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GN4064EN
(5/05)
INSPECTION AND ANALYSIS OF THE
ALLISON 3000 / B 300 / B 400 PRODUCT FAMILIES
A. Housings
D. Splines
B. Machined
Surfaces
C. Fluid
Passages C. Fluid
Passages
A. Cast Parts
A. Replace housings or other cast C. Inspect all fluid passages for Q Torque converter front cover
parts that are cracked or broken. obstructions, porosity, broken flexplate adapter bolt holes and
Inspect clutch housing sealing lands, cracks and land surface lockup clutch backplate bolt
surfaces for imperfections that imperfections. holes (starting with S/N
could damage the piston seals or 6510024410).
interfere with mating parts. D. Replace housings that have
Inspect threaded holes for bad splines worn beyond wear limits. Q Output shafts using a single bolt
threads. Clean damaged threads Refer to the Wear Limits Table for flange or yoke retention
with the correct size tap. (7-1) in Service Manual SM2148EN. (starting with S/N 6510184819).
B. Inspect all machined surfaces NOTE: Some parts have Spiralock® NOTE: Do not use impact guns
for damage that could cause fluid threaded holes . A standard tap will (air wrenches, electric impact
leakage. Inspect mounting faces eliminate the locking feature wrenches, etc.) when working with
and bores for damage. requiring the reworked part to be aluminum threads or when torque
replaced. For repair, use a sequencing bolts.
Spiralock® tap to repair Spiralock®
threaded holes. As of this printing,
the following parts have Spiralock®
threaded holes:
A. Gear
Teeth
A. Splines
B. Bearing
C. Retainer
Race
C. Retainer
A. Rollers
C. Retainer B. Bearing
Race
A. Bushing
A. Inspect bushings for wear General Bushing Information Some bushings are susceptible to
beyond service limits. Replace any material leaching. This can be
Mechanically, bushings are the
bushing which is excessively worn. caused by oxidized oil that has
simplest type of journal bearing and
Inspect bushings for discoloration turned acidic combined with heat
are often referred to as “plain”
and surface damage due to lack of and mechanical loading. The TAN
bearings. A bushing is simply a
lubrication. Replace any bushing (Total Acid Number) of the
sleeve of bearing material, such as
which is damaged. transmission oil should not change
bronze or aluminum, in which a
by more than 3 from the baseline
component rides. Bushing wear is
(new fluid) TAN. Changing
strongly influenced by the quantity
transmission oil per recommended
and condition of the lubricant.
change intervals or based on a
Bushing bearing surfaces are
successful oil sampling program
sometimes grooved to better
will help prevent material leaching.
distribute lubrication across the
bearing surface.
A. Retaining
Rings
Thrust
Washers
A. Inspect friction plate contact C. Measure friction plate oil stone or crocus cloth. Replace the
faces and splines for excessive groove depth. Replace any plates clutch plate if spline teeth are
wear, damage and coning. Inspect that are not within Service Manual broken or missing.
the plates for burrs, pitted faces, minimum groove depth NOTE: Anti-freeze (glycol) and/or
cracks, distortion and damaged specification. water can adversely affect the
spline teeth. bonding agent between the friction
D. Inspect spline teeth for
excessive wear and battering. material and steel core. Replace any
B. Measure friction plate friction plates which have been
thickness and coning. Reference Replace the clutch plate if damage
cannot be repaired using a soft exposed to water and/or glycol.
the Service Manual for minimum
(continued)
thickness and maximum coning
specifications. Do not reuse friction B. Clutch Plate
plates that do not meet published Thickness and
specifications. If reused plates are Coning Coned Plate
slightly coned (within
Check Using
specification), make sure each plate
Feeler Gauge
is stacked with the cone facing the Flat Plate
same direction.
Thickness
C. Tangs
Excessive scoring -
B. Thickness replace plates.
& Coning
(see prior
page
graphic)
Broken tangs -
replace plates.
A. Contact
Surfaces
NOTE: The current clutch friction 3060, MD-3560, B300, or 3000MH- cannot be repaired using a soft
plates were implemented April of 2000 Standard with former friction plates stone or crocus cloth.
starting with s/n 6510262117. Current will require a new ECU calibration
production friction plates will have from Allison Transmission to use the B. Measure reaction plate
two missing splines. Former friction current friction plates in C1, C2, C3 thickness and coning. Reference
plates will either have one spline and C4. Any WTEC III ECU equipped the Service Manuals for minimum
missing or none missing. Any 3000/B vehicle with an MD-3060, MD-3560, thickness and maximum coning
300/B 400 model transmission may be B300, or 3000MH-Standard with an specifications. Do not reuse plates
updated from former C5 friction plates ECU calibration installed prior to that do not meet published
to current C5 frictions without October 25th, 1999 will require an
specifications. If reused plates are
recalibrating the transmission ECU. updated ECU calibration to use the
The rest of the clutches in the main current friction plates in C1, C2, C3, slightly coned (within
housing (C1 through C4) must be and C4. Do not intermix both former specification), make sure each plate
updated with current friction plates if and current friction plates in a clutch is stacked with the cone facing the
any other individual clutch besides C5 pack. same direction.
is updated from former to current
friction plates. The MD-3066, A. Inspect reaction plates for C. Inspect reaction plate tangs
3000MH-High, and B400 do not excessive wear, warping, coning for damage. Replace the plate if
require recalibration for updating to and surface damage. Replace any damage cannot be repaired using a
current friction plates. Any WTEC II plate with wear exceeding service soft stone or crocus cloth.
ECU equipped vehicle with an MD- limits or with damage which
A. Springs
A. Valves
J. Oil Level
Sensor
Current Former
16 ALLISON TRANSMISSION TECHNICIANS’ GUIDE Stop Stop
2005 General Motors Corporation.
Supersession Information
Suction Filter Redesign -
SIL 1-WT-00 ALLISON 3000 / B 300 / B 400 PRODUCT FAMILIES
Replace the (continued) CONTROL MODULE
assembly
during
overhaul. Identification
C4 Pressure Detail
Feed C5 Pressure
Through C3 Pressure
Harness Oil Level
Lube Sensor
Pressure Stationary
Valve Body
Turbine Speed
Sensor
Main Valve
Supersession Information Body
Suction Main
Filter Pressure
Rotating
Valve Body Converter
Out
Lube Filter
Bore Pump C2 Pressure
Suction “To Cooler” Port
Kit must be used when “From Lube
Cooler” Pressure Coverter In
replacing former sensor
Port
with current sensor. C1 Pressure
E. Replace or repair the control Manual TS2470EN or design sump temperature sensor.
module wiring harness if the Troubleshooting Manual Sensor resistance specifications
wires, terminals or connectors are TS2973EN. differ between the former and
visibly damaged. On transmissions current designs. Be sure to use the
built after S/N 6510096671, inspect NOTE: Transmissions built prior to correct resistance specification
the molded harness channel for S/N 6510141464 used the former chart for the sensor being checked.
cracks or breaks. Replace the (continued)
harness if the
molded channel is 2-Inch Control
damaged. Check Module
sump temperature
sensor resistance
following the
guidelines and
specifications 4”
listed in Service
Manual
SM2148EN, 4-Inch
Troubleshooting Control
Module Main 2”
Pressure Tap
“From
“To Cooler” Port Lockup Pressure
Cooler”
Tap
Port
Main Filter
Bore
Main
Lube Pressure
Filter Tap
Bore
C4
C1 Pressure
Pressure Tap
Tap
C3
Pressure
Tap
C5
Pressure
Tap
Main C2
Drain Pressure Pressure
Plug Tap Tap
F, G, H. Valves, valve body bores NOTE: Do not use impact guns (air
Supersession Information
and oil passages must be free of wrenches, electric impact wrenches,
debris, nicks, burrs, scoring and etc.) when working with aluminum Internal Wiring Harness Design -
galling. Valves should move freely in threads or when torque sequencing SIL 7-WT-04, Rev. A
their bores, when dry, under their bolts.
own weight. Repair or replace valves
Replace valve springs which are
and/or valve bodies failing to meet
broken, permanently set or worn due
these requirements.
to rubbing adjacent parts. Reference
Valve body machined surfaces must the Spring Data Charts in the Service
be free of debris, nicks, burrs and Manual for spring specifications and
scoring. Light stoning of these identification.
machined surfaces is permitted to
Valve stops and retention pins must
correct minor defects. Replace any
not be damaged or battered. Replace
valve body that cannot be repaired.
valve stops or pins which have
Inspect all threaded holes for damage that cannot be removed
damage and debris. Replace the valve using a soft stone or crocus cloth.
Current standoff base is taller
body if the thread damage cannot be (continued) and made of composite
repaired.
material rather than aluminum.
Feed
Through
Harness
Feed
Through
Stand-Off
C3 Pressure A Solenoid (C1)
Switch
Turbine
Dust Seal Speed Sensor
O-Ring Seal
D Solenoid
(C4)
F Solenoid
(Lockup) C Solenoid
(C3)
B Solenoid
(C2)
Sump
G Solenoid Temperature E Solenoid Oil Level
(C2 Latch) Sensor (TID 2, 3) (C5) Sensor
Rotating
B Solenoid Clutch Valve
(C2) Body
Accumulator
Relay Valve
F Solenoid
(Lockup) C3
Pressure
Switch
A Solenoid
(C1)
D Solenoid
(C4)
C Solenoid
(C3)
Solenoid Solenoid
Regulator Regulator
Valves Springs
E Solenoid (continued)
(C5)
Identification Detail:
Main Valve Body Assembly
Lube Regulator
Valve Spring
Lockup
Lube Regulator Valve Spring
Valve
Converter
Converter Lube Regulator
Regulator Lockup
Regulator Valve Stop
Converter Spring Valve
Valve
Regulator Lockup
Valve Stop Valve Stop
C1 Latch Main
Valve Spring Regulator
Valve Stop
C1 Latch
Valve Stop C1 Latch Valve
B. Converter
A. Converter
Pump Hub
Pump Exterior
B. Converter
Pump Hub
Model
Identifiers Inspect the pump hub tangs for cracks,
(see chart) impact damage and broken tangs.
A. Inspect the converter pump NOTE: Do not use crocus cloth on NOTE: Pump hub tang breakage or
exterior for dents and sealing the converter pump hub. Polishing deformity accompanied by charging
surface damage. Replace the the hub with crocus cloth can cause pump bushing failure and ground
converter pump if damage cannot improper input seal performance sleeve wear is often caused by poor
be remove with a soft stone or resulting in fluid leakage. (continued)
crocus cloth. 3000 Product Family Torque Converter Identification Chart
B. Inspect the converter pump Torque Converter TC-421 TC-419 TC-418 TC-417 TC-415 TC-413 TC-411
Model Designation
hub for damage and excessive wear.
