Академический Документы
Профессиональный Документы
Культура Документы
Manual SM4013EN
Allison Transmission
ALLISON 4TH GENERATION CONTROLS
VOCATIONAL MODELS
3000 EVS 3200 SP 3500 EVS 3700 SP B 300
3000 HS 3200 TRV 3500 RDS B 400
3000 MH 3500 SP T 250
3000 PTS T 255
3000 RDS T 260
3000 TRV T 265
T 270
T 280
T 310
T 325
T 350
Shift Selector button and display names are printed in bold capital letters (Up) arrow, (Down) arrow,
DISPLAY MODE, MONITOR, SELECT, etc.).
The actual message displayed (text and/or letters) is printed within double quotation marks (“O L”, “O K”, etc.).
TRADEMARK USE
NOTE:
This publication is revised periodically to include improvements,
new models, special tools, and procedures. A revision is indicated
by letter suffix to the publication number. Check with your Allison
Transmission service outlet for the currently applicable publica-
tion. Additional copies of this publication may be purchased from
authorized Allison Transmission service outlets. Look in your tele-
phone directory under the heading of Transmissions—Truck,
Tractor, etc.
WARNING!
is used when an operating procedure, practice,
etc., which, if not correctly followed, could result
in personal injury or loss of life.
CAUTION:
is used when an operating procedure, practice,
etc., which, if not strictly observed, could result
in damage to or destruction of equipment.
NOTE:
is used when an operating procedure, practice, etc.,
is essential to highlight.
• Do not burn discarded Teflon® seals; toxic gases are produced by burning Teflon®.
• Never dry bearings by spinning them with compressed air. A spinning bearing can
disintegrate, allowing balls or rollers to become lethal flying projectiles. Also,
spinning a bearing without lubrication can damage the bearing.
• 3000 Product Family transmission dry weights are as follows:
—Base Transmission 243 kg (535 lb)
—With PTO Provision 261 kg (575 lb)
—With Retarder 279 kg (610 lb)
—With PTO and Retarder 297 kg (655 lb)
—With PTO, Retarder, and 336.5 kg (740 lb)
and Integral Sump Cooler
—3700 SP 530 kg (1170 lb)
Use proper tools and lifting equipment when installing or removing a transmission
from the repair stand.
• The transfer case module assembly weighs approximately 270 kg (595 lb).
• The control module assembly weighs approximately 25 kg (56 lb). Handle
carefully to avoid personnel injury or control module damage. The control
module assembly used in a 3700 SP weighs approximately 29 kg (65 lb).
• The retarder module assembly weighs approximately 64 kg (141 lb). Use care to
prevent injury to personnel while handling the retarder module assembly.
• Piston springs are highly compressed. Be extremely careful during disassembly.
Personal injury can occur if the spring force is not controlled.
• Transmissions installed in overhaul stands must be positioned vertically before
installing control module. Failure to do so could result in personal injury.
• To help avoid personal injury, securely support the cooler in its installed position
before installing the bolts retaining the cooler to the manifold. The cooler weighs
140 kg (64 lb), use care when handling the cooler.
a. Content and Organization. This Service Manual 1. The text is supported with line drawings and
describes overhaul procedures for 3000 Product Family cross-sectional views. Overhaul procedures are
automatic transmissions (Figures 1–1 through 1–6). illustrated by line drawings. Cross-sections
show the relationship of assembled parts.
• The major transmission components are Cross-sections and exploded views are on fold-
described and their functions explained. out pages in the back of the manual.
• Detailed instructions are provided for 2. Illustrations show correct procedures for all
disassembly, rebuild, and re-assembly. models—including models not illustrated.
• Part inspection instructions are in Section 3.
c. Maintenance Information. Each task described
• Wear limits and spring data are in Section 7.
in this manual has been successfully completed by
The 3000 Product Family consists of the following service organizations and individuals. Not every
transmission series and models: service organization or individual possesses the
required special tooling, training, or experience to
Highway Series
perform all described tasks. However, any task may be
• 3000 HS performed if the following conditions are met:
Rugged Duty Series
1. The organization or individual has the required
• 3000 RDS
knowledge of the task through:
• 3500 RDS
• Formal instruction at Allison Transmission
Emergency Vehicle Series or a Distributor training facility.
• 3000 EVS • On-the-job instruction by an Allison
• 3500 EVS Transmission or Distributor representative.
Motorhome Series • Experience in performing the task.
• 3000 MH 2. The work environment is suitable to prevent
Truck Recreational Vehicle Series contamination or damage to transmission parts
• 3000 TRV or assemblies.
