Allison Transmission 1000 Series Service Manual
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Allison Transmission 1000 Series Service Manual

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Service
Manual
Allison Transmission
1000 EVS
2100 EVS
1000 HS
2100 HS
1000 MH
2100 MH
1000 PTS
2100 PTS
1000 RDS
2100 RDS
1000 SP
2100 SP
Allison Transmission, General Motors Corporation
P.O. Box 894 Indianapolis, Indiana 46206-0894
www.allisontransmission.com
Printed in USA
2004 DECEMBER
SM3191EN
2200 EVS
2500 EVS
2200 HS
2500 HS
2200 MH
2500 MH
2200 PTS
2500 PTS
2200 RDS
2500 RDS
2200 SP
2500 SP
Copyright © 2004 General Motors Corporation
B 210
B 220

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  • Page 1 2200 PTS 2500 PTS 1000 RDS 2100 RDS 2200 RDS 2500 RDS 1000 SP 2100 SP 2200 SP 2500 SP Allison Transmission, General Motors Corporation P.O. Box 894 Indianapolis, Indiana 46206-0894 www.allisontransmission.com Printed in USA Copyright © 2004 General Motors Corporation...
  • Page 2 DuPont Corporation. • TranSynd™ is a trademark of Castrol Ltd. • 1000 Series™ is a trademark of General Motors Corporation. • 2000 Series™ is a trademark of General Motors Corporation. • 2400 Series™ is a trademark of General Motors Corporation.
  • Page 3 It is, however, important to understand that these Warnings and Cautions are not exhaustive. Allison Transmission could not possibly know, evaluate, and advise the service trade of all conceivable ways in which service might be done or of the possible hazardous consequences of each way.
  • Page 4 LIST OF WARNINGS This manual contains the following Warnings — IT IS YOUR RESPONSIBILITY TO BE FAMILIAR WITH ALL OF THEM. Operation with excessive loads can cause transmission damage and unexpected vehicle movement. To help avoid injury, property damage, and/or transmission damage, do not exceed 11 800 kg (26,000 lbs) GCW or the OEM vehicle rating, whichever is less.
  • Page 5 LIST OF WARNINGS This manual contains the following Warnings — IT IS YOUR RESPONSIBILITY TO BE FAMILIAR WITH ALL OF THEM. To help avoid injury or property damage caused by sudden and unexpected vehicle movement, do not start a stationary stall test until you: •...
  • Page 6 LIST OF WARNINGS This manual contains the following Warnings — IT IS YOUR RESPONSIBILITY TO BE FAMILIAR WITH ALL OF THEM. The 1000 and 2000 Product Families torque converter dry weights are approximately 29 kg (63 lb). To help avoid personal injury and/or property damage: •...
  • Page 7 TABLE OF CONTENTS Paragraph Page Paragraph Page Section 1. GENERAL INFORMATION 1–7. RESTORING TRANSMISSION TO SERVICE 1–1. SCOPE OF MANUAL a. Transmission Exterior ....1–10 a. Transmission Product Families And b.
  • Page 8 1000 AND 2000 PRODUCT FAMILIES SERVICE MANUAL Paragraph Page Paragraph Page 2–9. TRANSISSION FLUID AND FILTER 3–5. CLEANING AND INSPECTION CHANGE PROCEDURE a. Dirt Causes Malfunction ... . . 3–9 a.
  • Page 9 TABLE OF CONTENTS Paragraph Page Paragraph Page Section 4. TRANSMISSION DISASSEMBLY Section 5. MODULE REBUILD 5–1. TORQUE CONVERTER ASSEMBLY 4–1. INSTALLATION OF TRANSMISSION INTO REPAIR STAND ....4–1 a.
  • Page 10 1000 AND 2000 PRODUCT FAMILIES SERVICE MANUAL Paragraph Page Paragraph Page 5–10. ROTATING CLUTCH MODULE 5–13. MAIN SHAFT INSPECTION ..5–85 a. Disassembly of Rotating Clutch 5–14. P1 PLANETARY MODULE Module......5–40 a.
  • Page 11 TABLE OF CONTENTS Paragraph Page Paragraph Page f. Disassembly of the Main Valve 6–16. TRANSMISSION END PLAY CHECK . . 6–25 Body ......5–111 6–17.
