertight.
12. Install gaskets (3) and coolant ports (2).
remaining ten M10 x 1.5 x 60 bolts (1). Torque
the ten M10 x 1.5 x 60 bolts (1) to 5161 Nm
(3845 lb ft).
14. Install six M8 x 1.25 x 25 bolts (5) and torque
to 2429 Nm (1821 lb ft).
15. Lubricate and install the Orings on plugs (12),
(26), (14), (18), (21), and (23).
1. Rotate the transmission so the retarder is

facing up.
16. Install the plug assembly (11) and torque to

5468 Nm (4050 lb ft)
2. Install the two M10 guide studs into the

transmission housing.
17. Install the plug assembly (15) and (23).

Torque to 2025 Nm (1518 lb ft)
3. Install the gasket (4) over the M10 guide studs.
18. Install the pressure tap assembly (25), (20),

and (17). Torque to 1013 Nm (710 lb ft).
4. Install the cooler manifold (16) over the M10

guide studs.
5. Install the three M12 x 1.75 x 218 bolts (8).
Tighten bolts ngertight at this time.
the eight M10 x 1.5 x 210 bolts (9). Torque
the eight M10 x 1.5 x 210 bolts (9) to 5161
Nm (3845 lb ft).
7. Torque the three M12 x 1.75 x 218 bolts (8) to
90110 Nm (6681 lb ft).
8. Rotate the transmission so the breather is
facing up.
9. Install two M10 guide studs in cooler plate
assembly (7).
10. Install two gaskets (6) onto cooler plate
assembly (7).
614
u. Installation of Speed Sensors.

NOTE:
For units without retarder, go to
Step 1.
For units with retarder skip Step 1 and
go to Step 2.
1. Install output speed sensor assembly (29)
(Foldout 11A), Oring (30), retainer (31), and
M8 x 1.25 x 20 bolt (32) into the rear cover
assembly (21). Tighten M8 x 1.25 x 20 bolt
(32) to 2429 Nm (1821 lb ft). Skip to next
NOTE.
2. Install output speed sensor assembly (39)
(Foldout 11B), Oring (40), retainer (41), and
M8 x 1.25 x 20 bolt (42) into the retarder
housing. Tighten M8 x 1.25 x 20 bolt (42) to
2429 Nm (1821 lb ft).
NOTE:
For models without PTO, go to Step 3.
For models with PTO, skip Step 3 and
go to Step 4.
3. Install input speed sensor assembly (3)
(Foldout 61), Oring (4), retainer (5), and M8
x 1.25 x 20 bolt (6) into the converter housing
module. Tighten M8 x 1.25 x 20 bolt (6) to
2429 Nm (1821 lb ft).
4. Install input speed sensor assembly (18)
(Foldout 62), Oring (19), retainer (20), and
M8 x 1.25 x 20 bolt (21) into the converter
housing module. Tighten M8 x 1.25 x 20 bolt
(21) to 2429 Nm (1821 lb ft).
v. Installation of Common ExternallyMounted
Parts (Figure 618).
1. Install transmission breather (26), if not
previously installed. Tighten breather to 1216
Nm (912 lb ft).
10. Install an Oring (12) over M10 x 1.5 x 30 bolt

(10), so the Oring seats against the retainer
plug.
11. Install retainer plug (11) into the yoke or
ange. Tighten M10 x 1.5 x 30 bolt (10) to
7080 Nm (5259 lb ft).
12. If used, install brake drum (8) and eight 3/824
x 3/4 bolts (9). Tighten bolts to 5666 Nm
(4149 lb ft).
NOTE: If you have a 3700 SP model
transmission, complete Steps 13 and 14.
Refer to .
13. Replace gasket (9) (thin coated metal type),
and install scavenge pump (7). Install nine
M10 x 1.5 x 25 bolts (8). Tighten bolts to
5161 N.m (3845 lb ft).
14. Install Oring (4) and tting (3) into scavenge
pump (7). Tighten jam nut to 100120 Nm
(7488 lb ft).
2. Install ll tube seal (21), ll tube (22), bracket

(24), and screw (23). Tighten screw to 2429
Nm (1821 lb ft). Install dipstick (25).
3. Install seal (4) and plug (5). Plug (5) is fully
seated when the underside of the plug head
contacts seal (4).
4. If transmission has rear cooler ports, install
new cooler port gasket (20). Install remote
cooler port manifold (19) and six M10 x 1.5
x 35 bolts (17). Tighten bolts to 5161 Nm
(3845 lb ft).
5. For a transmission which uses front cooler
ports, install gasket (20), cover plate (18), and
six M10 x 1.5 x 35 bolts (17). Tighten the bolts
to 5161 Nm (3845 lb ft).
6. Install parking brake assembly (6). Install
four M16 x 2 x 40 bolts (7). Tighten bolts to
228266 Nm (168196 lb ft).
7. Install output ange (14) or yoke (15), and
slinger (16) if applicable.
8. Install lubricated Oring (13) on retainer plug
(11).
9. Insert M10 x 1.5 x 30 bolt (10) through retainer
plug (11).
615

Figure 618. ExternallyMounted Parts Installation
616
WARNING: Transmission dry weights are

as follows:
Base transmission243 kg (535 lbs)
With Retarder279 kg (615 lbs)
With PTO provision261 kg (575 lbs)
With Retarder and PTO
provision297 kg (655 lbs)
With PTO, Retarder, and Integral
Sump Cooler336.5 kg (740 lbs)
3700 SP530 kg (1170 lbs)
Use proper tools and lifting equipment
when installing or removing a
transmission from the repair stand.
Figure 619. 3700 SPScavenge Pump

Installation
w. Removal of Transmission From Repair
Stand (Figure 620). Using a hoist, remove the
transmission and holding xture from the repair
stand and prepare for vehicle installation.
NOTE: Refer to 311. ENGINE,
TRANSMISSION ADAPTATION
REQUIREMENTS for preparing the
transmission for installation and installing
the transmission into the vehicle.

repairs, the Transmission Control Module
(TCM) must be RESET TO UNADAPTED
SHIFTS. This will cause the TCM to erase
previous adaptive information and begin
to adapt in Fast Adaptive Mode from the
base calibration. Use the Allison DOC For
PCService Tool (refer to the Allison DOC
Users Guide for instructions) to RESET
TO UNADAPTED SHIFTS.
617

Figure 620. Removing Transmission From Repair Stand
618
SECTION 7WEAR LIMITS AND SPRING DATA

71.
WEAR LIMITS DATA
a. Maximum Variations. Wear limits information

in this section shows the maximum wear at which
components are expected to function satisfactorily.
Table 71 lists the Wear Limits Data and references
the disassembled views (Foldout 5 through
Foldout 192) 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. GENERAL OVERHAUL
INFORMATION.
72.
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
specications according to Table 72
b. Inspection. Inspection criteria (load vs.height)
and identication characteristics of the springs
are presented in Table 72. The Spring Data are
keyed to the disassembled views (Foldout 5 through
Foldout 192) in the back of this manual.
NOTE: When more than one spring part
number is listed for the same location,
refer to the latest edition of Parts Catalog
PC2150EN to determine which spring is
used in your specic assembly number.
Table 71. Wear Limits Data

Illustration
Description
Wear Limit
mm (inches)
Foldout 5
TORQUE CONVERTER MODULE
Bushing, Maximum ID
61.51 (2.422)
10
Lockup Piston, Minimum Thickness
5.71 (0.225)
12
Lockup Clutch Friction Plate Flatness, Maximum Distortion
0.51 (0.020)
12
Lockup Clutch Friction Plate, Minimum Thickness, Per Side
0.625 (0.025)
TurbineToDamper Spline Wear, Maximum Movement
0.38 (0.015)
13
Lockup Clutch Backplate, Maximum Cone
0.15 (0.006)
14
Lockup Clutch Backplate Wear Surface, Minimum

Thickness
8.58 (0.338)
12, 17
71

Table 71. Wear Limits Data (contd)
Illustration
Description
Wear Limit
mm (inches)
15
Turbine Hub HookType Sealring, Maximum ID When

Installed In Cover (7) Bore
56.75 (2.234)
17
Torque Converter Turbine Hub, Minimum OD
61.34 (2.415)
22
Stator Thrust Plate, Minimum Thickness
11.68 (0.460)
23
Stator Thrust Washer, Maximum Step Wear From Unworn

Surface
33
Torque Converter Pump Hub, Minimum OD
Foldout 62
74.99 (2.952)
TORQUE CONVERTER HOUSING MODULE WITH

PTO
Bearing Retainer Bushing, Maximum ID
75.23 (2.962)
Bearing Retainer Bore, Maximum ID
140.06 (5.514)
10, 16
PTO Gear Assembly Seals, When Installed in Sealing

Bore, Minimum End Gap
0.57 (0.022)
10, 16
PTO Gear Assembly Drive Hub Seals, When Installed in

Sealing Bore, Maximum End Gap
1.15 (0.045)
13
Oil Pump Drive Hub, Maximum Tang Wear
0.38 (0.015)
22
Converter Housing Bearing Bore, Maximum ID
Foldout 71
140.03 (5.513)
FRONT SUPPORT AND CHARGING PUMP MODULE
Pump Housing Bushing, Maximum ID
75.23 (2.962)
Pump Housing Gear Cavity, Maximum Depth
17.93 (0.706)
Pump Housing Gear Cavity, Maximum ID
127.30 (5.012)
9, 10
Driven GearToPump Housing, Maximum Diametrical