• 3200 TRV 3. Required tools and fixtures needed are shown
in Figure 3–3 and Table 3–1 (Section 3 of this
Pupil Transport/Shuttle Series
manual).
• 3000 PTS
4. Reasonable and prudent maintenance prac-
Specialty Series
tices are used.
• 3200 SP
• 3500 SP NOTE:
• 3700 SP Service organizations and individuals are
Bus Urban Series encouraged to contact their local Allison
• B 300 Transmission Distributor for information and
guidance on any task outlined in this manual.
• B 400
T 200 Series
1–2. SUPPLEMENTARY
• T 250/ T 255/ T260/ T 265/ T 270/T 280
INFORMATION
T 300 Series
• T 310/ T 325/ T 350 Supplementary information will be issued, as required,
if any changes occur after publication of this manual.
Power Takeoff (PTO) and output retarder options may Check with your dealer or distributor to be sure you
be added to a base transmission model. have the latest information.
ASSEMBLY PADS
(BOTH SIDES)
BREATHER
TORQUE CONVERTER
WITH LOCKUP CLUTCH
AND TORSIONAL DAMPER
MAIN-PRESSURE TAP
FLEXPLATE DRIVE NOTE: Inch Series Threads
PTO PROVISION
(AVAILABLE BOTH SIDES)
V05552.01.00
Figure 1–1. 3000 Product Family Transmission with PTO Provision—Left-Front View
BREATHER
ASSEMBLY PADS
OPTIONAL FRONT
COOLER PORTS
TO COOLER
NOTE: Inch Series Threads
NAMEPLATE
FROM COOLER
NOTE: Inch Series Threads
MAIN-PRESSURE TAP
FEEDTHROUGH HARNESS CONNECTOR NOTE: Inch Series Threads V01652.03.00
Figure 1–2. 3000 Product Family Transmission with PTO Provision—Right-Rear View
BREATHER
ASSEMBLY PADS
RETARDER
TEMPERATURE
SENSOR
OUTPUT SPEED
SENSOR
BREATHER
ASSEMBLY PADS
RETARDER TEMPERATURE
SENSOR
REMOTE SUMP
COOLER MANIFOLD
TACHOGRAPH PROVISION
NOTE: Metric series threads
V07393.01.00
Figure 1–4. 3000 Product Family Transmission with Retarder and Remote Sump Cooler Manifold
TRANSFER CASE
BREATHER
FEEDTHROUGH
CONNECTOR
Wor
ld Tr
Man an
ufac sm
d By issi
Divis ture
SER ion
IAL
NO.
of Gene
India ralon
XX XX napo Moto
lis, rs Corp
India orati
XX na on
O B IL E A E R O S P ACE
UAW
AND A
G
RIC U
PAR
L TU R A L I M P L E M ENT
933
UTOM
MOD
A
T NO.
TED
UNI
A
RIC
EL
WO
RK ERS OF AME
NO.
XX XX XX
XXXX XX X
NAMEPLATE
SCAVENGE PUMP
V01953.02.00
ASSEMBLY PADS
(BOTH SIDES)
TRANSFER CASE
PTO PROVISION
V05553.01.00
EM
EN
T WORKERS O
LTURAL
RICU
EM
E , A E ROSPACE
EN
BIL
T WORKERS O
MO
AM
00A00
00A00 EXXXXXX
EXXXXXX 2. The available torque converter models are:
XXXXXX
XXXXXX
TIDA
TIDA XXXXSP
XXXXSP Torque Converter Model
S/NS/N 6510XXXXXX
6510XXXXXX TC 411
TC 413
TRANSMISSION MODEL TC 415
(“SP” DESIGNATION SHOWN APPEARSTRANSMISSION MODEL
ON SP MODELS ONLY)
(“SP” DESIGNATION SHOWN APPEARS ON SP MODELS ONLY) TC 417
NAMEPLATE
REDESIGNED TC 418
(P/N
(P/N29543996)
29543996) V09569.05.00
V09569.00.00 TC 419
Figure 1–7. Transmission Nameplate TC 421
c. Power Takeoff Provision. Provision for a direct, j. Output Configuration. The output module in-
engine-driven PTO is available at two positions. cludes either an integral retarder and an output flange,
or a rear cover that includes pads for mounting a park-
d. Main Housing and Gear Module. The Main ing brake and a flange or yoke. A yoke is not available
Housing and Gear Module includes: with parking brake-equipped transmissions. The
• Main housing 3700 SP has a transfer case and adapter as an output
• Oil pump charging system module.