Front Cover Sticker Pink Yellow Green Orange Blue Brown White
Minimum pump hub diameter is and Converter Paint
74.999 mm (2.9527 inch). Inspect Dot Color (Exterior
the pump hub tangs for cracks, Marker)
impact damage or broken tangs. Engraved Letter A A B B C D E
Identifiers (Torus Ring
Maximum allowable tang step wear of Converter Pump)
is 0.38 mm (0.015 inch). On PTO- Ink Stamped Letter
equipped models, check the (Exterior of Converter
Pump)
splines inside the hub for wear and
Number of Stator 17 19 17 19 19 19 19
damage. Maximum spline wear is Blades
0.38 mm (0.015 inch). Paint Dot Color on Pink None Yellow None None None None
Stator
22 ALLISON TRANSMISSION
2005 General Motors Corporation.
Supersession Information ALLISON 3000 / B 300 / B 400 PRODUCT FAMILIES
Converter Plug and Front TORQUE CONVERTER MODULE
Cover Update - SIL-21-WT-98 (continued)
F. Flexplate
Adapter
C. Front
Cover
E. Ring Mounting
Gear Face
transmission fluid condition due to correct turbine shaft selective shim NOTE: The flexplate adapter bolt
improper maintenance intervals. is installed following the Service holes use Spiralock® threads
Observation of proper fluid change Manual procedures. starting with S/N 6510024410. A
intervals is key to optimum Spiralock® tap must be used when
transmission life. E. Inspect the engine starter ring repairing damaged threads. Using a
gear for chipped, worn or broken standard tap will destroy the
C. Inspect the torque converter teeth.
front cover mounting faces for locking feature. If this occurs, the
damage. Inspect the flexplate F. Inspect the flexplate adapter torque converter front cover must
adapter bolt holes for stripped or mounting faces for surface damage. be replaced.
(continued)
damaged threads. Replace the adapter if damage
cannot be repaired using a soft
D. Inspect the front cover pilot stone or crocus cloth. Inspect the
for damage and wear. Maximum flexplate adapter bolt holes for
pilot diameter is 50.914 mm (2.004 stripped or damaged threads. Clean
inches). Inspect the torque damaged threads using the
converter end plug and the correct size tap. Replace the
retaining bolt for stripped or adapter if damage cannot be
damaged threads. Verify that the repaired.
A. Converter
Pump Interior
Vanes
B. Torus
Ring
C. Sealring
Area
D. Turbine Hub
B. Torus
Ring
C. Rivets
E. Splines
Turbine
Assembly
Turbine A. Converter Exterior
Assembly Turbine
Interior Blades
A. Inspect the converter turbine E. Inspect the hub splines for (0.015 inch). Replace the turbine
assembly. Replace the assembly if damage and wear. Spline movment assembly if splines are excessively
the blades are cracked, broken or between the lockup damper and worn.
(continued)
loose. turbine hub cannot exceed 0.38 mm
B. Inspect the torus ring. Replace
the turbine assembly if the torus
ring is loose or cracked.
C. Inspect the rivets. Replace the
turbine assembly if the rivets are
loose or cracked.
D. Inspect the converter turbine
hub. Replace the converter turbine
assembly if the hub is worn beyond
limits. Minimum allowable hub
diameter is 61.34 mm (2.415 inches). Inspect the hub splines and
Inspect the sealring groove for rivets for damage and wear.
damage.
C. Lockup
B. Bushing A. Sealring Clutch F. Thrust
Bore Piston Bearing
Front
Cover
D. Backplate
Supersession Information
Lockup Damper Update
SIL-8-WT-98, Rev. B
E. Lockup
Inspect sealring bore Damper
and bushing.
A. Inspect the interior of the C. Inspect the lockup clutch distortion is 0.51 mm (0.020 inch).
front cover for damage and wear to piston for damage. Minimum Maximum allowable movement
the lockup damper and thrust allowable piston thickness is 5.71 between the damper and converter
bearing surfaces. Replace the front mm (0.225 inch). turbine splines is 0.38 mm (0.020
cover if damage cannot be repaired D. Inspect the lockup clutch inch). Replace the damper if any of
using a soft stone or crocus cloth. backplate for damage. Minimum these measurements are beyond
allowable plate thickness is 8.58 allowable limits.
Inspect for wear or grooving in the
mm (0.338 inch). Replace the NOTE: The current lockup damper is
turbine sealring bore located in the
backplate if it does not have a not compatible with WTEC II
front cover. Install a new turbine transmissions that had the former
usable wear surface.
sealring in the bore and measure the lockup damper only when the
NOTE: If the backplate is within
sealring inside diameter. Replace calibration date of the ECU is prior to
thickness limits but has surface damage
the cover assembly if diameter September of 1997. Updating those
due to metal transfer between the
exceeds 56.75 mm (2.234 inches). WTEC II ECU calibrations prior to
backplate and lockup damper, the plate
September 1997 will allow the current
B. Inspect the converter cover may be reused by turning it over so that
lockup damper to be used in place of the
the lockup damper has a new contact
bushing for wear that exceeds former lockup damper.
surface.
service limits. Maximum allowable F. Inspect the thrust bearing
E. Replace the lockup clutch
bushing inside diameter is 61.51 mm following the "General Inspection
damper if the friction surfaces are
(2.422 inches). Replace the bushing Guidelines for Bearings" section of
worn beyond service limits.
if it has damage which cannot be this manual. Replace the thrust
Minimum allowable friction surface
removed using a soft stone or bearing if it fails any of these
thickness is 8.05 mm (0.317 inch).
crocus cloth. inspection procedures. (continued)
Maximum allowable damper
26 ALLISON TRANSMISSION TECHNICIANS’ GUIDE
2005 General Motors Corporation.
ALLISON 3000 / B 300 / B 400 PRODUCT FAMILIES
(continued) TORQUE CONVERTER MODULE
D. Star E. Thrust
Washer Washer
F. Thrust
Bearing
A. Stator Race
B. Stator
Springs C. Stator
Rollers H. Stator G. Stator
Cam F. Thrust Thrust Plate
I. Roller
Assembly Bearing
Pockets
A. Inspect the stator race for E. Inspect the stator thrust H. Inspect the stator and cam
damage. Replace the race if damage washer for wear beyond service assembly for damage. Replace the
cannot be repaired using a soft limits. Replace the stator thrust stator and cam assembly if
stone or crocus cloth. washer it is worn 0.40 mm (0.010 damaged.
inch) or more. If it is within service
B. Inspect the stator springs for limits, the thrust washer can be NOTE: Use care when cleaning the
correct spring height following per turned over and the un-worn stator and cam assembly. Hot tank
the Service Manual. Replace any surface can be used. temperatures may be high enough
spring which is beyond service to release the cam assembly from
F. Inspect the thrust bearings
limits. following the "General Inspection the stator.
C. Inspect the stator rollers for Guidelines for Thrust Bearings" I. Inspect the stator roller
damage. Rollers should be smooth, section of this manual. Replace any pockets for wear and damage.
round and defect-free. Replace thrust bearings failing these Verify correct spring-to-roller
inspection procedures.
damage or worn rollers. orientation. Inspect the bottom of
G. Inspect the stator thrust plate the cam pocket for wear. Replace
D. Inspect the star washer for for damage and wear. Replace the the stator and cam assembly if it is
excessive wear. Replace the star plate if damage cannot be removed worn 0.40 mm (0.010 inch) or more
washer if damage cannot be using a soft stone or crocus cloth. in the bottom of the pocket.
repaired using a soft stone or Minimum allowable plate thickness (continued)
crocus cloth. is 11.68 mm (0.460 inch).
C. Speed
Sensor &
Bore
D. Bearing
Bore
B. Breather
A. Inspect for torque converter C. Replace the speed sensor if the E. Inspect the PTO bearing
housing damage. High spots may be sensor body or electrical terminals retainer mounting face surface
removed with crocus cloth or a soft are damaged. Speed sensor and threads for damage. Replace
stone. Inspect threaded holes for resistance is 300 ohms (plus or the housing if surface damage
debris and thread damage. Replace minus 30 ohms). cannot be repaired using a soft
the torque converter housing if it is stone or crocus cloth. Replace the
cracked, if it leaks from a damaged D. On PTO-equipped models, housing if thread damage cannot be
machined surface, or if it has thread inspect the converter housing repaired.
bearing bore for wear. Maximum (continued)
damage which cannot be repaired.
allowable bearing bore inside
B. Inspect the breather for diameter is 140.03 mm (5.513
damage and obstructions. Replace inches).
the breather if it is damaged. Clean Replace the Torque
Converter
the breather if it is blocked with housing if Housing
debris. damage (Non-PTO)
cannot be
repaired
using a soft
stone or
crocus cloth.
Torque Converter
28 ALLISON TRANSMISSION TECHNICIANS’ GUIDE
2005 General Motors Corporation.
Housing (PTO)
ALLISON 3000 / B 300 / B 400 PRODUCT FAMILIES
(continued) TORQUE CONVERTER HOUSING MODULE
L. PTO Drive
Gear Bearings
Bearing
Retainer
K. Splines
F. PTO Drive
Assembly
Bearing Retainer
Housing Bore
H. Oil Pump
Drive Hub
I. PTO Gear
Teeth
F. On PTO-equipped models, G. Inspect the retainer housing I. Inspect the PTO drive gear
inspect the PTO drive bearing bushing for damage and wear. teeth for chips, pitting and
retainer housing bore for damage. Replace the bushing if damaged. excessive wear. Replace the gear if
Replace the retainer if damage Maximum allowable bushing inside damage cannot be repaired using a
cannot be repaired using a soft diameter is 75.23 mm (2.962 soft stone or crocus cloth.
stone or crocus cloth. Replace the inches). Replace the bushing if it is
NOTE: Some axial movement fo the
retainer housing if the bushing has worn beyond service limits.
spun in the bushing bore. gear is normal, but movement
should not exceed 3.175 mm (0.125
H. Inspect the oil inch). Replace the PTO bearings if
G. Bushing pump drive hub. axial movement exceeds service
F. Bearing
Bore Replace the drive hub limit.
if damage cannot be
NOTE: Normal operating backlash
repaired using a soft
stone or crocus cloth. after the PTO is installed is 0.1 mm
to 0.66 mm (0.004 to 0.026 inch).
(continued)
K. Splines
I. PTO
Gear
Teeth
J. Inspect the oil pump drive hub K. Inspect the drive hub splines L. Inspect the PTO drive gear
tangs for step wear, deformation for wear. Replace the drive hub if bearings following the "General
and cracks. Replace the drive hub if spline wear exceeds 0.38 mm Inspection Guidelines for Bearings"
tang step wear exceeds 0.38 mm (0.015 inch). section of this manual. Replace
(0.015 inch) or if either tang is either bearing as needed.
deformed or cracked.
NOTE: Drive hub tang breakage or
deformity accompanied by charging
pump bushing failure and ground
J. Examine
sleeve wear is often caused by poor the oil pump
transmission fluid condition due to drive tangs
improper maintenance intervals. for excessive
Observation of proper fluid change battering.
intervals is key to optimum
transmission life.
D. Spring
Pack
E. Retaining
Ring
F. Clutch
3000 Series Close Ratio 3000 Series Wide Ratio
Plates
P3 Carrier Assembly P3 Carrier Assembly
A. Inspect the output speed repaired using a soft stone or crocus Service Manual SM2148EN for
sensor for damage. Replace any cloth. Replace the rear cover if it is spring specifications and
sensor that has body, terminal or cracked. identification.
connector seat damage. Allowable
C. Inspect the C5 clutch piston E. Replace the C5 retaining
output speed sensor resistance is
following the "General Inspection ring if it is bent or distorted.
300 ohms plus or minus 30 ohms.
Guidelines for Cast Parts and
(continued)
B. Inspect the rear cover Machined Surfaces" section of this
following the "General Inspection manual. Replace the piston if it fails Oil Passage
Guidelines for Cast Parts and to meet the inspection guidelines. Detail
Machined Surfaces" section of this Inspect the C5 piston tang for
manual. High spots on machined excessive wear.
surfaces can be removed using a
soft stone or crocus cloth. Inspect D. Inspect the C5 clutch spring
the slot on the back side of the pack for wear due to rubbing
housing where the C5 piston tang adjacent parts and cracked or C5 Pressure
indexes for excessive wear. Replace broken pieces. Check springs for
the rear cover if damage to any wear, breakage and damage.
machined surface cannot be Reference the Spring Data Charts in
F. Clutch
Plates
Current C5 Friction
Plate - missing
two splines.