Clearance
0.36 (0.014)
10
Drive/Driven Gear, Maximum Gear Tooth Tip Clearance
0.20 (0.008)
10
Driven Gear, Minimum OD
126.95 (4.998)
10
Drive/Driven Gear, Minimum Width
17.81 (0.701)
10, 14
GearToPlate Maximum Side Clearance
0.13 (0.005)
11
Pump Drive Gear Bushing, Maximum ID
57.30 (2.256)
14
Wear Plate, Minimum Thickness
4.70 (0.185)
Ground Sleeve Oil Pump Bushing Journal, Minimum OD
57.04 (2.246)
20
Front Support Sleeve, Minimum Dimension
98.83 (3.891)
23
Front Support Seal, Minimum End Gap
0.57 (0.022)
23
Front Support Seal, Maximum End Gap
1.44 (0.057)
16, 17
Foldout 72
72
0.25 (.010)
ROTATING CLUTCH MODULE
Turbine Shaft Bushing ID, Maximum
20.19 (0.795)
10
Turbine Shaft Seal, Minimum End Gap
0.46 (0.018)
10
Turbine Shaft Seal, Maximum End Gap
0.94 (0.037)
11
Drum, Maximum Spline Wear
0.38 (0.015)
WEAR LIMITS AND SPRING DATA

Illustration
Description
Wear Limit
mm (inches)
13
Rotating Clutch Hub Bushing, Maximum ID
99.25 (3.907)
29
C1 Clutch Apply Plate Flatness, Maximum Distortion
0.15 (0.006)
29
C1 Clutch Apply Plate, Minimum Thickness
4.20 (0.165)
32
C1 Clutch Backing Plate, Minimum Thickness
8.20 (0.323)
30, 38
C1, C2 Friction Plate, Maximum Cone
0.40 (0.016)
30, 38
C1, C2 Friction Plate, Minimum Thickness
2.21 (0.087)
30, 38
C1, C2 Friction Plate, Minimum Oil Groove Depth
0.20 (0.008)
31, 37
C1, C2 Steel Reaction Plate, Maximum Cone
0.40 (0.016)
31, 37
C1, C2 Steel Reaction Plate, Minimum Thickness
2.36 (0.093)
34, 36
C1, C2 Drive Hub, Maximum Spline Wear
0.38 (0.015)
39
C2 Clutch Pressure Plate, Maximum Cone
0.45 (0.018)
39
C2 Clutch Pressure Plate, Minimum Thickness
6.25 (0.246)
43
P1 Sun Gear Drive Hub Bushing, Maximum ID
68.22 (2.685)
Foldout 81
MAIN HOUSING MODULE
C3 Backplate Plate Flatness, Maximum Distortion
0.15 (0.006)
C3 Backplate Plate Flatness, Maximum Step Wear
0.13 (0.005)
5, 16
C3, C4 Wear Plate Flatness, Maximum Distortion
68.22 (0.006)
5, 16
C3, C4 Wear Plate, Minimum Thickness At Wear Point
2.81 (0.111)
P1 Ring Gear, Maximum Spline Wear
0.38 (0.015)
C3, C4, C5 Friction Plate Cone, Maximum Distortion
0.40 (0.016)
7, 15
C3, C4 Friction Plate, Minimum Thickness
2.21 (0.087)
7, 15
C3, C4 Friction Plate, Maximum Friction Material Erosion

Around Lubrication Slots
4.00 (0.157)
7, 15
C3, C4 Friction Plate, Minimum Oil Groove Depth
0.20 (0.008)
C3, C4, C5 Reaction Steel Plate Cone, Maximum Distortion
0.40 (0.016)
C3, C4 Reaction Steel Plate, Minimum Thickness
3.20 (0.126)
C5 Reaction Steel Plate, Minimum Thickness
2.36 (0.093)
9, 16
C3, C4 Piston Return Plate Cone, Maximum Distortion
0.40 (0.016)
9, 16
C3, C4 Piston Return Plate, Minimum Thickness
3.41 (0.135)
13, 18
C3, C4 Clutch Housing Flatness, Maximum Distortion
0.15 (0.006)
22
Main Housing Clutch Plate Splines, Maximum Wear
1.15 (0.045)
28
C5 Friction Plate, Minimum Thickness
2.90 (0.114)
28
C5 Friction Plate, Minimum Oil Groove Depth
0.20 (0.008)
7
7, 15, 29
8, 14, 28
8, 14
28
Foldout 82,
Foldout 91
MAIN SHAFT MODULE (3000, 3500)
NA
Main Shaft Spines Maximum Wear
0.38 (0.015)
9, 8
Main Shaft Pilot, Minimum OD
19.98 (0.787)
73

Illustration
Description
Wear Limit
mm (inches)
9, 8
42.97 (1.692)
Foldout 92
MAIN SHAFT MODULE (3700 SP)
NA
Main Shaft Spines Maximum Wear
0.38 (0.015)
Main Shaft Pilot (Front), Minimum OD
19.98 (0.787)
Main Shaft P2 Bushing Journal, Minimum OD
42.97 (1.692)
Main Shaft C6 Bushing Journal, Minimum OD
35.92 (1.414)
52.98 (2.086)
Foldout 101
P1 PLANETARY MODULE
9, 12
P1 Pinion Thrust Washer, Minimum Thickness
1.39 (0.054)
9, 12
P1 Pinion Thrust Washer, Maximum Step Wear
0.12 (0.005)
10
Pinion, Maximum End Play
0.94 (0.037)
14
0.38 (0.015)
Foldout 102
6
P2 PLANETARY MODULE
P2 Carrier Bushing, Maximum ID
43.20 (1.701)
7, 10
1.39 (0.054)
7, 10
0.12 (0.005)
0.94 (0.037)
14
0.38 (0.015)
Foldout 11A
RETARDER AND P3 PLANETARY MODULE
Output Shaft Bushing, Maximum ID
20.19 (0.795)
Output Shaft, Maximum Spline Wear
0.38 (0.015)
16, 19
1.39 (0.054)
16, 19
0.12 (0.005)
P3 Pinion, Maximum End Play
0.94 (0.037)
Retarder Rotor Sealring, Maximum ID
95.67 (3.767)
Rotor Hub, Maximum Spline Wear
0.38 (0.015)
17
29, 32
31
Foldout 11B
REAR COVER AND P3 PLANETARY MODULE
Output Shaft Bushing, Maximum ID
20.19 (0.795)
Output Shaft, Maximum Spline Wear
0.38 (0.015)
17, 20
1.39 (0.054)
17, 20
0.12 (0.005)
P3 Pinion, Maximum End Play
0.94 (0.037)
18
Foldout 13
74
C7 CLUTCH HOUSING
44
Yoke Journal Seal Wear, Minimum Diameter
76.20 (3.000)
61
C7 Backplate, Minimum Thickness
8.67 (0.341)
62
2.21 (0.087)

Illustration
Description
Wear Limit
mm (inches)
62
0.20 (0.008)
62
C7 Friction Plate, Maximum Cone
0.25 (0.010)
63
C7 Reaction Plate, Minimum Thickness
2.06 (0.081)
63
C7 Reaction Plate, Maximum Cone
0.25 (0.010)
68
Bushing, Maximum ID
47.26 (1.861)
69
Ball, Free Movement
1.00 (0.040)
Foldout 14
C6 CLUTCH HOUSING
Backplate, Minimum Thickness
7.90 (0.311)
Backplate, Maximum Cone
0.40 (0.016)
10
3.68 (0.145)
10
0.20 (0.008)
11
C6 Reaction Plate, Minimum Thickness
2.36 (0.093)
11
C6 Reaction Plate, Maximum Cone
0.40 (0.016)
19
C6 Housing, Maximum Groove Wear
2.29 (0.090)
21
C6 Housing Bushing
36.18 (1.424)
Foldout 172
6
TRANSFER CASE ADAPTER HOUSING AND P3

MODULE
P3 Carrier Bushing, Maximum ID
53.22 (2.095)
8, 11
1.39 (0.054)
8, 11
0.12 (0.005)
0.94 (0.037)
9
Foldout 191
16
SCAVENGE PUMP
Scavenge Pump Thrust Washer, Minimum Thickness
2.47 (0.097)
75
76
Table 72. Spring Data

Foldout
Ref.
Spring
Part No.
Color
Code
No. Coils
Wire Dia.
mm (in.)
Spring OD
mm (in.)
Approx.
Free Length
mm (in.)
Length Under Load