• Three planetary gear sets
• Two rotating clutches 1–6. MODEL DESIGNATION CODE
• Three stationary clutches The following explains the transmission model desig-
nation code stamped on the transmission nameplate
e. Range Clutches. Range clutches are multiple-
for vocational models.
disc, wet-type clutches. Exhaust backfill pressure is
used to reduce fill time for quick response and smooth
Highway Series 3000 HS
shifts.
Rugged Duty Series 3000 RDS, 3500 RDS
f. Gearing Ratios. Gear ratios are listed in Table 1–1
following Paragraph 1–11. Emergency Vehicle 3000 EVS, 3500 EVS
Series
g. Control System and Transmission Control
Motorhome Series 3000 MH
Module (TCM). The control system is capable of rec-
ognizing hydraulic and electronic conditions that are Truck Recreational 3000 TRV, 3200 TRV
not within the operating limits of the programmed cal- Vehicle Series
ibration. Some out-of-limit conditions can be cor- Pupil Transport/ 3000 PTS
rected by the control system. All out-of-limit condition Shuttle Series
diagnostic codes are stored for later retrieval by a tech-
nician. Specialty Series 3200 SP, 3500 SP, 3700 SP
Bus Series B 300, B 400
The Electronic Control System includes:
T 200 Series T 250/T 255/T 260/T 265/
• Transmission Control Module (TCM)
T 270/T 280
• Control module
T 300 Series T 310/T 325/T 350
• Shift selector
• Sensors
3000 Product Family gear ratios (digit following the 3
• Wiring harness (customer-furnished)
in 3000):
The TCM is a high-speed digital computer that re- 7 — Widest ratio coverage (WRC)
ceives information from the sensors and shift selector.
This information is processed and shift commands are 5 — Wide Ratio (WR)
sent to the control module for range selection.
2 — Close ratio (CR)
h. Oil Filters. Two disposable external-access oil 0 — Close ratio (CR)
filters are part of the control module. Each filter is in a
separate cavity which permits removal and replace-
ment without complete loss of transmission fluid. a. 3000 Product Family Vocational Model Stan-
dard and Optional Features. The following chart
i. Transmission Fluid Coolers. The main housing lists the standard (STD) and optional (OPT) features
accepts remote or integral transmission fluid coolers. of each 3000 Product Family vocational model.
Maximum
Vocational CR/WR/ Forward Deep Shallow
Model WCR Ranges PTO Retarder Sump Sump OLS
1. Pushbutton Shift Selector To view the second, third, fourth, and fifth positions
(d2, d3, d4, and d5), momentarily press the MODE
— When Oil Level Sensor (OLS) is present:
button as explained above. Momentarily press the
Press the ↑ (Up) and ↓ (Down) arrow keys
MODE button after the fifth position is displayed to
twice simultaneously. Diagnostics will be
restart the sequence of code list positions. An active
displayed immediately. The display will list
code is indicated by the illumination of the LED
the diagnostic codes logged by position
indicator when a code position is displayed while in the
(d1, d2, d3, etc.).
diagnostic display mode. In the normal operating mode,
— When OLS is not present: Press the ↑ (Up) the LED indicator illuminates to show a secondary
and ↓ (Down) arrow keys simultaneously. mode operation. Any code position which does not have
The display will list the diagnostic codes a diagnostic code logged will display “–” for the DTC.
logged by position (d1, d2, d3, etc.). No diagnostic codes are logged after an empty code
2. Lever Shift Selector position.
— When OLS is present—Press the g. Exiting Diagnostic Mode. Any one of the fol-
DISPLAY MODE button twice to enter lowing actions will result in exiting the diagnostic
Diagnostic Mode. The display will list the mode:
diagnostic codes logged by position (d1,
d2, d3, etc.). 1. Press the same buttons used to enter the diag-
nostic mode.
— When OLS is not present—Press the
DISPLAY MODE button. Diagnostics will 2. Select any range. The transmission will enter
be displayed immediately. the selected range if the range is not inhibited.
d. Diagnostic Codes. Diagnostic codes can be dis- 3. Turn off the ignition switch.
played on the display portion of the shift selector or 4. The TCM diagnostic mode is exited automati-
Allison DOC™ For PC–Service Tool. A diagnostic cally after approximately two minutes have
code is either active or historical. An active code is any elapsed without an operator input.
b. Sealed Breather and Openings. Remove all tape Check for proper fluid level. Add or drain transmission
from openings and the breather. fluid, as required, to obtain the proper level.
c. New Transmissions. If the transmission is new, 1–10. OPERATING INSTRUCTIONS
drain the residual preservative fluid. Refill the
transmission to the proper level with an Allison Detailed transmission operation information is in the
approved transmission fluid. 3000 and 4000 Product Families Principles of
Operation Manual, PO4016EN or vocational model
d. Stored Without Fluid. If the transmission was Operator’s Manuals (see Table 8–1). Refer to the
prepared for storage without fluid, drain the residual latest revision.
fluid and replace the oil filter elements. Refill the
transmission to the proper level with an Allison ap- 1–11. SPECIFICATIONS AND DATA
proved transmission fluid.