Former C5 Friction
Plate - one or no
missing splines.
F. Inspect the C5 friction clutch Discard any plates that do not meet C5 is updated from former to current
plates following the “General the guidelines. Minimum allowable friction plates. The MD-3066,
Inspection Guidelines for Friction thickness for reuse is 2.41 mm 3000MH-High, and B400 do not
Plates” section of this manual. (0.095 inch). Maximum cone for require recalibration for updating to
Discard any plates that do not meet reuse is 0.40 mm (0.016 inch). current friction plates. Any WTEC II
ECU equipped vehicle with an MD-
the guidelines. Minimum allowable
NOTE: The current clutch friction 3060, MD-3560, B300, or 3000MH-
thickness for reuse is 2.90 mm Standard with former friction plates
plates were implemented April of
(0.114 inch). Minimum oil groove will require a new ECU calibration
2000 starting with s/n 6510262117.
depth for reuse is 0.20 mm (0.008 Current production friction plates from Allison Transmission to use the
inch). Maximum cone for reuse is will have two missing splines. current friction plates in C1, C2, C3
0.40 mm (0.016 inch). Former friction plates will either and C4. Any WTEC III ECU
have one spline missing or none equipped vehicle with an MD-3060,
NOTE: Battered and worn spline missing. Any 3000/B 300/B 400 MD-3560, B300, or 3000MH-
teeth may be an indicator of model transmission may be updated Standard with an ECU calibration
driveline issues. Replace the clutch from former C5 friction plates to installed prior to October 25th, 1999
plates and check the driveline. current C5 frictions without will require an updated ECU
recalibrating the transmission ECU. calibration to use the current friction
Inspect the C5 reaction clutch The rest of the clutches in the main plates in C1, C2, C3, and C4. Do not
plates following the "General housing (C1 through C4) must be intermix both former and current
Inspection Guidelines for Reaction updated with current friction plates friction plates in a clutch pack.
Plates" section of this manual. if any other individual clutch besides (continued)
A. P3 Carrier Assembly
Current indexing
(Non-Retarder)
ring has stamped
star identifier.
K. Output Shaft
D. Indexing
Ring
DIMENSION A
DRILLED
IDENTIFICATION
HOLE
B. Output
Q. Output Shaft Speed
Sensor
V06961
Wheel
Current spindle has drilled
identification hole. C. Tapered Roller
G. Pinion H. Pinion Roller Bearing
Gear Bearings
E. Spindle
J. Output Shaft F. Thrust
Bearing races External I. Output Washers
located in rear cover. Retaining Shaft Spacer
Ring
A. Verify a proper press fit spindle has more than 0.051 mm C. Inspect the tapered roller
between the P3 carrier and rear (0.002 inch) clearance in the bore. bearings and races following the
cover or retarder housing by Inspect for thread damage on the "General Inspection Guidelines for
inverting the carrier over a table or carrier hub. Replace the carrier if Bearings" section of this manual.
workbench. If the P3 carrier falls threads are damaged. Replace any bearings failing to meet
the inspection guidelines. Bearing
out of the rear cover or retarder
Replace the output speed signal races are located in the rear cover
housing without using a press or housing and should also be
mallet, the press fit between the wheel roll pin if it is bent, broken,
loose in the housing or damaged in inspected for wear and damage.
tapered bearings and P3 carrier no (continued)
longer exists and the carrier must any way. Replace the carrier if a
be replaced. new roll pin is loose in the bore. Supersession Information
Inspect the P3 carrier for spline B. Inspect the output speed P3 Carrier Update -
wear. Replace the carrier if spline signal wheel following the "General SIL 8-WT-98, Rev B.
wear exceeds 0.38 mm (0.015 inch). Inspection Guidelines for Cast
Inspect the pinion spindle bores in Parts and Machined Surfaces"
the carrier and the pinion thrust section of this manual. Discard and
surfaces for excessive wear and replace the tone wheel if the teeth
damage. Replace the P3 carrier if a are damaged in any way or if the
keyway shows signs of battering.
Current P3 carriers are identified
by machined grooves
IANS’ G onU the
I D E 33
back face of General
2005 the carrier hub. 3 3
Motors Corporation.
ALLISON 3000 / B 300 / B 400 PRODUCT FAMILIES
STANDARD REAR COVER AND
P3 PLANETARY MODULE (continued)
No damage,
wheel can
be reused. Excessive damage:
this may be an
indication of driveline
issues - replace wheel.
D. Inspect the P3 indexing ring (0.054 inch). Replace damaged or I. Replace the output shaft
for step wear in the area where it worn thrust washers. spacer if it is bent, cracked or if it is
contacts the spindle. Replace the distorted in any way. An attempt
indexing ring if it is broken or if it G. Inspect the pinion gears can be made to repair some minor
has excessive step wear. Indexing following the "General Inspection damage using a soft stone. (continued)
rings with acceptable wear can be Guidelines for Gears" section of this
flipped during reassembly so that a manual. Replace any gears which
fail these inspection procedures or Replace the
new contact surface is used. output speed
if the damage cannot be repaired
signal tone
E. Inspect planetary spindles for using a soft stone.
wheel pin if it
wear and damage. Discoloration is
H. Inspect the pinion roller is bent, broken
only a concern if spindle surface or damaged in
damage exists. bearings following the "General
any way.
Inspection Guidelines for Bearings"
F. Inspect the pinion gear thrust section of this manual. Replace any
washers for damage, distortion and bearings which fail these inspection
excessive wear. Minimum allowable procedures.
thrust washer thickness is 1.39 mm
J. Inspect the output shaft K. Inspect the output shaft M. Replace the L. Locknut
external retaining ring. Replace following the "General Inspection output bearing Retainer
the retaining ring if it is distorted Guidelines for Cast Parts and locknut if it is
or fits loosely on the shaft. Machined Surfaces" and the cracked,
"General Inspection Guidelines for distorted, has
Splines" sections of this manual. damaged
K. Inspect the Replace the output shaft if it fails threads or has
output shaft these inspection procedures. damage to the
bushing for tangs where the
Inspect the output shaft bushing
damage. removal and M. Output
following the "General Inspection
Guidelines for Bushings" section of installation tool Bearing
this manual. Replace the bushing if indexes. An Locknut
it fails these inspection procedures. attempt can be
Maximum allowable bushing inside made to repair
diameter is 20.19 mm (0.795 inch). slight
L. Replace the output bearing imperfections
locknut retainer whenever the using a soft
locknut is removed. stone.
D. Flow Valve
Plug &
Retaining
Ring
B. Retarder
Rotor
E. Retarder
C. Stator Autoflow Valve,
Housing Spring and Plug
A. Inspect the retarder housing area. Replace the housing if sealring C. Inspect the stator housing
following the "General Inspection inside diameter is greater than 95.67 following the "General Inspection
Guidelines for Cast Parts and mm (3.767 inches). Guidelines for Cast Parts and
Machined Surfaces" section of this Machined Surfaces" section of this
manual. High spots on machined B. Inspect the retarder rotor manual. A bearing race fits into the
surfaces can be removed using a following the "General Inspection housing and should be inspected for
soft stone or crocus cloth. Replace Guidelines for Cast Parts and damage. Some light housing
the retarder housing if it is cracked Machined Surfaces" section of this imperfections can be removed using
or if machined surface damage manual. Check for loose, cracked or a soft stone. Discard and replace the
cannot be removed using a soft broken rivets. Replace the rotor if housing if damage is excessive.
stone or crocus cloth. movement exists between the
center hub and the vaned assembly. NOTE: Transmissions built prior to
Install a "known good" rotor Inspect the rotor splines for wear. January 1998 included two small
sealring in the retarder housing and Spline wear cannot exceed 0.38 mm check balls and retainers located in
measure sealring inside diameter. If (0.015 inch). Replace the rotor if it the retarder stator housing.
the retarder housing is slightly exceeds this wear limit. Minimum allowable check ball
grooved or worn, place the sealring movement is 0.50 mm (0.020 inch).
directly in the grooved or worn (continued)
Oil Passage
Details
C5
Pressure
Exhaust
Exhaust Exhaust
Inspect the slot on the back side of E. Inspect the retarder autoflow
the housing where the C5 piston valve for wear and damage. The
tang indexes for excessive wear. autoflow valve must move freely in
Replace the stator housing if its bore, when dry, under its own
damage to any machined surface weight. Replace or repair the
cannot be repaired using a soft autoflow valve and/or retarder
stone or crocus cloth. Replace the housing as necessary. Crocus cloth
stator housing if it is cracked. can be used to remove slight high
spots.
D. Inspect the valve plugs and
retaining rings. Replace damaged Inspect the autoflow valve spring
valve plugs. Replace damaged or for defects and permanent set.
distorted retaining rings. Reference the Spring Data Charts in
Service Manual SM2148 for spring
specifications and identification.
Replace the spring if it fails any
inspection procedures.
(continued)
Oil Passage
Detail
Exhaust
Main
Pressure
Exhaust
Control Main
E. To Retarder
(Retarder On) To
Lube (Retarder Off)
F. From Retarder
(Retarder On) From
Converter (Retarder Off) Supersession Information
Sump Cooling Feature - SIL 13-WT-00
A. Retarder
Control
Body
D. Plug
E. Relay
Valve
Spring
F. Relay
Valve
H. Retarder
Control
I. Charge Valve
G. Charge Pressure
Pressure
Port Plug
J. Plug Spring
A. Inspect the retarder control resistance between each solenoid rubbing adjacent parts. Reference
valve body following the “General terminal and the solenoid body. the Spring Data Charts in Service
Inspection Guidelines for Cast Replace the solenoid if either Manual SM2148EN for spring
Parts and Machined Surfaces” reading is less than 100k ohms specifications and identification.
section of this manual. All passages resistance.
must be clean and debris free. Valve F, H. Inspect the retarder
bores must be free of nicks, burrs C. Replace the retarder valve control valve and relay valve for
and scoring. Crocus cloth or a light body wiring harness if the wires, nicks, burrs, scoring and other
stone can be used to attempt terminals or connectors are visibly damage. A soft stone or crocus cloth
removal of slight irregularities, damaged. Check the installed can be used to attempt removal of
however no honing of any kind is harness for tight bends or crimps slight irregularities. Valves must
permitted. which might damage harness wires. move freely in their bores, when
dry, under their own weight.
B. Replace the retarder solenoid D, G, J. Replace any valve plug
if the body, connector or terminals which is cracked or has stripped or K. Inspect the separator plate for
show visible signs of damage. damaged threads. nicks, burrs, scoring and distortion
Solenoid resistance should be 3 to 4 (flatness). Replace the plate if
E, I. Replace any valve springs damage cannot be repaired using a
ohms measured between the two which are broken, cracked,
solenoid terminals. Check light stone or crocus cloth.
permanently set or worn due to (continued)
Retarder
Pressure
Control
Main
Main
Pressure
Exhaust
Main
Pressure
NOTE: Retarders built prior to S/N NOTE: Reference SILs 1-WT-98, NOTE:Transmissions built prior to
6510021203 included a retarder Rev A. and 13-WT-00 for retarder S/N 6510141464 used the former
signal valve located under the flow update details. design retarder temperature sensor.
valve plug. Inspect the signal valve Pre and post-serial number sensor
NOTE: Retarders built prior to
for nicks, burrs and scoring. resistance specifications differ. Be
Replace valves if damage cannot be January 1998 included a retarder sure to use the appropriate
repaired using a soft stone or crocus valve body channel plate. Inspect the specification chart for the sensor
cloth. The valve must operate in the channel plate following the “General being checked.
bore smoothly without sticking or Inspection Guidelines for Cast and
hanging. Machined Parts” section of this
manual. Replace the valve body if it
fails any of these inspection
procedures. All channel plate
passages must be clean and debris
free.