N (lb) min
3.3 (0.13)
0.71.6
(0.160.36)
Foldout 5
25
Stator
29500064
No Code
N/A
Convoluted
N/A
N/A
17.8 (0.70)
Foldout 72
21
C2 Return
Spring
Assembly
29503215
No Code
12*
2.04 (0.080)*
13.00
(0.512)*
45.3 (1.78)*
37.0
(1.46)
48235379
(10841209)**
Foldout 72
25
C1 Return
Spring
Assembly
23045586
No Code
10*
2.19 (0.086)*
16.00
(0.630)*
45.2 (1.78)**
27.5
(1.08)
57636369
(12961432)**
Foldout 81
10
C3 Return
29505570
No Code
11*
1.70 (0.067)*
12.00
(0.472)*
38.9** (1.53)
24.5
(0.96)
232256**
(52.257.6)
Foldout 81
20
C4 Return
29505570
No Code
11*
1.70 (0.067)*
12.00
(0.472)*
38.9 (1.53)**
24.5
(0.96)
232256
(52.257.6)**
Foldout 11A
Foldout 11B
23/23
C5 Retainer
29507780
No Code
9.5*
1.83 (0.072)*
14.35
(0.565)*
39.2 (1.54)*
25.0
(0.98)
30443364
(684756)**
Foldout 11A
Foldout 11B
46/55
Retarder
29515692
None
11.4
4.12 (0.162)
36.17 (1.42)
114.3 (4.50)
91.1
(3.59)
200.0226.6
(44.9650.94)
Foldout 11B
Foldout 172
23/16
C5 Retainer
29500867
No Code
11.5*
2.16 (0.085)*
16.00
(0.630)*
52.1 (2.05)**
33.0
(1.30)
30343498
(682.1786.4)**
Foldout 14
13
C6 Spring
Retainer
Assembly
29501191
No Code
10
1.84 (0.072)
12.70
(0.500)
35.10 (1.382)
26.20
(1.032)
212331
(474524)**
Foldout 151
71
A Trim
23049338
No Code
0.67 (0.026)
11.05
(0.435)
6.5 (0.26)
3.45
(0.14)
3.24.2
(0.720.94)
Foldout 151
66
Lock Up
29542938
No Code
0.67 (0.026)
11.05
(0.435)
6.5 (0.26)
3.45
(0.14)
0.720.94
(0.720.94)
Foldout 151
89
D Trim
29542936
No Code
0.67 (0.026)
11.05
(0.435)
6.5 (0.26)
3.45
(0.14)
3.24.2
(0.720.94)
Foldout 151
76
B Trim
29542936
No Code
0.67 (0.026)
11.05
(0.435)
6.5 (0.26)
3.45
(0.14)
3.24.2
(0.720.94)
Foldout 151
Foldout 151
79 83
Diagnostic
Trim C
29542941
No Code
No Code
1.30 (0.039)
10.50
(0.433)
27.03 (1.06)
15.49
(1.02)
2.45 (0.78)
29542936

mm (in.)
Table 72. Spring Data (contd)

Foldout
Ref.
Spring
Part No.
Color
Code
No. Coils
Wire Dia.
mm (in.)
Spring OD
mm (in.)
Approx.
Free Length
mm (in.)
Length Under Load

mm (in.)
N (lb) min
100
Lockup
Relay
23049326
No Code
10
1.37 (0.054)
14.10
(0.555)
42.1 (1.66)
17.0
(0.67)
49.260.2
(11.0613.53)
Foldout 151
104
Lube
Regulator
23049327
Red
13
1.22 (0.048)
11.10
(0.437)
46.3 (1.82)
23.5
(0.93)
46.551.3
(10.511.5)
Foldout 151
108
Main
Regulator
29500963
Lt. Blue
15
2.87 (0.113)
22.0 (0.866)
98.5 (3.88)
54.6
(2.15)
305337
(68.675.8)
Foldout 151
112
Control Main
29542926
Orange
10
1.83 (0.072)
14.8 (0.583)
44.6 (1.76)
24.2
(0.95)
131145
(29.532.6)
Foldout 151
123
C2 Latch
29542929
Lt. Green
11
1.32 (0.052)
11.43
(0.450)
41.3 (1.63)
19.0
(0.75)
64.178.3
(14.417.6)
Foldout 151
127
Exhaust
Back
23049391
No Code
17
0.61 (0.024)
7.80 (0.307)
29.2 (1.15)
18.2
(0.72)
2.402.94
(0.540.66)
Foldout 151
130
C1 Latch
29542929
Blue
12
1.37 (0.054)
16.26
(0.640)
46.2 (1.82)
29.2
(1.15)
16.718.9
(3.754.25)
Foldout 151
134
Converter
Regulator
29507456
Pink
10.2
1.57 (0.060)
11.00
(0.433)
30.3 (1.19)
22.8
(0.90)
53.759.3
(12.013.3)
Foldout 11A
67/74
Retarder
Valve Body
29529310
Lt Green/
Lt Gray
10.45
0.97 (0.038)
12.19 (0.50)
38.15 (1.50)
17.70
(0.70)
14.70 (10.84)
Foldout 71
26
Main
Pressure
Relief Valve
29507709
No Code
10.0
3.25 (0.128)
17.96 (0.71)
52.38 (2.06)
40.66
(1.61)
509.30 (375.59)
Foldout 151
161
Filter Life
29546549
Lt Blue
10.77
1.09 (0.043)
10.80 (0.43)
27.30 (1.07)
16.67
(0.66)
18.69 (13.78)
Individual Springs
the Complete Spring Assembly
OD at Larger End
**For
Foldout 151
77
78

SECTION 8CUSTOMER SERVICE

81.
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
service 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 use Allison Transmissions Sales and Service
Locator tool on the Allison Transmission web site at
www.allisontransmission.com. You may also refer to
Allison Transmissions 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 threestep procedure to be followed in the
event a problem has not been handled satisfactorily.
Step OneDiscuss your problem with a member
of management from the distributor or dealership.
Frequently, complaints are the result of a breakdown
in communication and can be resolved quickly 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 distributor with whom the dealer has
his service agreement. The dealer will provide his
Allison Transmission distributors name, address,
and telephone number on request.
Step TwoWhen it appears the problem cannot

be readily resolved at the distributor level without
additional assistance, contact the Allison Technical
Assistance Center at 8002525283. They will place
you in contact with the regional customer support
manager for your area.
For prompt assistance, please have the following
information available.
Name and location of the 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
Transmission Control Module [TCM] assembly
number)
Transmission delivery date and accumulated
miles and/or hours of operation
Nature of problem
Chronological summary of your transmissions
history
Step ThreeIf you are still not satised after
contacting the regional customer support manager,
present the entire matter to the home ofce by
writing to the following address:
Allison Transmission
Manager, Warranty Administration
P.O. Box 894, Mail Code A01
Indianapolis, IN 462060894
Including all pertinent information will assist the
home ofce in expediting the matter.
When contacting the home ofce, please keep
in mind that ultimately the problem will likely be
resolved at the distributor or dealership using their
facilities, equipment, and personnel. Therefore,
it is suggested that Step 1 be followed when
experiencing a problem.
Your purchase of an Allison Transmission product is
greatly appreciated, and it is our sincere desire to
assure complete satisfaction.
81

82.
SERVICE LITERATURE
Publication Name
Additional service literature is available. This service

literature provides fully illustrated instructions for
operation, maintenance, service, overhaul, and
parts support for your transmission. To make sure
that you get maximum performance and service life
from your transmission, you may order publications
from:
Troubleshooting Manual
TS3989EN
*Worldwide
SA2229EN
Sales and Service
Directory
*
Also Available On The Internet At

www.allisontransmission.com
SGI, Inc.
Attn: Allison Literature Fulllment Desk
8350 Allison Avenue
Indianapolis, IN 46268
TOLL FREE: 8886665799
INTERNATIONAL: 3174714995
Table 81. Service Literature
3000 Product
Family
Publication Name
Allison DOC For PC Service Tool
User Guide
GN3433EN
*Mechanics
Tips
MT4015EN
MT4108EN
*Mechanics
Tips (Emergency Vehicle
MT3657EN
Tips (Truck Recreational

Vehicle Series)
MT3655EN
*Mechanics
MT4085EN
Series)
*Mechanics
*Operators
Tips (T Series)
Manual (Bus Series)
OM3749EN
Manual (Emergency
Vehicle Series)
OM3656EN
*Operators
Manual (Highway Series)
OM3750EN
*Operators
Manual (Motorhome
OM3349EN
*Operators
Series)
*Operators
Manual (Pupil
Transport/Shuttle Series)
OM3751EN
*Operators
Manual (Rugged Duty
OM3752EN
*Operators
Manual (Specialty Series)
OM3753EN
*Operators
Manual (T Series)
OM3529EN
Series)
Parts Catalog
PC2150EN
Parts Catalog on CDROM
CD2150EN
Principles of Operation
PO4016EN
*Service
SM4013EN
82
Manual
3000 Product
Family

Legend for Foldout 1 Is On The Opposite Side Of This Page.
Foldout 1

Legend for Foldout 1

(1)
(2)
(3)
(4)
(5)
(6)
(7)
(8)
(9)
(10)
(11)
(12)
(13)
(14)
(15)
(16)
(17)
(18)
(19)
(20)
(21)
(22)
(23)
(24)
Lockup clutch and damper assembly

Converter turbine
Converter pump
Converter housing
Front support
Rotating clutch module
C2 clutch
Main case module
C3 clutch
P1 planetary module
C4 clutch
P2 planetary module
C5 clutch
P3 planetary module
Rear cover module
Output shaft
Main shaft module
Oil level sensor
C1 clutch
Oil pump
Ground sleeve
Converter stator
Turbine shaft
Foldout 1
FOLDOUT 1
Foldout 1. 3000 Product Family TransmissionCross Section

Foldout 2


(1)
(2)
(3)
(4)
(5)
(6)
(7)
(8)
(9)
(10)
(11)
(12)
(13)
(14)
(15)
(16)
(17)
(18)
(19)
(20)
(21)
(22)
(23)
(24)
(25)
(26)
(27)
(28)
(29)
(30)

Converter turbine
Converter pump
Converter housing
PTO gear assembly
Front support
C2 clutch
Main case module
C3 clutch
P1 planetary module
C4 clutch
P2 planetary module
C5 clutch
P3 planetary module
Retarder housing
Stator assembly
Rotor assembly
Output speed sensor
Remote manifold
Output shaft
Main shaft module
Oil level sensor
C1 clutch
Oil pump
Input speed sensor
Ground sleeve
Converter stator
Turbine shaft
Foldout 2
FOLDOUT 2
Foldout 2. 3000 Product Family Transmission (Except 3700 SP) with PTO Provision and RetarderCross Section