  • Page 12 1000 AND 2000 PRODUCT FAMILIES SERVICE MANUAL LIST OF FOLDOUT ILLUSTRATIONS (Back of Service Manual) CROSS-SECTION VIEWS Foldout 1000 Product Family 2000 Product Family 2000 Product Family with Park Pawl 1000 Product Family Direct Mount with Transfer Case Adapter EXPLODED VIEWS SAE No.
  • Page 13 • are: g. Vocational Models (refer to WATCH 309) . Be- Internal Wiring Harness • ginning January 2004, Allison Transmission began Separator Plate • shipping new 1000 and 2000 Product Families trans- mission models for North America. 1000 and 2000 Modulated Main Body Assembly •...
  • Page 14 Parts Catalog. Replacement parts are listed in Parts Catalog PC3062EN. Do not order by the item Formal instruction at Allison Transmission • numbers used on exploded views in this manual. Use or a Distributor training facility.
  • Page 15 GENERAL INFORMATION OIL VENT PARKING BRAKE (BREATHER) MOUNTING PROVISION TURBINE SPEED SENSOR INPUT SPEED SENSOR OUTPUT SPEED SENSOR NSBU SWITCH SELECTOR SHAFT SAE 6-BOLT PTO PAD (DRIVE GEAR OPTIONAL) AVAILABLE OIL FILL TUBE LOCATION CONTROL MAIN OIL FILTER V04779.03.00 Figure 1–1. 1000 and 2000 Product Families Transmission—Left-Front View INPUT SPEED SENSOR TURBINE SPEED...
  • Page 16 1000 AND 2000 PRODUCT FAMILIES SERVICE MANUAL DIV. OF GENERAL MOTORS CORP. DIV. OF GENERAL MOTORS CORP. INDIANAPOLIS, INDIANA, USA INDIANAPOLIS, INDIANA, USA MODEL DATE X X X X X X X X X X X X X X X SERIAL NO.
  • Page 17 GENERAL INFORMATION DIVISION OF GENERAL MOTORS CORP. DIVISION OF GENERAL MOTORS CORP. INDIANAPOLIS, INDIANA INDIANAPOLIS, INDIANA MODEL X X – X X X X X X – X X X X 1 0 0 0 S E R I E S X X –...
  • Page 18 10. Parking Pawl/Parking Brake 6. Transmission Fluid Filtration. Fluid filtration is provided by two filter systems. A suction fil- All 1000 models, 2200 models, 1000 Series™, • ter, located in the sump, provides general pro- and 2400 Series™ transmissions have a tection to the entire hydraulic system by park pawl.
  • Page 19 GENERAL INFORMATION b. General Description. Several transmission NOTE: configurations are available within the 1000 and 2000 Product Families. The CHECK ENGINE light may serve the CHECK TRANS function for vehicles which are compliant 1000* Heavy-duty automatic transmission with to industry On Board Diagnostics II (OBD-II) re- parking pawl quirements.
  • Page 20 1000 AND 2000 PRODUCT FAMILIES SERVICE MANUAL 2. At the same time these events occur, a required — Make sure throttle is closed and engine OEM-supplied RANGE INHIBITED light, speed is below 900 rpm. mounted on the dash or near the shift selector, —...
  • Page 21 GENERAL INFORMATION 3. To help locate intermittents, it sometimes helps d. One Year Storage (With Fluid) to place the appropriate tester on the suspect 1. Drain the fluid and replace the oil filter elements. component or circuit and simulate operating conditions—wiggle, pull, bump, and bend 2.
  • Page 22 1000 AND 2000 PRODUCT FAMILIES SERVICE MANUAL 1–7. RESTORING TRANSMISSION and refill the transmission with new transmission fluid. Check for proper fluid level. Add or drain transmission TO SERVICE fluid, as required, to obtain the proper level. a. Transmission Exterior. Wash all external grease from the transmission with mineral spirits.
  • Page 23 GENERAL INFORMATION Copyright © 2004 General Motors Corp. 1–11...
  • Page 24 GENERAL INFORMATION 1–12 Copyright © 2004 General Motors Corp.
  • Page 25 GENERAL INFORMATION Table 1–1. Specifications And Data Chart* INPUT/OUTPUT RATINGS (1000 Models): Refuse Input Speed** General*** (On-Highway) Motorhome Transit Bus Max Full Load Gov. Speed 4600 rpm 4600 rpm 4600 rpm 4600 rpm Min Full Load Gov. Speed 2200 rpm 2200 rpm 2200 rpm 2200 rpm...

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