H. P3 Sun
Gear
D. Thrust
Bearings
G. Selective
F. Bearing Shim
Spacer
E. P2 Sun B. Main
Gear Shaft
Pilots
D. Thrust
Bearing
I. Spiral
Retaining
Ring
A. Main
B. Main Shaft
Shaft
C. Journal
Pilots
A. Inspect the main shaft journal diameter is less than 42.97 and Machined Surfaces" and
following the "General Inspection mm (1.692 inch). “General Inspection Guidelines for
Guidelines for Gears" and "General D. Inspect the thrust bearings
Splines” sections of this manual.
Inspection Guidelines for Splines" following the "General Inspection Replace the spacer if it fails any of
sections of this manual. Replace the Guidelines for Bearings" section of these inspection procedures.
main shaft if it fails any of these this manual. Replace any bearing G. Inspect the selective shim for
inspection procedures. that fails any of these inspection damage and distortion. Replace the
B. Inspect the front and rear procedures. shim if it is distorted or if damage
main shaft pilots for damage. The E. Inspect the P2 sun gear
cannot be removed by light stoning.
front main shaft pilot fits inside the following the "General Inspection H. Inspect the P3 sun gear
turbine shaft. The rear main shaft Guidelines for Gears" and "General following the "General Inspection
pilot fits inside the output shaft. Inspection Guidelines for Splines" Guidelines for Gears" and "General
Replace the main shaft if pilot sections of this manual. Replace the Inspection Guidelines for Splines"
outside diameter is less than 19.98 gear if it fails any of these inspection sections of this manual. Replace the
mm (0.787 inch). procedures. gear if it fails any of these
C. Inspect the P2 bushing journal inspection procedures.
F. Inspect the main shaft bearing
area for damage. Replace the main spacer following the "General I. Replace the spiral retaining
shaft if the P2 planetary bushing Inspection Guidelines for Cast Parts ring if it is removed.
C. Journal
B. Main Shaft
Pilots
A. Main Shaft
E. Thrust
G. Selective Bearing
Shim
F. Bearing
Spacer
E. Thrust
D. P2 Sun Bearing
H. Spiral Gear
Retaining
Ring
A. Inspect the main shaft C. Inspect the P2 bushing journal F. Inspect the main shaft bearing
following the "General Inspection area for damage. Replace the main spacer following the "General
Guidelines for Gears" and "General shaft if P2 planetary bushing Inspection Guidelines for Cast
Inspection Guidelines for Splines" journal diameter is less than 42.97 Parts and Machined Surfaces"
sections of this manual. Replace the mm (1.692 inch). “General Inspection Guidelines for
main shaft if it fails any of these Splines” sections of this manual.
D. Inspect the P2 sun gear
inspection procedures. Replace the spacer if it fails any of
following the "General Inspection
these inspection procedures.
B. Inspect the front and rear Guidelines for Gears" and "General
main shaft pilots for damage. The Inspection Guidelines for Splines" G. Inspect the selective shim for
front main shaft pilot fits inside the sections of this manual. Replace the damage and distortion. Replace the
turbine shaft. The rear main shaft gear if it fails any of these shim if it is distorted or if damage
pilot fits inside the output shaft. inspection procedures. cannot be removed by light stoning.
Replace the main shaft if the pilot
E. Inspect the thrust bearings H. Replace the spiral retaining
outside diameter is less than 19.98
following the "General Inspection ring if it is removed.
mm (0.787 inch).
Guidelines for Bearings" section of this
manual. Replace any bearing that fails
any of these inspection procedures.
D. P3 Ring A. P2 Planetary
Gear Carrier
B. Carrier
E. Index Bushing
Ring I. Pinion
Gear
C. Carrier
Hub
J. Retaining
Rings G. Pinion
Spindle
H. Pinion
Roller
Bearings
F. Pinion Thrust
Washers
Supersession Information
Planetary Spindle and
Indexing Ring Update -
SIL 15-WT-01. Both parts
are backward compatible.
Current indexing
ring has stamped
star identifier.
Q. Output Shaft
C. Index Ring
E. Pinion
Spindle
F. Pinion
Gear
D. Pinion
Thrust
H. Retaining Washers
Rings G. Pinion Roller
Bearings
Supersession Information
Current indexing
ring has stamped
star identifier. V06961
Current spindle has drilled
identification hole.
Q. Output Shaft
E. Index
Ring
B. Inspect the P1 ring gear D. Replace the pinion gear thrust G. Inspect the pinion roller
following the "General Inspection washers if they are damaged, bearings following the "General
Guidelines for Gears" and the distorted, galled or showing signs of Inspection Guidelines for Bearings"
"General Inspection Guidelines for excessive wear. Minimum allowable section of this manual. Replace any
Splines" sections of this manual. thrust washer thickness is 1.39 mm bearing failing these inspection
Replace the ring gear if it fails any (0.054 inch). procedures.
of these inspection procedures.
E. Replace planetary spindles if H. Inspect the P1 carrier retaining
C. Inspect the P1 indexing ring they are worn or damaged. rings for damage or distortion.
for step wear in the area where it Discoloration is only a concern if Replace any retaining rings with
contacts the spindle. Replace the spindle surface damage exists. damage that cannot be removed
indexing ring if it is broken or if it using a soft stone.
has excessive step wear or damage F. Inspect the P1 pinion gears
which cannot be repaired using a following the "General Inspection
soft stone or crocus cloth. Indexing Guidelines for Gears" section of this
rings with acceptable wear can be manual. Replace any gear that fails
flipped during reassembly so that a these inspection procedures or if
new contact surface is used. damage cannot be removed using a
soft stone.
E. Bushing
Journal
I. Roller
Bearing
B. Front
K. Charging Pump Support
Gear Set Sleeve
F. Charging
Pump
Housing I. Thrust
Bearing
C. Sealring
H. Main Grooves
Pressure
Relief Ball
& Spring
M. Wear Plate
L. Stiffening Plate
A. Inspect the front support procedures. If the ground sleeve has D. Inspect the ground sleeve
assembly following the "General rotated in the front support, replace following the "General Inspection
Inspection Guidelines for Cast Parts both components (the ground sleeve Guidelines for Splines" section of this
and Machined Parts" section of this and the front support assembly). If manual. Replace the shaft if it fails
manual. Replace the assembly if it the ground sleeve is replaced, check any of these inspection procedures.
fails any of these inspection the front support for flatness after
E. Inspect the journal area where
ground sleeve installation. Replace
the charging pump driven gear
G. Bushing the front support if it is more than
bushing rides. Replace the shaft if
0.051 mm (0.002 inch) from flat.
the journal is damaged or galled.
B. Replace the front support if the Minimum allowable journal diameter
sleeve has nicks, burrs or other is 57.04 mm (2.246 inch).
damage which cannot be repaired
NOTE: Ground sleeve galling is
using a soft stone or crocus cloth.
typically an indicator of poor
Minimum allowable front support
transmission fluid condition due to
sleeve diameter is 98.83 mm (3.891
improper maintenance intervals.
inches).
Observation of proper fluid change
C. Inspect the three sealring intervals is key to optimum
grooves on the front support transmission life.
Non-PTO Charging Housing assembly hub for nicks, burrs, cracks (continued)
and other damage.
ALLISON TRANSMISSION TECHNICIANS’ GUIDE 47
2005 General Motors Corporation.
ALLISON 3000 / B 300 / B 400 PRODUCT FAMILIES
FRONT SUPPORT & OIL PUMP MODULE (continued)
C1 Pressure
C2 Pressure
Lube
Pressure
Main
Pressure
Pump Main
Suction Pressure
Lockup
Pressure Converter In Lockup
Converter Converter
C2 C1 C1 C2 Pressure
Out Out
Pressure Pressure Pressure Pressure
Inspect the area in the ground sleeve F. Inspect the charging pump H. Replace the main pressure relief
where the turbine shaft sealrings ride housing following the "General check ball if it is chipped, nicked,
for grooves, scoring and other wear Inspection Guidelines for Cast Parts battered or damaged in any way.
or damage. Install new sealrings in and Machined Parts" section of this Inspect the main pressure relief
the ground sleeve and measure the manual. Replace the housing if it fails spring following the "General
end gap. If the ground sleeve is worn any of these inspection procedures. Inspection Guidelines for Springs"
or grooved, place the sealrings Replace the charging pump housing section of this manual. Replace the
directly in the grooves or worn area. if gear cavity depth exceeds 17.93 mm spring if it fails any of these
Maximum allowable sealring end gap (0.706 inch). Replace the charging
is 0.94 mm (0.037 inch). Replace the inspection procedures. Refer to the
pump housing if gear cavity diameter Spring Data Charts in Service
ground sleeve if any of the seal ring exceeds 127.30 mm (5.012 inch).
end gaps exceeds this specification. Manual SM2148EN for spring
G. Non-PTO models include a specifications and identification.
NOTE: When replacing the ground
bushing that fits in the front of the
sleeve, total shaft runout cannot I. The front support thrust
housing. Replace the bushing if it has
exceed 0.30 mm (0.012 inch) once it bearing fits on the back of the front
nicks, burrs, scoring or other damage
is pressed into the front support.On support assembly. Inspect this thrust
transmissions built prior to S/N which cannot be removed using
crocus cloth. Maximum allowable bearing following the "General
6510024410 the turbine shaft must Inspection Guidelines for Bearings"
also be replaced when replacing the bushing diameter is 75.23 mm (2.962
inches). (continued)
ground sleeve.
48 ALLISON TRANSMISSION TECHNICIANS’ GUIDE
2005 General Motors Corporation.
ALLISON 3000 / B 300 / B 400 PRODUCT FAMILIES
(continued) FRONT SUPPORT & OIL PUMP MODULE
Supersession Information
Redesigned Charging Pump
Gear Set - SIL 13-WT-04 Ground
sleeve oil
passage
detail.
Former Current
Arrow on front
support lines
up with flat on
ground sleeve.
C2
Lockup Pressure
Pressure
C1
Flat Lube Pressure
Pressure
section of this manual. Replace the bushing has spun in the gear. inch). The maximum allowable
bearing if it fails any of these Maximum allowable bushing inside clearance between the outer gear and
inspection procedures. diameter is 57.30 mm (2.256 inches). the pump housing is 0.36 mm (0.014
Minimum allowable outside inch).
J. The roller bearing fits inside the diameter of the outer gear is 126.95
back of the front support hub. L. The stiffening plate is used on
mm (4.998 inches).
Inspect this bearing following the 3066 and B400 models only. Replace
"General Guidelines for Bearings" NOTE: Install the pump gear set in the stiffening plate if it is bent, shows
section of this manual. Replace the the oil pump housing to perform the signs of overheating or if it has
bearing if it fails any of these following inspections and scoring, cracks or other damage
inspection procedures. measurements. which cannot be repaired using a soft
stone or crocus cloth.