Foldout 3


(1)
(2)
(3)
(4)
(5)
(6)
(7)
(8)
(9)
(10)
(11)
(12)
(13)
(14)
(15)
(16)
(17)
(18)
(19)
(20)
(21)
(22)
(23)
(24)

Converter turbine
Converter pump
Converter housing
Front support
C2 clutch
Main case module
C3 clutch
P1 planetary module
C4 clutch
P2 planetary module
C5 clutch
P3 planetary module
Rear cover module
Output shaft
Main shaft module
Oil level sensor
C1 clutch
Oil pump
Ground sleeve
Converter stator
Turbine shaft
Foldout 3
FOLDOUT 3
Foldout 3. 3500 TransmissionCross Section

Foldout 4


(1)
(2)
(3)
(4)
(5)
(6)
(7)
(8)
(9)
(10)
(11)
(12)
(13)
(14)
(15)
(16)
(17)
(18)
(19)
(20)
(21)
(22)
(23)
(24)
(25)
(26)
(27)
(28)
(29)

Converter turbine
Converter pump
Converter housing
PTO gear assembly
Front support
C2 clutch
Main housing module
C3 clutch
P1 planetary module
C4 clutch
P2 planetary module
C5 clutch
P3 planetary module
Transfer case adapter housing
Transfer case module
C6 clutch
Transfer case rear output shaft
C7 clutch
Transfer case front output shaft
Main shaft module
C1 clutch
Oil pump
Oil pump drive hub
Ground sleeve
Converter stator
Turbine shaft
Foldout 4
FOLDOUT 4
Foldout 4. 3700 SP TransmissionCross Section

Foldout 5


(1)
(2)
(3)
(4)
(5)
(6)
(7)
(8)
(9)
(10)
(11)
(12)
(13)
(14)
(15)
(16)
(17)
(18)
(19)
(20)
(21)
(22)
(23)
(24)
(25)
(26)
(27)
(28)
(28)
(28)
(29)
(30)
(31)
(32)
(33)
(34)
Converter end plug, threaded

Oring
Torque converter module
Nut, M8 (36), A
Torque converter cover assembly
Cover and bushing assembly
Torque converter cover
Bushing
Lockup piston sealring
Lockup piston assembly
Lockup piston sealring
Lockup clutch backplate
Bolt, M8 x 1.25 x 30 A
Hooktype sealring
Thrust bearing assembly
Torque converter turbine assembly
Stator thrust bearing assembly
Star washer
Torque converter stator assembly
Retaining ring
Stator thrust plate assembly
Stator thrust washer
Torque converter stator race
Torque converter stator spring (13)
Torque converter stator roller (13)
Stator and cam assembly
Shim, converter, 0.2540 mm (0.010 inch),
selective
selective
selective
Pump thrust bearing assembly
Oring
Torque converter pump assembly
Pump thrust washer
Torque converter pump assembly
Thead bolt (36)
Torque
Nm
lb ft
3035
2226
Foldout 5
FOLDOUT 5
Foldout 5. Torque Converter ModuleDisassembled View

Foldout 6


61
(1)
(2)
(3)
(4)
(5)
(6)
(7)
(8)
(9)
(10)
(11)
(12)
(13)
62
Torque converter housing module

Torque converter housing
Speed sensor assembly
Oring
Speed sensor retainer
Bolt, M8 x 1.25 x 20, A
Torque converter housing gasket
Bolt, M10 x 1.5 x 35 (20), B
Vent assembly, M10 x 1.5, C
Sensor shipping cover
Pressure tap plug assembly, D
Oring
Pressure tap plug
Torque
Nm
lb ft
2429
1821
5161
3845
1216
912
1013
710
Foldout 6
(1)
(2)
(3)
(4)
(5)
(6)
(7)
(8)
(9)
(10)
(11)
(12)
(13)
(14)
(15)
(16)
(17)
(18)
(19)
(20)
(21)
(22)
(23)
(24)
(25)
(26)
(27)
(28)
(29)
(30)
Converter housing module

Bolt, M10 x 1.5 x 35 (10), A
Bearing retainer assembly
Oil seal assembly
Bearing retainer assembly
Bearing retainer bushing
Bearing retainer
Sealring
PTO gear assembly
Sealring
Single row ball bearing
PTO gear
Oil pump drive hub
Single row ball bearing
Internal retaining ring
Sealring
Converter housing assembly
Oring
Bolt, M8 x 1.25 x 20, B
Converter housing
Sensor shipping cover
PTO cover gasket (2)
PTO cover (2)
Bolt, M10 x 1.5 x 25 (20), A
Bolt, M10 x 1.5 x 35 (20), A
Vent assembly, M10 x 1.5, C
Breather adapter, M10 x 1.5, C
Torque converter housing gasket
Torque
Nm
lb ft
5161
3845
2429
1821
1216
912
FOLDOUT 6
Foldout 61. Converter Housing Module, Without PTO ProvisionDisassembled View
Foldout 62. Converter Housing Module, With PTO ProvisionDisassembled View

Foldout 7


71
(1)
(2)
(3)
(4)
(5)
(6)
(7)
(8)
(9)
(10)
(11)
(12)
(13)
(14)
(15)
(16)
(17)
(18)
(19)
(20)
(21)
(22)
(23)
(24)
(25)
(26)
(27)
Bolt, M10 x 1.5 x 60 (6), A

Bolt, M10 x 1.5 x 35 (5), A
Front support module
Oring (without PTO only)
Oil seal assembly (without PTO only)
Bolt, M10 x 1.5 x 60 (8), A
Pump housing assembly
Bushing (without PTO only)
Pump housing
Gear set assembly
Bushing
Bolt, M10 x 1.5 x 25 (10), A
Stiffening plate
Wear plate
Front support assembly
Ground sleeve (with PTO)
Ground sleeve (without PTO)
Front support assembly
Dowel pin, 10 x 32 (2)
Front support sleeve
Front support
Roller bearing assembly
Sealring (3)
Dowel pin, 6 x 35
Pressure relief spring
Pressure relief ball
Torque
Nm
lb ft
5161
3845
72
(1)
(2)
(2)
(2)
(2)
(2)
(2)
(2)
Bolt, M16 x 2.0 x 50, A

Torque converter turbine shim
Shim, torque converter turbine, 5.092 mm (0.201
inch), selective
inch), selective
inch), selective
inch), selective
inch), selective
inch), selective
Foldout 7
(2)
(3)
(4)
(5)
(6)
(7)
(8)
(9)
(10)
(11)
(12)
(13)
(14)
(15)
(16)
(17)
(18)
(19)
(20)
(21)
(22)
(23)
(24)
(25)
(26)
(27)
(28)
(29)
(30)
(31)
(32)
(33)
(34)
(35)
(36)
(37)
(38)
(39)
(40)
(41)
(42)
(43)
(44)

inch), selective
Oring
Turbine shaft assembly (without PTO)
Turbine shaft
Turbine shaft bushing
Turbine shaft assembly (with PTO)
Turbine shaft
Sealring (3)
Rotating clutch drum
Rotating clutch hub assembly
Rotating clutch hub bushing
Rotating clutch hub assembly
Thrust bearing
Turbine shaft retaining ring
C2 piston sealring
C1 piston sealring
C2 piston sealring
C2 piston
C2 spring assembly
C1 piston sealring
C1 piston
C1 spring assembly
Rotating clutch balance piston
Rotating clutch balance piston sealring
External retaining ring
C1 clutch apply plate
C1 friction plate (6)
C1 reaction plate (5)
C1 clutch backing plate
C1 drive hub
Thrust bearing (2)
C2 drive hub
C2 reaction plate (6)
C2 friction plate (6)
C2 clutch pressure plate
Sun gear assembly
Sun gear
Sun gear bushing
Torque
Nm
lb ft
100120
7489
FOLDOUT 7
Foldout 71. Front Support and Oil Pump ModuleDisassembled View
Foldout 72. Rotating Clutch ModuleDisassembled View

Foldout 8


81
(1)
(2)
(3)
(4)
(5)
(6)
(7)
(8)
(9)
(10)
(11)
(12)
(13)
(14)
(15)
(16)
(17)
(18)
(19)
(20)
(21)
(22)
(23)
(24)
(25)
(26)
(27)
(28)
(29)
82
C3/C4 clutch assembly

Bolt, M10 x 1.5 x 90 (12), A
C3 backplate assembly
Clutch backplate
Clutch wear plate (3)
P1 ring gear
C3 clutch friction plate (5)
C3 clutch reaction plate (5)
Piston return plate
C3 clutch piston
C3 clutch housing assembly
Clutch wear plate (3)
C3 clutch housing
Piston return plate
C4 clutch piston
C4 clutch housing
Bolt, M10 x 1.5 x 25 (3), A
Converter shipping bracket (3)
Main housing assembly
Main housing
Insert, recoil (12)
Nameplate
Screw, #4 x 14
Shipping Cover
Bolt, M10 x 1.5 x 35 (12), A
(1)
(1)
(1)
(1)
(1)
(1)
(1)
(2)
(3)
(4)
(5)
(6)
(7)
(8)
(9)
Torque
Nm
lb ft
5161
3845
Foldout 8
Shim (selective), 0.27 mm (0.01 inch)

Thrust bearing
Main shaft module
Spiral retaining ring
Thrust bearing
P2 sun gear
Bearing spacer
P3 sun gear
Main shaft
FOLDOUT 8
Foldout 81. Main Housing ModuleDisassembled View
Foldout 82. 3000 Product Family Main Shaft Module (Except 3500 and 3700 SP)Disassembled View

Foldout 9


91
(1)
(2)
(3)
(4)
(5)
(6)
(7)
(8)
A 3500
Selective shim
Main shaft module
P2 sun gear
Bearing spacer
Main shaft
92
(1)
(2)
(3)
(4)
(5)
(6)
(7)
(8)
B 3700SP
Main shaft module
Thrust bearing
P2 sun gear
Bearing spacer
P3 sun gear
Main shaft
Foldout 9
FOLDOUT 9
Foldout 91. Main Shaft Module 3500Disassembled View
Foldout 92. Main Shaft Module 3700 SPDisassembled View

Foldout 10


101
(1)
(2)
(3)
(4)
(5)
(6)
(7)
(8)
(9)
(10)
(11)
(12)
(13)
(14)
P1 planetary module
P1 planetary carrier assembly
Retaining ring
P1 indexing ring
P1 planetary spindle (6)
P1 planetary carrier
P1 thrust washer (6)
P1 pinion gear (6)
Roller bearing assembly (12)
P2 planetary ring gear
102
(1)
(2)
(3)
(4)
(5)
(6)
(7)
(8)
(9)
(10)
(11)
(12)
(13)
(14)
P2 planetary module
Carrier and bushing assembly
Bushing
Thrust washer (4)
Roller bearing (8)
P2 pinion gear (4)
Thrust washer (4)
P2 indexing ring
P3 planetary ring gear
Foldout 10
FOLDOUT 10
Foldout 101. P1 Planetary ModuleDisassembled View
Foldout 102. P2 Planetary ModuleDisassembled View

Legend for Foldout 11A Is On The Opposite Side Of This Page.
Foldout 11A

Legend for Foldout 11A

(1)
(2)
(3)
(4)
(5)
(6)
(7)
(8)
(9)
(10)
(11)
(12)
(13)
(14)
(15)
(16)
(17)
(18)
(19)
(20)
(21)
(22)
(23)
(24)
(25)
(26)
(27)
(28)
(29)
(30)
(31)
(32)
(33)
(34)
(35)
(36)
(37)
(38)
(39)
(40)
(41)
(42)
(43)
(44)
(45)
(46)
(47)
(48)
Retarder housing gasket

Bolt, M12 x 1.75 x 130 (14), A
Bolt, M12 x 1.75 x 190 (4), A
Bolt, M10 x 1.5 x 182 (4), B
Retarder and P3 planetary module
Output shaft assembly
Bushing
Output shaft
P3 indexing ring
Cone and roller bearing assembly
Retaining ring
P3 pinion gear set (set of four pinion gears)
P3 thrust washer
Retarder stator assembly
Spring and retainer assembly
C5 clutch piston
Piston sealring, 258.7 mm Dia
Internal sealring, 140.3 mm Dia
Roller bearing cup
Retarder stator
Oring
Sealring, rotating
Gasket
Rotor
Sealring, rotating
Bolt, M10 x 1.5 x 90 (3), C
Retarder housing assembly
Temperature sensor assembly
Oring
Temperature sensor bracket
Bolt, M8 x 1.25 x 20, C
Oring
Bolt, M8 x 1.25 x 20, C
Retaining ring
Flow valve plug
Roller bearing cup
Retarder housing subassembly
Tachograph plug
Washer, plug
Foldout 11A
(49)
(50)
(51)
(52)
(53)
(54)
(55)
(56)
(57)
(58)
(59)
(60)
(61)
(62)
(63)
(64)
(65)
(66)
(67)
(68)
(69)
(70)
(71)
(72)
(73)
(74)
(75)
(76)
(77)
(78)
(79)
(80)
(81)
(82)
(83)
(84)
(85)
(86)
(87)
(88)
(89)
Retarder housing
Gasket
Cover
Bolt, M8 x 1.25 x 25 (9), C
Spring pin, 5 x 45
Retarder valve
Retarder valve spring
Oring
Valve plug
Oil seal assembly
Nut, bearing retainer
Belleville spring washer
Roller bearing
Separator plate
Retarder control body assembly
Retarder valve body
Valve
Spring
Plug assembly
Oring, 16.4 mm ID
Plug
Plug assembly
Plug
Oring, 16.4 mm ID
Spring
Regulator valve
Retainer pin
Solenoid and connector assembly
Solenoid, variable bleed
Oring, square cut
Oring
Bolt, M8 x 1.25 x 65, C
Plug assembly
Plug, C
Oring
Shipping cover
Gasket
Jumper manifold
Remote manifold
Bolt, M10 x 1.5 x 30 (4), B
Torque
Nm
lb ft
90110
6681
5161
3845
2429
1821

Torque
Nm
lb ft
6067
4450
7488
5565
1013
710
Foldout 11A

Foldout 11A
FOLDOUT 11A
Foldout 11A. Retarder and P3 Planetary ModuleDisassembled View

Legend for Foldout 11B Is On The Opposite Side Of This Page.
Foldout 11B

Legend for Foldout 11B

(1)
(2)
(3)
(4)
(5)
(6)
(7)
(8)
(9)
(10)
(11)
(12)
(13)
(14)
(15)
(16)
(17)
(18)
(19)
(20)
(21)
(22)
(23)
(24)
(25)
(26)
(27)
(28)
(29)
(30)
(31)
(32)
(33)
(34)
(35)
(36)
(37)
(38)
(39)
(40)
(41)
(42)
Rear cover gasket

Bolt, M12 x 1.7 x 45 (19), A
Rear support bracket
Rear cover and P3 planetary module
Output shaft assembly
Bushing
Output shaft
Indexing ring
Spring pin, 5 x 12
Output spacer
Thrust washer (4)
P3 pinion gear (set of four gears)
Rear cover assembly
Spring and retainer assembly
C5 clutch piston
Piston sealring, 281 mm (11.06 inch) dia
Internal sealring, 140 mm (5.51 inch) dia
Roller bearing cup
Rear cover
Oring
Bolt, M8 x 1.25 x 20, B
Output speed signal wheel
Roller bearing cup
Belleville spring washer
Bearing retainer nut, M70 x 20, C
Oil seal assembly
Tachograph plug
Washer
Rear cover
Shipping cover
Torque
Nm
lb ft
90110
6681
2429
1821
7488
5565
Foldout 11B
FOLDOUT 11B
Foldout 11B. Rear Cover and P3 Planetary ModuleDisassembled View

Foldout 12


121
(1)
(2)
(3)
(4)
(5)
(6)
(7)
(8)
(9)
(10)
(11)
(12)
(13)
A KentMoore Tools
J 38547 Forward/rear output seal installer
J 38568 Bearing cup installers
J 385681 Drive/driven bearing cup installer
J 385682 Idler bearing cup installer
J 385683 Forward/rear output bearing cup
installer
J 38569 P3 carrier/C6/C7 housing bushing
installer
J 38572 Transfer case holding xture
J 38573 C6 spring compressor
J 38579 Bearing installers
J 385791 Drive/driven bearing installler
J 385792 Forward/rear output and idler bearing
installer
J 38547 Front and rear output seal installer
J 39623 Bearing end play checker
122
(1)
(2)
(3)
(4)
(5)
(6)
(7)
(8)
(9)
(10)
(11)
(12)
(13)
(14)
(15)
(16)
(17)
(18)
(19)
(20)
(21)
(22)
Bolt, M10 x 1.5 x 55 (8), A

Oil pump assembly
Input bearing retainer shim, 0.254 mm (0.010
inch)
inch)
inch)
Transfer case housing assembly
Transfer case housing
Transfer case cover
Tapered roller bearing cup
Spring retainer assembly
C6 piston
OD sealring
ID sealring
Bolt, M10 x 1.5 x 100 (15), A
Bolt, M10 x 1.5 x 40 (5), A
Idler cover
Idler cover oring
Idler bearing retainer shim, 0.254 mm (0.010
inch)
inch)
Foldout 12
(23) Idler bearing retainer shim, 0.076 mm (0.003

inch)
(24) Idler cover gasket
(25) Tapered roller bearing cup
(27) Output oil seal
(29) Output housing
(31) Bolt, M10 x 1.5 x 35 (8), A
(32) Manifold assembly
(33) Output bearing retainer shim, 0.254 mm (0.010
inch)
inch)
inch)
(39) Output housing
(41) Output oil seal
(42) Bolt, M10 x 1.5 x 100 (15), A
Torque
Nm
lb ft
5161
3845
FOLDOUT 12
Foldout 121. Transfer Case Special ToolsDisassembled View
Foldout 122. Transfer Case, Special Disassembly/Assembly InstructionsDisassembled View

Foldout 13


(1)
(2)
(3)
(4)
(5)
(6)
(7)
(8)
(9)
(10)
(11)
(12)
(13)
(14)
(15)
(16)
(17)
(18)
(19)
(20)
(21)
(22)
(23)
(24)
(25)
(26)
(27)
(28)
(29)
(30)
(31)
(32)
(33)
(34)
(35)
(36)
(37)
(38)
(39)
(40)
(41)
(42)
(43)
Transfer case module