K. Replace the charging pump gear Maximum allowable clearance
set if the sides, faces or gear teeth are between the installed gear set and M. Replace the wear plate if it is
damaged. Replace the gear set if the mounting face of the pump housing galled or moderately scored. Pay
inside gear shows damage or is 0.13 mm (0.005 inch). This is often particular attention to the area
battering where the converter pump referred to as pump gear side where the charging pump gear set
or PTO drive tangs index into the clearance. Maximum allowable gear rides. Minimum allowable wear plate
gear. Replace the gearset if the tooth tip clearance (the gap between thickness is 4.70 mm (0.185 inch).
a tooth on the outer gear and a tooth
on the inner gear) is 0.20 mm (0.008
L. C1 Clutch
H. Rotating Drum M. C2 Return Spring
E. Retaining Bolt Piston
Assembly
F. Shim I. Rotating
Clutch Hub
Non-PTO Model
T. C1 Drive
Hub
N. C2 Clutch O. C1 Return P. C1 R. C1
Q. C1 Clutch S. C1 Backing
Piston Spring Balance Pressure
Pack Plate
Assembly Piston Plate
V. Thrust
Bearing
U. C2 Drive V. Thrust
W. C2 Clutch Pack Y. P1 Sun Gear Bearing
Hub X. C2 Backing Plate
Assembly
K. Bushing
50 ALLISON TRANSMISSION TECHNICIANS’ GUIDE
2005 General Motors Corporation.
ALLISON 3000 / B 300 / B 400 PRODUCT FAMILIES
(continued) ROTATING CLUTCH MODULE
Supersession Information Supersession Information
C1 and C2 Friction Plate Turbine Shaft Update -
Update - SIL 4-WT-00, Rev. B. SIL 8-WT-98, Rev. B.
Groove
identifies
current
Current C2 friction plate - two turbine
missing splines. Previous shaft.
versions had one or no
missing splines.
Supersession Information
Rotating Clutch Hub Update - Former Current
SIL 8-WT-99, Rev. A (No Weld) (Weld)
E. Replace the torque converter drum if it fails any of these K. Inspect the rotating hub
retaining bolt if the threads are inspection procedures. Maximum bushing following the "General
distorted or damaged. allowable spline wear is 0.38 mm Inspection Guidelines for Bushings"
(0.015 inch). section of this manual. Replace the
F. Replace the selective turbine
I. Inspect the rotating clutch bushing if it fails any of these
shaft shim if it is damaged.
hub following the "General inspection procedures or if it has
G. Inspect the turbine shaft Inspection Guidelines for Cast damage which cannot be repaired
retaining ring following the Parts and Machined Surfaces" and using a soft stone or crocus cloth.
"General Inspection Guidelines for “General Inspection Guidelines for Maximum allowable bushing inside
Snap Rings" section of this manual. Splines” sections of this manual. diameter is 99.25 mm (3.907 inch).
Replace the retaining ring if it fails Replace the hub if it fails any of
any of these inspection procedures NOTE: The rotating clutch hub was
these inspection procedures.
or if the ring is bent, distorted or updated beginning with S/N
J. Inspect the area inside the hub 6510184386 (3060 and 3560 models)
shows other signs of damage.
where the front support sealrings and S/N 6510130438 (3066 and
H. Inspect the rotating drum ride for grooves and damage. B300/B400 models). The former
following the "General Inspection Install three new sealrings in the hub has no weld in the area shown.
Guidelines for Cast Parts and wear area of the bore and check The current hub is welded and
Machined Surfaces" and “General each seal's end gap. Replace the machined in the area shown.
Inspection Guidelines for Splines” rotating clutch hub if end gap
(continued)
sections of this manual. Replace the exceeds 1.44 mm (0.057 inch).
ALLISON TRANSMISSION TECHNICIANS’ GUIDE 51
2005 General Motors Corporation.
ALLISON 3000 / B 300 / B 400 PRODUCT FAMILIES
ROTATING CLUTCH MODULE (continued)
Rotating clutch
hub oil passage
detail.
C2 Pressure
C1 Pressure Supersession Information
C1 Piston Update - SIL 4-WT-00, Rev. B.
Current piston
is completely
interchangeable
with former.
Etched housing - do NOT use. FORMER CURRENT
L, N, P. Inspect the C1 clutch M, O. Replace the C1 and C2 NOTE: Battered and worn spline
piston, C2 clutch piston and C1 return spring assemblies if they teeth may be an indicator of
balance piston following the have a permanent spring set, wear driveline issues. Replace the clutch
"General Inspection Guidelines for due to rubbing adjacent parts or if plates and check the driveline.
Cast Parts and Machined Surfaces" they are cracked or broken.
section of this manual. Replace any NOTE: The current clutch friction
Reference the Spring Data Charts in
component if it fails any of these plates were implemented April of
Service Manual SM2148EN for 2000 starting with s/n 6510262117.
inspection procedures. spring specifications and Current production friction plates
NOTE: Aluminum castings (like identification. will have two missing splines.
clutch housings) can be etched by Former friction plates will either
Q, W. Inspect the C1 and C2
caustic parts cleaners and solvents. have one spline missing or none
clutch friction plates following the missing. Any 3000/B 300/B 400
Etched components are identified
"General Inspection Guidelines for model transmission may be updated
by a dull to dark gray color - not the
Friction Plates" section of this from former C5 friction plates to
bright finish of a normal machined
manual. Replace any plates failing current C5 frictions without
aluminum part. Etched components
are also identified by roughness in these inspection procedures. recalibrating the transmission ECU.
the piston seal surface which can Minimum allowable friction plate The rest of the clutches in the main
cause piston seals to abrade and thickness is 2.21 mm (0.087 inch). housing (C1 through C4) must be
result in low clutch apply pressure Minimum allowable oil groove updated with current friction plates
and transmission damage. Replace depth is 0.20 mm (0.008 inch). if any other individual clutch
Maximum allowable plate coning is besides C5 is updated from former
etched or damaged components.
0.40 mm (0.016 inch). (continued)
Supersession Information
C1 Backing Plate and Apply Plate Updates -
SIL 22-WT-98, Rev. A
to current friction plates. The MD- Inspect the C1 clutch reaction Current C1 backing plate minimum
3066, 3000MH-High, and B400 do plates following the "General allowable thickness is 8.25 mm
not require recalibration for Inspection Guidelines for Reaction (0.325 inch). Maximum allowable
updating to current friction plates. Plates" section of this manual. distortion of all plates is 0.15 mm
Any WTEC II ECU equipped Replace any plates failing these (0.006 inch).
vehicle with an MD-3060, MD-
inspection procedures. Minimum
3560, B300, or 3000MH-Standard NOTE: Transmissions built prior to
with former friction plates will allowable reaction plate thickness
is 2.41 mm (0.095 inch). Maximum S/N 6510164169 used two identical
require a new ECU calibration from C1 pressure plates. Transmissions
Allison Transmission to use the allowable reaction plate coning is
0.40 mm (0.016 inch). built after that used different plates.
current friction plates in C1, C2, C3
and C4. Any WTEC III ECU The current C1 apply pressure plate
equipped vehicle with an MD-3060, R, S. Inspect the C1 pressure (next to the C1 piston) is
MD-3560, B300, or 3000MH- plate and C1 backplate for flatness, approximately 2 mm thinner and has
Standard with an ECU calibration galling and other damage. Replace a different shape than the current C1
installed prior to October 25th, any plate with damage that cannot backplate (opposite end of the C1
1999 will require an updated ECU be removed using a soft stone or clutch pack). When replacing the
calibration to use the current crocus cloth. Former C1 pressure former pressure plates in a
friction plates in C1, C2, C3, and plate minimum allowable thickness transmission having the current
C4. Do not intermix both former is 6.25 mm (0.246 inch). Current C1 plates, both current plates must be
and current friction plates in a
apply plate minimum allowable used. Mixing former and current
clutch pack.
thickness is 4.25 mm (0.167 inch). plates will result in C1 clutch failure.
(continued)
ALLISON TRANSMISSION TECHNICIANS’ GUIDE 53
2005 General Motors Corporation.
ALLISON 3000 / B 300 / B 400 PRODUCT FAMILIES
ROTATING CLUTCH MODULE (continued)
T. Inspect the C1 drive hub Maximum allowable spline wear is for Splines” sections of this manual.
following the "General Inspection 0.38 mm (0.015 inch). Replace the assembly if it fails any
Guidelines for Cast Parts and of these inspection procedures or if
V. Inspect the thrust bearings
Machined Surfaces" and the it has damage which cannot be
following the "General Inspection
"General Inspection Guidelines for repaired using a soft stone or crocus
Guidelines for Bearings" section of
Splines" sections of this manual. cloth. Inspect the P1 sun gear
this manual. Replace any bearings
Replace the hub if it fails any of bushing following the "General
which fail any of these inspection
these inspection procedures. Inspection Guidelines for Bushings"
procedures.
Maximum allowable spline wear is section of this manual. Replace the
0.38 mm (0.015 inch). X. Inspect the C2 backing plate bushing if it fails any of these
for damage. Replace any plate with inspection procedures. Maximum
NOTE: Only the newest C1 drive
damage that cannot be removed allowable bushing inside diameter
hub is available for service. It is
using a soft stone or crocus cloth. is 68.22 mm (2.685 inches).
backwards compatible for units
without the newest C1 hub. Minimum allowable backing plate
Z. Inspect the retaining rings
thickness is 6.25 mm (0.246 inch).
following the "General Inspection
U. Inspect the C2 drive hub Check the plate for flatness.
Guidelines for Retaining Rings"
following the "General Inspection Maximum allowable distortion is
section of this manual. Replace any
Guidelines for Cast Parts and 0.45mm (0.018 inch).
retaining rings failing any of these
Machined Surfaces" and the
Y. Inspect the P1 sun gear inspection guidelines or if the rings
"General Inspection Guidelines for
assembly following the "General are distorted or have damage which
Splines" sections of this manual.
Inspection Guidelines for Gears" cannot be repaired using a soft
Replace the hub if it fails any of
and “General Inspection Guidelines stone or crocus cloth.
these inspection procedures.
54 ALLISON TRANSMISSION TECHNICIANS’ GUIDE
2005 General Motors Corporation.
ALLISON 3000/ B 300/ B 400 PRODUCT FAMILIES
C3 / C4 CLUTCH MODULE
Housing in good condition - reuse.
A. C3 Backplate B. P1 Ring
Assembly Gear
D. C4
Clutch
Housing
A. Inspect the C3 backplate allowable spline wear is 0.38 mm identifier) is compatible with the
assembly following the "General (0.015 inch). black wear plates. Do not change the
Inspection Guidelines for Cast Parts former P1 ring gear just because a unit
and Machined Surfaces" section of NOTE: The P1 ring gear end face grind has the black wear plates installed.
this manual. Replace the assembly if operation was eliminated starting Reference SIL 18-WT-04.
it fails any of these inspection with S/N 6610136125. The former P1
ring gear identifier was a groove C. Inspect the C3 clutch housing
procedures. Check the backplate
and wear plates for flatness. machined on the outside diameter of following the "General Inspection
Maximum allowable distortion is the gear. The current P1 ring gear does Guidelines for Cast Parts and
0.15 mm (0.006 inch). Minimum not have a groove on the O.D. The Machined Surfaces" section of this
current P1 ring gear is not compatible manual. Replace the housing if it
allowable wear plate thickness is
with aluminum wear plates riveted to fails any of these inspection
2.81 mm (0.111 inch).
the C3 housing and the clutch procedures. Check the housing for
B. Inspect the P1 ring gear backplate. If the former P1 ring gear is flatness. Maximum allowable
following the "General Inspection replaced with the current P1 ring gear distortion is 0.15 mm (0.006 inch).
Guidelines for Gears" and General and the unit has aluminum wear Check the wear plates for flatness.