Bolt, M10 x 1.5 x 40 (15), A
Transmission shaft adapter
Bolt, M10 x 1.5 x 55 (8), A
Oil pump assembly
Pressure relief valve
Spring
Plug, D
Spring pin
inch)
inch)
inch)
Transfer case housing
Dowel
Splitline gasket (front and rear cases)
Tapered roller bearing cone
Drive gear (30T)
Bolt, M10 x 1.5 x 40 (5), A
Idler cover
Idler cover oring
inch)
inch)
inch)
Idler cover gasket
Electrical connector plate
Electrical connector gasket
Electrical connector assembly
Bolt, M8 x 1.25 x 25 (4), B
Lube hole plug (2), C
Oriced plug (lube hole) (2), D
Plug assembly (2), D
Oring (9.25 ID)
Idler gear (37T)
Front output shaft nut, E
Flat washer
Foldout 13
(44)
(45)
(46)
(47)
(48)
(49)
(50)
(51)
(52)
(53)
(54)
(55)
(56)
(57)
(58)
(59)
(60)
(61)
(62)
(63)
(64)
(65)
(66)
(67)
(68)
(69)
(70)
(71)
(72)
(73)
(74)
(75)
(76)
(77)
(78)
(79)
(80)
(81)
(82)
(83)
(84)
(85)
(86)
Front yoke assembly (16 TYS)

Bolt, M10 x 1.5 x 40 (15), A
Output oil seal
Output housing
Output housing gasket
inch)
inch)
inch)
Output bearings spacer
Front output shaft
C7 clutch hub
C7 clutch backplate
C7 friction plate
C7 reaction plate
C7 piston
External sealring
Internal sealring
C7 clutch housing
Bushing, 53.10 mm (2.08 inch) dia
Ball, 6.35 mm (0.250 inch) dia
Manifold sealring
Bolt, M10 x 1.5 x 35 (8), A
Manifold assembly
Manifold
Ball, 0.218 dia
Output bearing retainer shim, 0.254 mm (0.010
inch)
inch)
inch)
Driven gear
Lube charging pump front cover
Lube charging pump drive gear
Lube charging pump driven gear
Lube charging pump reversing ring

(87) Lube charging pump rear cover
(88) Connector nut, F
Torque
Nm
lb ft
5161
3845
58
46
2429
1821
1214
910
610815
450600
2.734.09
2436 lb in.
Foldout 13

Foldout 13
FOLDOUT 13
Foldout 13. Front Main Transfer CaseDisassembled View

Foldout 14


(1)
(2)
(3)
(4)
(5)
(6)
(7)
(8)
(9)
(10)
(11)
(12)
(13)
(14)
(15)
(16)
(17)
(18)
(19)
(20)
(21)
(22)
(23)
(24)
(25)
(26)
(27)
(28)
(29)
(30)
(31)
(32)
(33)
(34)
(35)
(36)
(37)
(38)
(39)
(40)
(41)
(42)
(43)
(44)
(45)
(46)
(47)
(48)

Transfer case cover
Bearing retainer
Bolt, M10 x 1.5 x 35 (8), A
C6 hub
Thrust bearing
C6 backplate
C6 friction plate
C6 reaction plate
C6 piston
C6 OD sealring
C6 ID sealring
C6 housing assembly with bushing
C6 housing assembly
C6 housing
C6 sleeve
Bushing
C6 housing gasket
Bolt, M10 x 1.5 x 100 (15), A
Bolt, M10 x 1.5 x 40 (2), A
Lube hole plug, B
Oriced plug (lube hole), C
Plug assembly, C
Oring (9.25 ID)
Control valve body assembly
Control body
Valve
Spring
Stop
Pin
Solenoid, N/C modulating
Oring, 0.551 ID
Oring, 0.364 ID
Valve
Solenoid spring
Pin
Bolt, M8 x 1.25 x 50 (6), B
Control cover gasket
Control cover
Bolt, M8 x 1.25 x 30 (10), B
Speed sensor
Bolt, M8 x 1.25 x 25 (2), B
Idler cover gasket
Idler cover oring
Foldout 14
(49)
(50)
(51)
(52)
(53)
(54)
(55)
(56)
(57)
(58)
(59)
(60)
(61)
(62)
(63)
(64)
(65)
(66)
(67)
(68)
(69)
(70)
(71)
(72)
(73)
(74)
(75)
(76)
(77)
(78)
(79)
(80)
(81)
(82)
Idler cover
Bolt, M10 x 1.5 x 40 (5), A
Orice plug, 5 mm (0.197 inch)
Drain plug assembly, D
Oring
Bearing retainer
Bolt, M10 x 1.5 x 35 (8), A
P4 carrier assembly
P4 carrier
Planetary pinion shaft setscrew (3), D
P4 spindle
Roller bearings
Pinion gear (17T)
Thrust washer
Sun gear
Ring gear (59T)
Rear output shaft
Output bearings spacer
Output bearing retainer shim 0.254 mm (0.010
inch)
inch)
inch)
Output housing gasket
Output housing
Bolt, M10 x 1.5 x 40 (6), A
Output oil seal
Rear yoke assembly (16 TYS)
Flat washer
Rear output shaft nut, E
Bolt, M10 x 1.5 x 100 (9), A
Torque
Nm
lb ft
5161
3845
2429
1821
1214
910
2535
1826
610815
450600
FOLDOUT 14
Foldout 14. Rear Main Transfer CaseDisassembled View

Foldout 15


152
(1)
(2)
(3)
(4)
(5)
(6)
(7)
(8)
(9)
(10)
(11)
(12)
(13)
(14)
(15)
(16)
(17)
(18)
(19)
(20)
(21)
(22)
(23)
(24)
(25)
(26)
(27)
(28)
(29)
(30)
(31)
(32)
(33)
(34)
(35)
(36)
(37)
(38)
(39)
(40)
(41)
(42)
(43)
(44)
(45)
(46)

Suction lter assembly kit
Bolt, M6 x 1.0 x 30, A
Suction lter assembly
Suction lter
Face seal
Suction lter gasket
Control harness assembly
Connector assembly
Electronic connector
Seal
Sealring
Standoff assembly
Cavity plug
Bolt, 20F connector, C
Temperature sensor (OIL T)
Connector assembly
Connector, 2Way
Pin terminal
Pin terminal
Secondary lock
Connector Assembly (OLS)
Terminal
Terminal
Connector, 2way
Connector Assembly (SS1)
Terminal
Terminal
Connector, 2way
Channel
Solenoid connector assembly (SS2)
Connector, 2way
Terminal
Terminal
2Way solenoid connector (PCS4)
2Way connector (C3 pressure switch)
Terminal
Terminal
Connector, 2way
2Way solenoid connector (TCC)
Shoulder bolt M6 x 1.0 x 45 (3), B
Foldout 15
(47)
(48)
(49)
(50)
(51)
(52)
(53)
(54)
(55)
(56)
(57)
(58)
(59)
(60)
(61)
(62)
(63)
(64)
(65)
(66)
(67)
(68)
(69)
(70)
(71)
(72)
(73)
(74)
(75)
(76)
(77)
(78)
(79)
(80)
(81)
(82)
(83)
(84)
(85)
(86)
(87)
(88)
(89)
(90)
(91)
(92)
(93)
Bracket
Bolt, M6 x 1.0 x 45 (2), A
Face seal
Accumulator spring
Accumulator plug (2)
Accumulator plug (2)
Accumulator spring (2)
Switch assembly
Switch
Bracket
Bolt, M6 x 1.0 x 95 (12), A
Solenoid body assembly
Body Assembly valve and pin
Body
Pin (3)
Variable bleed solenoid (TCC)
Oring
Oring
TCC valve
Spring
Variable bleed solenoid (PCS1)
Oring
Oring
PCS1 valve
Spring
Oring
Oring
PCS2 valve
Spring
Clip
Diagnostic valve
Spring
Oring
Oring
PCS3 valve
Spring
Oring
Oring
PCS4 valve
Spring
Variable bleed solenoid (Main Mod)
Oring
Oring
Bolt, M6 x 1.0 x 20 (2), A

(94)
(95)
(96)
(97)
(98)
(99)
(100)
(101)
(102)
(103)
(104)
(105)
(106)
(107)
(108)
(109)
(110)
(111)
(112)
(113)
(114)
(115)
(116)
(117)
(118)
(119)
(120)
(121)
(122)
(123)
(124)
(125)
(126)
(127)
(128)
(129)
(130)
(131)
(132)
(133)
(134)
(135)
(136)
(137)
(138)
(139)
(140)
(141)
(142)
(143)
Speed sensor
Bolt, M6 x 1.0 x 60 (2), A
Separator plate
Main valve body assembly
Retention pin 5 OD x 43
Lockup valve
Spring
Valve stop
Lube regulator valve
Spring
Valve stop
Main regulator valve
Spring
Valve stop
Retention pin, 5 OD x 43
Control main valve
Spring
Clip
Retention pin, 2.5 OD x 40
Solenoid assembly
Oring
Oring
Control valve body
C2 latch valve
Spring
Valve stop
Exhaust backll valve
Spring
Valve stop
C1 latch valve
Spring
Valve stop
Converter regulator valve
Spring
Valve stop
Bolt, M6 x 1.0 x 45 (2), B
Oil level sensor assembly
Ferrule Viton (2)
Separator plate
Channel plate gasket
Oil transfer plate assembly
Drain plug
Dowel pin (2)
(144)
(145)
(146)
(147)
(148)
(149)
(150)
(151)
(152)
(153)
(154)
(155)
(156)
(157)
(158)
(159)
(160)
(161)
(162)
(163)
(164)
(165)
(166)
(167)
(168)
(169)
(170)
(171)
(172)
(173)
(174)
(175)
(176)
(177)
(178)
(179)
(180)
(181)
(182)
(183)
(184)
(185)
(186)
Oil transfer plate

Plug assembly
Oring
Plug assembly
Oring
Pressure tap plug
Oil transfer plate assembly
Dowel pin (2)
Oil transfer plate
Plug assembly
Oring
Plug assembly
Plug
Plug
Filter cover (2)
Gasket (2)
Oring (2)
Oring (2)
Oil lter
Bolt, M10 x 1.5 x 55 (32), E
Bolt, M10 x 1.5 x 100 (25, 4 inch sump), E
Filter cover gasket (2)
C6 solenoid module assembly (7speed)
Speed nut, push on
Solenoid protective plate
Solenoid, C6
Oring
Oring
Valve
Spring
Pin
Body
Accumulator retaining bracket
Accumulator spring
Spring
Valve
Solenoid
Oring
Oring
Bracket
Screw
Bolt, M6 x 1.0 x 60 (4), A
Bracket
Torque
Nm
lb ft
1013
710
58
46
2.53.5
2231 lb inch
Foldout 15

Torque
Nm
lb ft
2532
1824
5161
3845
Foldout 15
FOLDOUT 15
Foldout 151. Control Valve ModuleDisassembled View
Foldout 152. Control Valve ModuleDisassembled View

Foldout 16


162
(1)
(2)
(3)
(4)
(5)
(6)
(7)
(8)
(9)
(10)
(11)
(12)
(13)
(14)
(15)
(16)
(17)
(18)
(19)
(20)
(21)
(22)
(23)
(24)
(25)
(26)
(27)
(28)
(29)
(30)
(31)
(32)
(33)
(34)
(35)
(36)
(37)
(38)
(39)
(40)
(41)
(42)
(43)
(44)
Valve Assembly, Control

Filter Assembly Kit, Suction
Gasket, Suction Filter
Filter Assembly, Suction
Filter Assembly, Suction
Seal, Face
Bolt, M6 x 1.0 x 30 (3)
Harness Assembly, Control, Internal
Connector Assembly
Connector
Seal
Sealring
Standoff, Wiring Harness
Grommet
Bolt, 20F Connector
Sensor, Temperature (OIL T)
Connector Assembly (TEMP)
Connector, 2 Way
Terminal, Socket
Terminal, Socket
Lock, Secondary
Connector Assembly (SS1)
Terminal, Socket
Terminal, Socket
Connector, 2 Way
Channel
Oil Level Sensor
Connector, Plug, 3Way
Terminal, Socket
Lock, Secondary
Connector Assembly, 2Way (PCS3)
Connector Assembly, 2Way Speed Sensor
(NT1)
Terminal, Socket
Terminal, Socket
Connector
Connector Assembly, 2Way (Main Modulator)
Connector Assembly, 2Way Speed Sensor
(NT1)
Terminal, Socket
Terminal, Socket
Connector
Connector Assembly, 2Way Pressure Switch
(PS1)
Terminal, Socket
Terminal, Socket
Foldout 16
(45)
(46)
(47)
(48)
(49)
(50)
(51)
(52)
(53)
(54)
(55)
(56)
(57)
(58)
(59)
(60)
(61)
(62)
(63)
(64)
(65)
(66)
(67)
(68)
(69)
(70)
(71)
(72)
(73)
(74)
(75)
(76)
(77)
(78)
(79)
(80)
(81)
(82)
(83)
(84)
(85)
(86)
(87)
Connector
Connector Assembly, 2Way (TCC)
Bolt, M6 x 1.0 x 45 (3)
Bracket
Bolt, M6 x 1.0 x 45 (2)
Seal, Face (3)
Spring, Accumulator (2)
Plug, Accumulator (2)
Plug, Accumulator (2)
Spring, Accumulator (2)
Switch Assembly
Switch
Bracket
Bolt, M6 x 1.0 x 95 (12)
Body Assembly, Solenoid
Body Assembly, Solenoid Valve And Pin
Body
Pin (3)
Solenoid, TCC, Variable Bleed, CENL. Connector
Body
Oring, 13.0 mm ID
Oring, 10.5 mm ID
Valve, Lockup Trim
Spring
Solenoid, PCS1, Variable Bleed, CENH.
Connector Body
Oring, 13.0 mm ID
Oring, 10.5 mm ID
Valve, Clutch Trim
Spring, Trim
Solenoid, PCS2, Variable Bleed, CENH.
Connector Body
Oring, 13.0 mm ID
Oring, 10.5 mm ID
Valve, Clutch Trim
Spring, Trim
Clip
Valve, Diagnostic (3)
Spring, Diagnostic (3)
Solenoid, PCS3, Variable Bleed, CENL.
Connector Body
Oring, 13.0 mm ID
Oring, 10.5 mm ID
Valve, Clutch Trim
Spring, Trim

(88) Solenoid, PCS4, Variable Bleed, CENL.
Connector Body
(89) Oring, 13.0 mm ID
(91) Valve, Clutch Trim
(92) Spring, Trim
(93) Solenoid, Main Mod, Variable Bleed, CENL.
Connector
(96) Bolt, M6 x 1.0 x 20 (2)
(97) Sensor, Speed
(98) Bolt, M6 x 1.0 x 60 (2)
(99) Plate, Solenoid Separator
(100) Body Assembly, Main Valve
(101) Pin, Retention, 5 OD x 43 mm
(102) Valve, Lockup
(103) Spring, Lockup
(104) Stop, Lockup
(106) Valve, Lube Regulator
(107) Spring, Lube Regulator
(108) Stop, Lube Regulator
(110) Valve, Main Regulator
(111) Spring, Main Regulator
(112) Stop, Main Regulator
(113) Valve, Control Main
(114) Spring, Control Main
(115) Clip, Control Main
(116) Pin, Retention, 2.5 OD x 40 mm
(117) Solenoid Assembly
(118) Oring, 18.8 mm ID
(119) Oring, 14.0 mm ID
(120) Body, Control Valve
(121) Pin, Spring
(123) Valve, C2 Latch
(124) Spring, C2 Latch
(125) Stop, C2 Latch
(127)
(128)
(129)
(130)
(131)
(132)
(133)
(134)
(135)
(136)
(137)
(138)
(139)
(140)
(141)
(142)
(143)
(144)
(145)
(146)
(147)
(148)
(149)
(150)
(151)
(152)
(153)
(154)
(155)
(156)
(157)
(158)
(159)
(160)
(161)
(162)
(163)
(164)
(165)
(166)
Valve, Exhaust Back

Spring, Exhaust Back
Stop, Exhaust Back
Pin, Retention, 5 OD x 43 mm
Valve, C1 Latch
Spring, C1 Latch
Stop, C1 Latch
Pin, Retention, 3 OD x 43 mm
Valve, Converter Regulator
Spring, Converter Regulator
Stop, Converter Regulator
Bolt, M6 x 1.0 x 45 (2)
Sensor Assembly, Oil Level
Ferrule, Viton (2)
Plate, Separator
Gasket, Channel Plate
Plate Assembly, Channel
Pin, Dowel, 10 x 50 mm (2)
Plate, Oil Transfer
Plug Assembly, Oil Drain
Oring, 16.4 mm ID
Plug Assembly, Pressure Tap (10)
Oring, 8.9 mm ID
Plug, Pressure Tap
Filter, Oil (2)
Oring, 75.9 mm ID (2)
Oring, 85.3 mm ID (2)
Gasket, Filter Cover (2)
Cover, Filter (2)
Bolt, M6 x 1.0 x 45 (4)
Pressure Switch
Body Assembly, Filter Life Valve
Body, Filter Life
Valve, Filter Life
Spring, Filter Life
Plug
Clip
Bolt, M10 x 1.5 x 100 (25)
Bolt, M10 x 1.5 x 55 (7)
Gasket, Case
Foldout 16

Foldout 16
FOLDOUT 16
Foldout 161. Control Valve Module with PrognosticsDisassembled View
Foldout 162. Control Valve Module with PrognosticsDisassembled View

Foldout 17


171
(1)
(2)
(3)
(4)
(5)
(6)
(7)
(8)
(9)
(10)
(11)
(12)
172
Output ange
Blank ange
Oring
Oring
Oring
Retainer plug
Bolt, M10 x 1.5 x 30 (2), A
Output shipping cover
Output yoke
Output yoke
Bolt
Slinger
Torque
Nm
lb ft
3035
2226
7080
5160
Foldout 17
(1)
(2)
(3)
(4)
(5)
(6)
(7)
(8)
(9)
(10)
(11)
(12)
(13)
(14)
(15)
(16)
(17)
(18)
(19)
(20)
(21)
(22)
(23)
(24)
(25)
(26)
(27)
(28)
(29)
(30)
(31)
(32)
(33)
P3 carrier assembly
P3 indexing ring
Carrier and bushing assembly
Bushing
P3 pinion gear set (contains 4 pinions)
Selective shim
Adapter housing gasket
Adapter housing assembly
C5 clutch piston
C5 outer piston sealring
C5 inner piston sealring
Adapter housing
Plug assembly
Plug, A
Oring
Filter screen
Bolt, M10 x 1.5 x 70 (4), B
Transfer case housing gasket
Bolt, M10 x 1.5 x 205, (stepped and knurled
shank) B
Bolt, M10 x 1.5 x 205, (bulged shank) B
Bolt, M12 x 1.75 x 60 (3), C
Bolt, M10 x 1.5 x 100 (3), B
Bolt, M10 x 1.5 x 40 (2), B
Bolt, M12 x 1.7 x 45 (15), C
Bolt, M10 x 1.5 x 40 (19), B
Torque
Nm
lb ft
3447
2535
5161
3845
90110
6681
FOLDOUT 17
Foldout 171. Output Flange and YokeDisassembled View
Foldout 172. Transfer Case Adapter HousingDisassembled View