Inspection Guidelines for Splines" plates, then the wear plates must be Maximum allowable distortion is
sections of this manual. Replace the updated to the current wear plates 0.15 mm (0.006 inch). Minimum
ring gear if it fails any of these that are black in color. The former P1 allowable wear plate thickness is
inspection procedures. Maximum ring gear (with the O.D. groove 2.81 mm (0.111 inch).
(continued)
NOTE: Aluminum castings (like procedures. Check the housing for F. Inspect the C3 and C4 clutch
clutch housings) can be etched by flatness. Maximum allowable piston return plate assemblies
caustic parts cleaners and solvents. distortion is 0.15 mm (0.006 inch). following the "General Inspection
Etched components are identified by Guidelines for Reaction Plates"
a dull to dark gray color - not the E. Inspect the C3 and C4 spring section of this manual. Minimum
bright finish of a normal machined retainer assemblies following the allowable plate thickness is 3.41 mm
aluminum part. Etched components "General Inspection Guidelines for (0.135 inch). Maximum allowable
are also identified by roughness in Cast Parts and Machined Surfaces" plate coning is 0.40 mm (0.016 inch).
the piston seal surface which can section of this manual. Inspect the Replace springs which are cracked,
cause piston seals to abrade and assemblies for wear due to rubbing broken or permanently set.
result in low clutch apply pressure adjacent parts and cracked, broken Reference the Spring Data Charts in
and transmission damage. Replace or permanently set springs. Service Manual SM2148EN for
etched or damaged components. Reference the Spring Data Charts in spring specifications and
Service Manual SM2148EN for identification.
D. Inspect the C4 clutch housing (continued)
spring specifications and
following the "General Inspection
identification.
Guidelines for Cast Parts and
Machined Surfaces" section of this
manual. Replace the housing if it
fails any of these inspection
Supersession Information
C3 Clutch Housing & C3 Back plate Update -
SIL 17-WT-04, Rev. B.
G. Inspect the C3 and C4 clutch friction plates will either have one and C4. Any WTEC III ECU equipped
friction plates following the spline missing or none missing. Any vehicle with an MD-3060, MD-3560,
"General Inspection Guidelines for 3000/B 300/B 400 model transmission B300, or 3000MH-Standard with an
Friction Plates" section of this may be updated from former C5 ECU calibration installed prior to
manual. Replace any plates failing friction plates to current C5 frictions October 25th, 1999 will require an
these inspection procedures. without recalibrating the transmission updated ECU calibration to use the
Minimum allowable plate thickness ECU. The rest of the clutches in the current friction plates in C1, C2, C3,
is 2.21 mm (0.087 inch). Maximum main housing (C1 through C4) must and C4. Do not intermix both former
allowable plate coning is 0.40 mm be updated with current friction and current friction plates in a clutch
(0.016 inch). plates if any other individual clutch pack.
besides C5 is updated from former to
NOTE: Battered and worn spline
Inspect the C3 and C4 clutch
current friction plates. The MD-3066,
teeth may be an indicator of 3000MH-High, and B400 do not reaction plates following the
driveline issues. Replace the clutch require recalibration for updating to "General Inspection Guidelines for
plates and check the driveline. current friction plates. Any WTEC II Reaction Plates" section of this
ECU equipped vehicle with an MD- manual. Replace any plates failing
NOTE: The current clutch friction 3060, MD-3560, B300, or 3000MH- these inspection procedures.
plates were implemented April of Standard with former friction plates Minimum allowable reaction plate
2000 starting with s/n 6510262117. will require a new ECU calibration thickness is 2.41 mm (0.095 inch).
Current production friction plates will from Allison Transmission to use the Maximum allowable reaction plate
have two missing splines. Former current friction plates in C1, C2, C3 coning is 0.40 mm (0.016 inch).
A. Main Housing
(rear view)
B. Splines
Wiring
Harness
Feedthrough
C6 Pressure
C5 Pressure Lube
Pressure
C4 Pressure
Lube Filter
Cavity
Main Filter
Cavity
Pump Suction
Lock-up C2 C1
Pressure Converter Converter In
Out Pressure Pressure
C5 Pressure
Main
Pressure
To Cooler
Main
Lube Pressure
Pressure
Lock-up
Pressure
Pump
Suction Converter Out Control Main
C6 Pressure Sump
Converter In C2 Pressure From Cooler
C1 Pressure
Non-Retarder
D. Hose
Connector
A. Cooler
Housing
B. Cooler
Housing
Cover
C. Cooler
Plate
F. Copper Assembly
Washers
E. O-Ring
E. O-Ring
A. Inspect the cooler housing B. Inspect the cooler housing D. Inspect the hose connector on
following the “General Inspection cover following the “General each side of the cooler housing for
Guidelines for Cast Parts and Inspection Guidelines for Cast cracks, obstructions and burrs.
Machined Surfaces” section of this Parts and Machined Surfaces” Replace either hose connector id
manual. Inspect the copper washer section of this manual. Inspect the damage cannot be repaired.
seats for pitting and galling. Inspect cooler inlet and outlet bores for
the cooler inlet and outlet bores for cracks, burrs and obstructions. E. Always replace the O-rings
cracks, burrs and obstructions. Replace the housing if damage whenever the cooler is
Replace the housing if damage cannot be repaired using a soft disassembled.
cannot be repaired using a soft stone or crocus cloth. F. Replace any copper washers if
stone or crocus cloth. Inspect bolt they show signs of corrosion or
holes for stripped or damaged C. Inspect the cooler plate
assembly for cracks, obstructions distortion.
threads. Replace the housing if
damage cannot be repaired. and debris. Inspect the O-ring
grooves for chips, burrs and damage
which many prevent proper sealing.
Replace the assembly if damage
cannot be repaired.
C. Journal
C. Journal
(P3)
(P2)
B. Main
P4 Planetary A. Main Shaft Shaft
Pilot
C. Journal D. Thrust
(C6) Bearing
D. Thrust H. Spiral
Bearing Retaining
Ring
E. P2 Sun
F. Bearing
G. P3 Sun Gear
Spacer
Gear
3070PT Main
Shaft Assembly
A. Inspect the main shaft journal diameter is 35.92 mm (1.414 F. Inspect the main shaft bearing
following the "General Inspection inches). Minimum allowable P2 spacer following the "General
Guidelines for Gears" and "General journal diameter is 42.97 mm (1.692 Inspection Guidelines for Cast
Inspection Guidelines for Splines" inches). Minimum allowable P3 Parts and Machined Surfaces" and
sections of this manual. Replace the journal diameter is 52.98 mm (2.086 "General Inspection Guidelines for
main shaft if it fails any of these inches). Splines" sections of this manual.
inspection procedures. Replace the Replace the spacer if it fails any of
main shaft if spline wear exceeds D. Inspect the thrust bearings these inspection procedures.
0.38 mm (0.015 inch). following the "General Inspection Replace the bearing spacer if spline
Guidelines for Bearings" section of wear exceeds 0.38 mm (0.015 inch).
B. Inspect the front main shaft
this manual. Replace any bearing
pilot for damage. The front main G. Inspect the P3 sun gear
that fails any of these inspection
shaft pilot fits inside the turbine following the "General Inspection
procedures.
shaft. Minimum allowable front Guidelines for Gears" and "General
pilot diameter is 19.98 mm (0.787 E. Inspect the P2 sun gear Inspection Guidelines for Splines"
inch). Replace the main shaft if following the "General Inspection sections of this manual. Replace the
worn beyond service limits. Guidelines for Gears" and "General gear if it fails any of these
Inspection Guidelines for Splines" inspection procedures. Replace the
C. Inspect the bushing journal
sections of this manual. Replace the sun gear if spline wear exceeds 0.38
areas for damage. Replace the main
gear if it fails any of these mm (0.015 inch).
shaft if any of the three journals is
inspection procedures. Replace the
galled or worn beyond service H. Replace the spiral retaining
sun gear if spline wear exceeds 0.38
limits. Minimum allowable C6 ring if it is removed.
mm (0.015 inch).
C. Scavenge
Pump Body
B. Scavenge
Pump Gear
Set Scavenge
Pump Cover
F. Thrust
Washers
G. Roller
A. Scavenge Bearing
Pump
Housing
D. Scavenge
Pump Driven E. Scavenge
Gear Assembly Pump Scavenge Pump
Shaft Assembly
A. Inspect the scavenge pump the depth of the scavenge pump body E. Inspect the scavenge pump
housing assembly following the where the gears fit. Subtract the shaft for damage. Replace the shaft if
"General Inspection Guidelines for thickness of each gear from the depth damage cannot be removed using a
Cast Parts and Machined Surfaces" of the pump body. Maximum soft stone or crocus cloth.
section of this manual. Replace the allowable clearance is 0.125 mm
F. Inspect the scavenge pump
housing if it fails any of these (0.0005 inch). Replace components if
inspection procedures or if the they are beyond service limits. thrust washers following the
damage cannot be repaired using a "General Inspection Guidelines for
C. Inspect the scavenge pump body Thrust Washers" section of this
soft stone or crocus cloth.
and scavenge pump cover for galling. manual. Replace the thrust washer if
B. Inspect the scavenge pump gear Replace the pump body if it is galled it fails any of these inspection
set following the "General Inspection or damaged. procedures or if it has damage that
Guidelines for Gears" section of this cannot be repaired using a soft stone
manual. Replace the gear set if it D. Inspect the scavenge pump
or crocus cloth.
fails any of these inspection driven gear assembly following the
procedures. Replace the gear set if "General Inspection Guidelines for G. Inspect the driven gear roller
damage cannot be repaired with a Gears" section of this manual. bearing following the “General
light stone or crocus cloth. Measure Replace the gear if it fails any of Inspection Guidelines for Bearings”
the thickness of each gear. Measure these inspection procedures. section of this manual. Replace the
bearing if it fails any of these
inspection procedures.
B. 3070 7-inch
Control Module.
C6 Clutch
Valve Body
7”
A. Adapter
Housing
Note: Component detail is the same as other
models with the addition of C6 valve body.
NOTE: Reference the "Inspection B. Refer to the "Control Module" Inspect all threaded holes for
and Analysis of the Rear Cover and section of this manual for details damage and debris. Replace the
P3 Planetary Module" section of this (except for the C6 clutch valve valve body if the thread damage
manual for P3 planetary, output body). cannot be repaired.
shaft and C5 clutch assembly
C, D. Valves, valve body bores NOTE: Do not use impact guns (air
inspection.
and oil passages must be free of wrenches, electric impact
A. Inspect the adapter housing debris, nicks, burrs, scoring and wrenches, etc.) when working with
following the "General Inspection galling. Valves should move freely aluminum threads or when torque
Guidelines for Cast Parts and in their bores, when dry, under sequencing bolts.
Machined Surfaces" section of this their own weight. Repair or replace
manual. Replace the housing if it valves and/or valve bodies failing to Replace valve springs which are
fails any of these inspection meet these requirements. broken, permanently set or worn
procedures. due to rubbing adjacent parts.
Valve body machined surfaces
Reference the Spring Data Charts in
must be free of debris, nicks, burrs
the Service Manual for spring
and scoring. Light stoning of these
specifications and identification.
machined surfaces is permitted to
correct minor defects. Replace any (continued)
valve body that cannot be repaired.
C6 Clutch
Body
C6
Interlock Regulator
Valve Valve Solenoid
Assembly
C6 Interlock
Valve Spring
Regulator
C6 Clutch Body
Valve Solenoid
Cover Plate
Assembly
Valve stops and retention pins Inspect the C6 clutch body cover
must not be damaged or battered. plate for damage. Replace the plate
Replace valve stops or pins which if damage cannot be repaired using
have damage that cannot be a soft stone or crocus cloth.
removed using a soft stone or
crocus cloth. D. C7 Clutch
Valve Body
Replace solenoids if they are visibly Spring
damaged. Proper solenoid
Signal Valve
resistance is 3 to 4 ohms measured
between the two solenoid
terminals. Check resistance C7
between each solenoid terminal and Solenoid
the solenoid body. Replace the
solenoid if resistance measures less
Pin
than 100k ohms. Control
Valve Spring
Stop
D. Oil Pump
Assembly
F. Shims
E. Transfer
Case
Wiring
Harness
Idle
Cover
B. Transfer
Case
Adapter
A. Transfer Shaft
Case
Housing
C. Manifold
Assembly
A. Inspect the transfer case B. Inspect the transfer case C. Inspect the manifold assembly
housing following the "General adapter shaft following the "General following the "General Inspection
Inspection Guidelines for Cast Parts Inspection Guidelines for Cast Parts Guidelines for Cast Parts and
and Machined Surfaces" section of and Machined Surfaces" and Machined Surfaces" section of this
this manual. Replace the housing if it "General Inspection Guidelines for manual. Replace the manifold if it
fails any of these inspection Splines" sections of this manual. fails any of these inspection
procedures. Inspect cover and Replace the shaft if it fails any of procedures. Inspect the manifold
manifold mounting surfaces for these inspection procedures. inside diameter where the C7 clutch
nicks, burrs and flatness. Replace housing seal rings ride for grooving,
Spline wear cannot exceed 0.35 mm
both housings if damage cannot be scoring and other damage. Replace
(0.015 inch). Replace the adapter
repaired using a soft stone or crocus the manifold if it is excessively worn.
shaft if spline wear exceeds this limit.
cloth. (continued)
NOTE: Transfer case housing halves
are matched sets and must be
replaced in pairs.
Identification Detail:
Oil Pump Assembly
Driven Gear
Front Cover
Drive
Gear
Pressure Rear
Reversing
Relief Valve Cover
Spring Ring
Plug
D. Inspect the oil pump assembly Reference the Spring Data Charts in
following the "General Inspection Service Manual SM2148EN for
Guidelines for Cast Parts and spring specifications and
Machined Surfaces" section of this identification.
manual. Replace the assembly if it E. Inspect the transfer case
fails any of these inspection controls wiring harness for
procedures. damaged connectors, wires and
Inspect the oil pump pressure relief terminals. Repair or replace the
valve and pin for scoring, nicks and harness components as necessary.
signs of battering. Replace the valve F. Replace the transfer case
and pin if damage cannot be repaired shims if they are damaged in any
using a light stone or crocus cloth. way.
(continued)
Replace the pressure relief valve plug
if its threads are damaged. Replace
the pressure relief valve spring if it is
bent, broken or permanently set.
B. Transfer Case
Controls Cover
C. Idler
Cover
D. Output Speed
A. Transfer
Sensor
Case
Housing
A. Inspect the transfer case B. Inspect the transfer case D. Inspect the output speed
housing following the "General controls cover following the sensor for damage. Replace the
Inspection Guidelines for Cast "General Inspection Guidelines for sensor if it has body, terminal or
Parts and Machined Surfaces" Cast Parts and Machined Surfaces" connector seat damage. Allowable
section of this manual. Replace the section of this manual. Replace the output speed sensor resistance is
cover if it fails any of these cover if it fails any of these 300 ohms plus or minus 30 ohms.
inspection procedures. Inspect inspection procedures. Replace the sensor if it is outside
cover and bearing retainer service specifications.
mounting surfaces for nicks, burrs C. Inspect the idler cover
and flatness. Replace both covers if following the "General Inspection
damage cannot be repaired using a Guidelines for Cast Parts and
soft stone or crocus cloth. Machined Surfaces" section of this
manual. Replace the cover if it fails
NOTE: Transfer case housing halves any of these inspection procedures.
are matched sets and must be
replaced in pairs.
B. Tapered Roller
Bearings
A. Inspect the transfer case drive, B. Inspect the transfer case gear
driven and idler gears following tapered roller bearings following
the "General Inspection Guidelines the "General Inspection Guidelines
for Gears" and "General Inspection for Bearings" section of this manual.
Guidelines for Splines" sections of Replace any bearings failing any of
this manual. Replace any gears these inspection procedures.
which fail these inspection Replace the corresponding transfer
procedures or if the gears have case housing bearing cup when a
damage which cannot be repaired bearing is replaced.
using a soft stone or crocus cloth.
C. C6 Clutch
Hub A. C6 Clutch
Housing
E. C6 Clutch
Friction Plates
D. C6 Clutch
Piston
C6
Backplate
B. C6
Bushing
G. C6 Clutch
Hub Thrust
F. C6 Spring Bearing
H. Retaining Retainer
Rings Assembly
A. Inspect the C6 clutch housing B. Inspect the C6 clutch sleeve D. Inspect the C6 clutch piston
following the "General Inspection and C6 clutch bushing for damage. following the "General Inspection
Guidelines for Cast Parts and Replace the sleeve or bushing if Guidelines for Cast Parts and
Machined Surfaces" and “General excessively worn or if damage Machined Surfaces" section of this
Inspection Guidelines for Splines” cannot be removed using a light manual. Replace the piston if it fails
sections of this manual. Replace the stone or crocus cloth. Maximum any of these inspection procedures.
housing if it fails any of these allowable C6 bushing inside
NOTE: Aluminum castings (like
inspection procedures. Maximum diameter is 36.18 mm (1.424 inches).
allowable spline wear is 2.29 mm clutch pistons) can be etched by
C. Inspect the C6 clutch hub caustic parts cleaners and solvents.
(0.090 inch).
following the "General Inspection Etched components are identified
Guidelines for Cast Parts and by a dull to dark gray color - not the
Machined Surfaces" and the bright finish of a normal machined
"General Inspection Guidelines for aluminum part. Etched components
Splines" sections of this manual. are also identified by roughness in
Replace the hub if it fails any of the piston seal surface which can
these inspection procedures. cause piston seals to abrade and
result in low clutch apply pressure
and transmission damage. Replace
etched components.
(continued)
ALLISON TRANSMISSION TECHNICIANS’ GUIDE 69
2005 General Motors Corporation.
ALLISON 3000 / B 300 / B 400 PRODUCT FAMILIES
TRANSFER CASE C6 CLUTCH ASSEMBLY (continued)
E. Inspect the C6 clutch friction Replace any plates failing any of broken in any way. Reference the
plates following the "General these inspection procedures. Spring Data Charts in Service
Inspection Guidelines for Friction Minimum allowable plate thickness Manual SM2148EN for spring
Plates" section of this manual. is 2.41 mm (0.095 inch). Maximum specifications and identification.
Replace any plates failing these allowable coning is 0.40 mm (0.016
G. Inspect the C6 clutch hub
inspection procedures. Minimum inch).
thrust bearing following the
allowable plate thickness is 3.68 mm
Inspect the C6 clutch backplate "General Inspection Guidelines for
(0.145 inch). Minimum allowable oil
for damage. Replace the backplate if Bearings" section of this manual.
groove depth is 0.20 mm (0.008
damage cannot be repaired using a Replace the bearing if it fails any of
inch). Maximum allowable coning is
soft stone or crocus cloth. these inspection procedures.
0.40 mm (0.016 inch).
Minimum allowable backplate
H. Inspect the C6 clutch pack
NOTE: Battered and worn spline thickness is 7.90 mm (0.311 inch).
retaining rings for damage and
teeth may be an indicator of Check the backplate for flatness.
distortion following the "General
driveline issues. Replace the clutch Maximum allowable distortion is
Inspection Guidelines for Retaining
plates and check the driveline. 0.40 mm (0.016 inch).
Rings" section of this manual.
Inspect the C6 steel reaction F. Replace the C6 spring retainer Replace any retaining ring with
plates following the "General assembly if it has a permanent damage that cannot be repaired
Inspection Guidelines for Reaction spring set, wear due to rubbing using a light stone or crocus cloth.
Plates" section of this manual. adjacent parts or if it is cracked or
A. C7 Clutch
B. C7 Clutch
Housing
Hub
D. C7 Clutch
C7
Pack
Bushing
C7 Backplate
C. C7 Clutch
Piston
E. C7 Clutch Pack
Retaining Ring
A. Inspect the C7 clutch housing Inspect the C7 clutch hub bushing B. Inspect the C7 clutch hub
following the "General Inspection following the "General Inspection following the "General Inspection
Guidelines for Cast Parts and Guidelines for Bushings" section of Guidelines for Cast Parts and
Machined Surfaces" and "General this manual. Replace the bushing if Machined Surfaces" and the
Inspection Guidelines for Splines" it fails any of these inspection "General Inspection Guidelines for
sections of this manual. Replace the procedures or if it has damage Splines" sections of this manual.
housing if it fails any of these which cannot be repaired using a Replace the hub if it fails any of
inspection procedures. soft stone or crocus cloth. these inspection procedures or if it
Maximum allowable bushing inside has damage which cannot be
Inspect the pressure relief check diameter is 47.26 mm (1.861 inch). repaired using a soft stone or crocus
ball for free movement. Minimum cloth.
allowable check ball movement is
1.00 mm (0.040 inch). Replace the C. Inspect the C7 clutch piston
check ball if it is stuck in the bore. following the "General Inspection
The ball is staked in the housing. Guidelines for Cast Parts and
Machined Surfaces" section of this
manual. Replace the piston if it fails
any of these inspection procedures.
(continued)
D. Inspect the C7 clutch friction Inspect the C7 steel reaction Check the backplate for flatness.
plates following the "General plates following the "General Maximum allowable distortion is
Inspection Guidelines for Friction Inspection Guidelines for Reaction 0.40 mm (0.016 inch).
Plates" section of this manual. Plates" section of this manual.
Replace any plates failing these Replace any plates failing any of E. Inspect the C7 clutch pack
inspection procedures. Minimum these inspection procedures. retaining ring for damage and
allowable plate thickness is 2.21 Minimum allowable plate thickness distortion following the "General
mm (0.087 inch). Minimum is 2.11 mm (0.083 inch). Maximum Inspection Guidelines for Retaining
allowable oil groove depth is 0.20 allowable coning is 0.25 mm Rings" section of this manual.
mm (0.008 inch). Maximum (0.010 inch). Replace the retaining ring if damage
allowable coning is 0.25 mm cannot be repaired using a light
(0.010 inch). Inspect the C7 clutch backplate for stone or crocus cloth.
damage. Replace the backplate if
NOTE: Battered and worn spline damage cannot be repaired using a
teeth may be an indicator of soft stone or crocus cloth.
driveline issues. Replace the clutch Minimum allowable backplate
plates and check the driveline. thickness is 8.67 mm (0.341 inch).