Foldout 18


181
(1)
(2)
(3)
(4)
(5)
(6)
(7)
(8)
(9)
(10)
(11)
(12)
(13)
(14)
(15)
(15)
(16)
(17)
(18)
(19)
(20)
(21)
(22)
(23)
(24)
(25)
(26)
(27)
(28)
(29)
182
Gasket
Cover
Cooler port manifold
Bolt, M10 x 1.5 x 28 (6), A
Gasket (without retarder)
Gasket (retarder)
Cooler housing
Gasket (2)
Connector (2)
Bolt, M10 x 1.5 x 35 (8), A
Washer
Bolt, M10 x 1.5 x 205 (used with retarder), A
Bolt, M12 x 1.75 x 230 (3, with retarder), B
Washer (3)
Bolt, M10 x 1.5 x 70 (9, without retarder), A
Bolt, M10 x 1.5 x 225 (6, with retarder), A
Washer (9, or 6)
Pressure tap plug assembly (2), C
Pressure tap plug
Oring
Plug, 1/214, D
Elbow (2)
Gasket
Cover
Bolt, M12 x 1.75 x 25 (2), E
Bolt, M10 x 1.5 x 35 (17), A
Oring (2)
Plate assembly
Oring
Oring
Torque
Nm
lb ft
5161
3845
100120
7488
1013
710
2227
1620
90110
6681
Foldout 18
(1)
(2)
(3)
(4)
(5)
(6)
(7)
(8)
(9)
(10)
(11)
(12)
(13)
(14)
(15)
(16)
(17)
(18)
(19)
(20)
(21)
(22)
(23)
(24)
(25)
(26)
(27)
Bolt, M10 x 1.5 x 60 (16), B

Adapter
Gasket, manifold to Water
Gasket, integral cooler
Bolt, M8 x 1.25 x 25 (6), A
Gasket, manifold to cooler, (2)
Cooler, integral
Bolt, M12 x 1.75 x 218 (3), C
Bolt, M10 x 1.5 x 210 (8), B
Manifold assembly, integral cooler
Plug assembly, shipping, SAE No. 16
Shipping plug
Oring
Plug assembly, pressure tap
Oring, 11.6 mm ID
Manifold, integral, strapped
Plug, pressure tap
Oring, 8.9 mm ID
Plug, pressure tap
Oring, 8.9 mm ID
Oring, 9.3 mm ID
Plug, pressure tap
Oring, 8.9 mm ID
Torque
Nm
lb ft
33
24
63
47
113
79
FOLDOUT 18
Foldout 181. Oil CoolerDisassembled View
Foldout 182. Integral Sump CoolerDisassembled View

Foldout 19


191
(1)
(2)
(3)
(4)
(5)
(6)
(7)
(8)
(9)
(10)
(11)
(12)
(13)
(14)
(15)
(16)
(17)
(18)
(19)
Scavenge pump module

Pin
Pump housing
Shaft
Oring, 12.4 mm (0.488 inch) ID
Oring, 12.4 mm (0.488 inch) ID
Bolt, M8 x 1.25 x 30 (3), A
Driven gear assembly
Driven gear
Thrust washer
Pump assembly
Pump cover
Gear set
Thrust washer
Pump body
Gasket
Bolt, M8 x 1.25 x 20 (3), A
Torque
Nm
lb ft
3035
2325
192
(1)
(2)
(3)
(4)
(5)
(6)
(7)
(8)
(9)
(10)
(11)
(12)
Parking brake, 12 x 4
Bolt, M16 x 2.0 x 40 (4), A
Brake drum
Bolt, 3824 x 34 (2), B
Stud (2)
PTO gasket
Bolt, M10 x 1.5 x 35 (8), C
PTO assembly
Stud (2)
PTO gasket
Bolt, M10 x 1.5 x 35 (8), C
PTO assembly
Torque
Nm
lb ft
228266
168196
5666
4149
5161
3845
Foldout 19
FOLDOUT 19
Foldout 191. Scavenge PumpDisassembled View
Foldout 192. Support EquipmentDisassembled View
FOLDOUT 20
Foldout 20 . 3000 Product Family Hydraulic SchematicNeutral
FOLDOUT 21
Foldout 21 . 3000 Product Family Hydraulic SchematicReverse
FOLDOUT 22
Foldout 22 . 3000 Product Family Hydraulic Schematic7Speed, Low Range
FOLDOUT 23
Foldout 23 . 3000 Product Family Hydraulic SchematicFirst Range
FOLDOUT 24
Foldout 24 . 3000 Product Family Hydraulic SchematicSecond Range
FOLDOUT 25
Foldout 25 . 3000 Product Family Hydraulic SchematicThird Range
FOLDOUT 26
Foldout 26 . 3000 Product Family Hydraulic SchematicFourth Range
FOLDOUT 27
Foldout 27 . 3000 Product Family Hydraulic SchematicFifth Range
FOLDOUT 28
Foldout 28 . 3000 Product Family Hydraulic SchematicSixth Range
FOLDOUT 29
Foldout 29 . 3000 Product Family Hydraulic SchematicRetarder OFF
FOLDOUT 30
Foldout 30 . 3000 Product Family Hydraulic SchematicRetarder ON
FOLDOUT 31
Foldout 31 . 3000 Product Family Hydraulic SchematicNeutral With Prognostics
FOLDOUT 32
Foldout 32 . 3000 Product Family Hydraulic SchematicReverse Range With Prognostics
FOLDOUT 33
Foldout 33 . 3000 Product Family Hydraulic SchematicFirst Range With Prognostics
FOLDOUT 34
Foldout 34 . 3000 Product Family Hydraulic SchematicSecond Range With Prognostics
FOLDOUT 35
Foldout 35 . 3000 Product Family Hydraulic SchematicThird Range With Prognostics
FOLDOUT 36
Foldout 36 . 3000 Product Family Hydraulic SchematicFourth Range With Prognostics
FOLDOUT 37
Foldout 37 . 3000 Product Family Hydraulic SchematicFifth Range With Prognostics
FOLDOUT 38
Foldout 38 . 3000 Product Family Hydraulic SchematicSixth Range With Prognostics
SM4013EN 200906
Printed in USA 200907

3K Service Manual 4th Gen SM4013EN 200906

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3K Service Manual 4th Gen SM4013EN 200906

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SERVICE MANUAL

3000 PRODUCT FAMILY

SERVICE MANUAL ALLISON 4th GENERATION CONTROLS

Copyright 2009 Allison Transmission, Inc.

SERVICE MANUAL3000 Product FamilyAllison 4th Generation

Copyright 2009 Allison Transmission, Inc.

SERVICE MANUAL3000 Product FamilyAllison 4th Generation

IMPORTANT SAFETY INFORMATION

WARNINGS, CAUTIONS, NOTES

Copyright 2009 Allison Transmission, Inc.

SERVICE MANUAL3000 Product FamilyAllison 4th Generation

Copyright 2009 Allison Transmission, Inc.

SERVICE MANUAL3000 Product FamilyAllison 4th Generation

LIST OF WARNINGS (contd)

3000 Product Family transmission dry weights are as follows:

243 kg (535 lb)

With PTO Provision

261 kg (575 lb)

279 kg (610 lb)

With PTO and Retarder

297 kg (655 lb)

With PTO, Retarder, and Integral Sump

336.5 kg (740 lb)

530 kg (1170 lb)

Copyright 2009 Allison Transmission, Inc.

SERVICE MANUAL3000 Product FamilyAllison 4th Generation

LIST OF WARNINGS (contd)

Copyright 2009 Allison Transmission, Inc.

e. Displaying Diagnostic Trouble Codes

IMPORTANT SAFETY INFORMATION . . . . . . . iii

f. Diagnostic Trouble Code (DTC)

g. Exiting Diagnostic Mode . . . . . . . . . . 111

Section 1. GENERAL INFORMATION

a. Preservation Methods . . . . . . . . . . . . 111

a. Content and Organization . . . . . . . . . .11

b. Storage (New Transmissions, Before

c. Maintenance Information . . . . . . . . . . .11

c. One Year Storage (Without Fluid). . . . . 111

12. SUPPLEMENTARY INFORMATION . . . . . .16

d. One Year Storage (With Fluid). . . . . . . 112

13. ORDERING PARTS . . . . . . . . . . . . . . . .16

19. RESTORING TRANSMISSION TO

a. Transmission Nameplate . . . . . . . . . . .16

a. Transmission Exterior . . . . . . . . . . . . 112

b. Parts Catalog . . . . . . . . . . . . . . . . . .16

b. Sealed Breather and Openings . . . . . . 112

c. New Transmissions . . . . . . . . . . . . . 112

a. Major Modules. . . . . . . . . . . . . . . . . .16

d. Stored Without Fluid . . . . . . . . . . . . . 112

b. General Features . . . . . . . . . . . . . . . .16

e. Stored With Fluid . . . . . . . . . . . . . . . 112

a. Input Module . . . . . . . . . . . . . . . . . . .17

111. SPECIFICATIONS AND DATA . . . . . . . . . 113

e. Range Clutches . . . . . . . . . . . . . . . . .17

Section 2. PREVENTIVE MAINTENANCE

g. Control System and Transmission

21. SCOPE . . . . . . . . . . . . . . . . . . . . . . . .21

h. Oil Filters . . . . . . . . . . . . . . . . . . . . .18

a. Oil Life Monitor . . . . . . . . . . . . . . . . .21

Transmission Fluid Coolers . . . . . . . . .18

b. Filter Life Monitor . . . . . . . . . . . . . . . .21

Output Conguration . . . . . . . . . . . . . .18

c. Transmission Health . . . . . . . . . . . . . .21

16. MODEL DESIGNATION CODE . . . . . . . . .18