Seal
F. Front Output
Yoke, Nut &
Washer
C. Tapered
Roller
Bearings
B. Front
Output
Shaft
D. Bearing
Spacer
A. Inspect the transfer case front C. Inspect the front output shaft F. Inspect the front output yoke
output housing following the tapered roller bearings following following the "General Inspection
"General Inspection Guidelines for the "General Inspection Guidelines Guidelines for Cast Parts and
Cast Parts and Machined Surfaces" for Bearings" section of this manual. Machined Surfaces" and the "General
section of this manual. Replace the Replace any bearings failing any of Inspection Guidelines for Splines"
housing if it fails any of these these inspection procedures. sections of this manual. Replace the
inspection procedures. Replace the Replace the corresponding bearing yoke if it fails any of these inspection
roller bearing races or "cups" if they cup when a bearing is replaced. procedures. Minimum allowable seal
are damaged. journal outside diameter is 76.20 mm
D. Inspect the front output shaft (3.00 inches). Inspect the output
B. Inspect the front output shaft bearing spacer for damage. Replace yoke nut for damaged threads.
following the "General Inspection the spacer if damage cannot be Replace the nut if damaged. Replace
Guidelines for Cast Parts and
removed using a soft stone or the output nut washer if it has
Machined Surfaces" and the "General
crocus cloth. damage which cannot be repaired
Inspection Guidelines for Splines"
using a soft stone or crocus cloth.
sections of this manual. Replace the E. Replace the output bearing
Replace the output nut if it does not
shaft if it fails any of these inspection shims if they damaged in any way. have at least 25 pound feet of
procedures. Inspect the shaft bearing
turning torque while being threaded
journal areas for galling and other
onto the shaft.
damage. Replace the shaft if
damaged.
A. Rear Output
Housing
G. P4 Ring Gear
F. Output Yoke,
Nut & Washer
C. Tapered
Roller
Bearings
E. Bearing
Shims
B. Rear
Output I. P4 Sun
Shaft D. Bearing Gear
Spacer H. P4 Carrier
(25 Teeth)
Assembly
A. Inspect the transfer case rear C. Inspect the rear output shaft F. Inspect the rear output yoke
output housing following the tapered roller bearings following following the "General Inspection
"General Inspection Guidelines for the "General Inspection Guidelines Guidelines for Cast Parts and
Cast Parts and Machined Surfaces" for Bearings" section of this manual. Machined Surfaces" and the "General
section of this manual. Replace the Replace any bearings failing any of Inspection Guidelines for Splines"
housing if it fails any of these these inspection procedures. Replace sections of this manual. Replace the
inspection procedures. Replace the the corresponding bearing cup when yoke if it fails any of these inspection
roller bearing races or "cups" if they a bearing is replaced. procedures. Minimum allowable seal
are damaged. journal outside diameter is 76.20 mm
D. Inspect the rear output shaft
(3.00 inches). Inspect the output
B. Inspect the rear output shaft bearing spacer for damage. Replace
yoke nut for damaged threads.
following the "General Inspection the spacer if damage cannot be
Replace the nut if damage cannot be
Guidelines for Cast Parts and removed using a soft stone or crocus
repaired using a soft stone or crocus
Machined Surfaces" and the "General cloth.
cloth. Replace the output nut
Inspection Guidelines for Splines"
E. Replace the output bearing washer if it is damaged. Replace the
sections of this manual. Replace the
shims if they are damaged in any output nut if it does not have at least
shaft if it fails any of these inspection
way. 25 pound feet of turning torque
procedures. Inspect the shaft bearing
while being threaded onto the shaft.
journal areas for excessive wear or
galling. Replace the shaft if damaged. (continued)
M. P4
Pinion
K. Thrust
Washers
L. Roller
Bearing
J. Spindle
G. Inspect the P4 ring gear I. Inspect the P4 sun gear L. Inspect the pinion needle
following the "General Inspection following the "General Inspection roller bearings following the
Guidelines for Cast Parts and Guidelines for Gears" and the "General Inspection Guidelines for
Machined Surfaces" and the "General "General Inspection Guidelines for Bearings" section of this manual.
Inspection Guidelines for Splines" Splines" sections of this manual. Replace any bearings failing these
sections of this manual. Replace the Replace the gear if it fails any of inspection procedures.
ring gear if it fails any of these
these inspection procedures.
inspection procedures. M. Inspect the P4 pinion gears
H. Inspect the P4 planetary J. Replace the pinion spindles if following the "General Inspection
carrier following the "General they are damaged. Replace the Guidelines for Gears" section of this
Inspection Guidelines for Cast pinion spindle set screws if manual. Replace any gear that fails
Parts and Machined Surfaces" and threads are damaged. these inspection procedures or if
the "General Inspection Guidelines damage cannot be removed using a
K. Replace the pinion gear thrust soft stone.
for Splines" sections of this manual.
washers if they are galled or
Replace the housing if it fails any of
excessively worn.
these inspection procedures.
10,A 10 C3 Return 29505570 No Code 11* 1.70* 12.00* 38.9** 24.5 232–256**
(0.067) (0.472) (1.53) (0.96) (52.2–57.6)
10,A 12 C3 Retainer 29505861 No Code 4* 2.59* 13.26* 12.8** 11.0 11310–14610**
ALLISON
(0.102) (0.522) (0.50) (0.43) (2543–3284)
10,A 20 C4 Return 29505570 No Code 11* 1.70* 12.00* 38.9** 24.5 232–256**
(0.067) (0.472) (1.53) (0.96) (52.2–57.6)
10,A 22 C4 Retainer 29505861 No Code 4* 2.59* 13.26* 12.8** 11.0 11310–14610**
(0.102) (0.522) (0.50) (0.43) (2543–3284)
13,A/13,B 23/23 C5 Retainer 29507780 No Code 9.5* 1.83* 14.35* 39.2** 25.0 3044–3364**
TRANSMISSION
(0.072) (0.565) (1.54) (0.98) (684–756)
13,A 46 Retarder 6880775 Yellow/ 12 1.93 16.61 53.85 35.31 73–89
Red Stripe (0.076) (0.654) (2.12) (1.39) (16.5–20.1)
13,A 46 Retarder 29512751 Silver (End) 10.5 2.16 19.05 61.5 25.9 177.5–196.3
(0.085) (0.75) (2.42) (1.02) (39.9–44.1)
13,A 46 Retarder 29515101 Green 16.0 3.78 36.6 106.7 73.66 120.1–146.7
TECHNICIANS’
(0.149) (1.44) (4.20) (2.90) (27.0–33.0)
13,A/13,B 46/55 Retarder 29515692 None 11.4 4.12 36.17 114.3 91.1 200.0–226.6
(0.162) (1.42) (4.50) (3.59) (44.96–50.94)
GUIDE
2005 General Motors Corporation.
13,A 92 Retarder Control 29510494 Solid Orange 7 1.60 15.50 27.8 18.0 44–50.9
Low, 27 psi (0.063) (0.610) (1.09) (0.71) (9.9–11.4)
ALLISON 3000 / B 300 / B 400 PRODUCT FAMILIES
LIMITS AND SPRING DATA
81
* Individual Springs
** For the complete Spring Assembly
Table 7–2. Spring Data (cont’d)
82
Spring Approx. Free
Length Under Load
Color No. Wire Dia. OD Length
Foldout Ref. Spring Part No. Code Coils mm (in.) mm (in.) mm (in.) mm (in.) N (lb) min.
13,A 92 Retarder Control 29510495 Solid Silver 7.5 1.40 15.09 30.8 18.0 32.5±35.9
Medium, 36 psi (0.055) (0.594) (1.21) (0.71) (7.3±8.05)
ALLISON
13,A 92 Retarder Control 29510496 Solid Blue 8 1.14 14.59 36.0 18.0 19.8±21.9
High, 45 psi (0.045) (0.574) (1.42) (0.71) (4.5±4.9)
13,B 78 Retarder Control 29529300 White/ 8.52 1.27 13.46 33.02 16.51 34.22±37.86
TRANSMISSION
13,B 78 Retarder Control 29529298 Pink/ 8.23 0.94 12.19 31.47 16.51 9.39±10.37
High, 76 psi White Ends (0.037) (0.480) (1.24) (0.650) (2.11±2.33)
13,D/18,B 23/16 C5 Retainer 29500867 No Code 11.5* 2.16* 16.00* 52.1** 33.0 3034±3498**
(0.085) (0.630) (2.05) (1.30) (682.1±786.4)
2109±
C6 Spring Retainer 1.84 12.70 35.10 26.20
16 13 29501191 No Code 10 2331**
Assembly (0.072) (0.500) (1.382) (1.032)
(474±524)
TECHNICIANS’
17,A 53, 79, Solenoid Regulator 29502195 No Code 4 0.67 11.05 ² 6.5 3.45 3.2±4.2
88, 103 (0.026) (0.435) (0.26) (0.14) (0.72±0.94)
17,B 60, 75 Solenoid Regulator 29502195 No Code 4 0.67 11.05 ² 6.5 3.45 3.2±4.2
GUIDE
84, 109 (0.026) (0.435) (0.26) (0.14) (0.72±0.94)
17,C 61, 76 Solenoid Regulator 29502195 No Code 4 0.67 11.05 ² 6.5 3.45 3.2±4.2
89, 110 (0.026) (0.435) (0.26) (0.14) (0.72±0.94)
17,A/17,B 65/96 Accumulator Relay 29507455 Silver 12.8 1.28 11.68 43.6 20.0 47.3±52.3
WEAR LIMITS AND SPRING DATA
17,A/17,B 73/103 Overdrive 23049332 Orange 12 0.76 7.75 26.6 12.5 12.4±15.2
17,C 104 (0.030) (0.305) (1.05) (0.49) (2.79±3.42)
* Individual Springs
** For the complete Spring Assembly
² OD at larger end
(continued)
(continued) WEAR
ALLISON
Foldout Ref. Spring Part No. Code Coils mm (in.) mm (in.) mm (in.) mm (in.) N (lb) min.
17,A/17,B 111/119 Lockup Relay 23049326 No Code 10 1.37 14.10 42.1 17.0 49.2–60.2
17,C 120 (0.054) (0.555) (1.66) (0.67) (11.06–13.53)
17,A/17,B 115/123 Lube Regulator 23049327 Red 13 1.22 11.10 46.3 23.5 46.5–51.3
17,C 124 (0.048) (0.437) (1.82) (0.93) (10.5–11.5)
17,A/17,B 119/127 Main Regulator 29500963 Lt. Blue 15 2.87 22.0 98.5 54.6 305–337
TRANSMISSION
17,C 128 (0.113) (0.866) (3.88) (2.15) (68.6–75.8)
17,A/17,B 123/131 Control Main 23049325 Orange 10 1.83 14.8 44.6 24.2 131–145
17,C 132 (0.072) (0.583) (1.76) (0.95) (29.5–32.6)
17,A/17,B 133/141 C2 Latch 29501071 Lt. Green 11 1.32 11.43 41.3 19.0 64.1–78.3
17,C 142 (0.052) (0.450) (1.63) (0.75) (14.4–17.6)
17,A/17,B 137/145 Exhaust Back 23049391 No Code 17 0.61 7.80 29.2 18.2 2.40–2.94
TECHNICIANS’
17,C 146 (0.024) (0.307) (1.15) (0.72) (0.54–0.66)
17,A/17,B 141/149 C1 Latch 6885065 Blue 12 1.37 16.26 46.2 29.2 16.7–18.9
17,C 150 (0.054) (0.640) (1.82) (1.15) (3.75–4.25)
GUIDE
2005 General Motors Corporation.
17,A/17,B 145/153 Converter Regulator 29507456 Pink 10.2 1.53 11.00 30.3 22.8 53.7–59.3
17,C 154 (0.060) (0.433) (1.19) (0.90) (12.1–13.3)
ALLISON 3000 / B 300 / B 400 PRODUCT FAMILIES
LIMITS AND SPRING DATA
83
ALLISON 3000 / B 300 / B 400 PRODUCT FAMILIES
NOTES
Allison Transmission
General Motors Corporation
Indianapolis, IN 46206-0894
1-800-252-5283
www.allisontransmission.com
GN4064EN
(5/05)
ALLISON 3000 / B 300 / B 400 PRODUCT FAMILIES