The following specifications and data provide a quick
e. Stored With Fluid. If the transmission was pre- reference to the major characteristics of the transmis-
pared for storage with fluid, it is not necessary to drain sion. More detailed information may be obtained from
and refill the transmission with new transmission fluid. Sales Tech Data books.
Gear Ratios:**
HYDRAULIC SYSTEM:
Fluid type . . . . . . . TranSynd™ (TES-295), MIL-L-2104, MIL-L-46167, MIL-PRF-21260, DEXRON®-III,
C-4 (Refer to Section 2, Paragraph 2–10.)
Filters, main
and cooler . . . . . . . Dual integral, replaceable cartridge type
Cooler . . . . . . . . . . Remote mounted, optional integral
With PTO
Base With PTO Provision and
SIZES: Transmission Provision With Retarder Retarder 3700 SP
Length (transmission 719.4 mm 821.9 mm 718.6 mm 821.6 mm 1310.3 mm
mounting face to end (28.32 in.) (32.36 in.) (28.29 in.) (32.35 in.) (51.58 in.)
of output shaft)
Depth (centerline to 327.7 mm 327.7 mm 327.7 mm 327.7 mm 555.3 mm
lowest point) (12.90 in.) (12.90 in.) (12.90 in.) (12.90 in.) (21.87 in.)
Dry Weight 243 kg 261 kg 279 kg 297 kg 530 kg
(535 lb) (575 lb) (615 lb) (655 lb) (1170 lb)
Dry Weight with integral retarder sump cooler 336.5 kg (740 lb)
(Refer to drawings AS66-001 through S66-005 for more information.)
NOTES
c. Shift selector display fluid level information is Table 2–3. Invalid for Display Messages (cont’d)
displayed two characters at a time as in Table 2–1.
Display Code DDR Message
Table 2–1. Table Fluid Level Shift Selector Display OL SUMP TEM LO
Display Sequence Interpretation of Display OL SUMP TEMP HIGH
oL oK Fluid level is correct OL OUTPUT SPEED HIGH
oL Lo 01 Fluid level is 1 quart low OL CHECK CODES
d. The shift selector will show “invalid for display” • Pushbutton shift selector—press the
codes two characters at a time. An “invalid for dis- N (Neutral) button once.
play” code is returned when the fluid level data is re-
• Lever shift selector—press the MODE
quested, but an operational condition has not been button once or move the lever.
met. The “invalid for display” codes and their meaning
are shown in Table 2–2. • For Allison DOC™ For PC–Service Tool,
follow directions in the Allison DOC™
Table 2–2. Invalid for Display Codes User Guide GN3433EN.
Display Sequence Interpretation of Display
oL—50 Engine rpm too low 2–5. MANUAL FLUID LEVEL
oL—59 Engine rpm too high CHECK PROCEDURE
oL—65 Fluid level is 1 quart high
WARNING!
oL—70 N (Neutral) not selected
To help prevent personal injury or property
oL—79 Sump fluid temperature too low damage caused by sudden and unexpected vehi-
cle movement, do not check the fluid until you:
oL—89 Sump fluid temperature too high
• Put the transmission in N (Neutral)…and
oL—95 Sensor failure
• Apply the parking brake and emergency
brakes and make sure they are properly en-
gaged…and
NOTE:
• Chock the wheels and take any other steps
Report sensor failure to a distributor or dealer in necessary to keep the vehicle from moving.
your area. (Check the Allison Transmission website
www.allisontransmission.com or a telephone direc-
tory for an Allison Transmission distributor or a. Preparation. Clean all dirt from around the end
dealer nearest you.) of the fluid fill tube before removing the dipstick. Do
not allow dirt or foreign matter to enter the transmis-
sion. Dirt or foreign matter in the hydraulic system
e. On Allison diagnostic tools, invalid for display
may clog passages and cause undue transmission part
messages are shown in the Oil (±) field of the Data
wear or sticking valves.
Monitor as shown in Table 2–3.
Table 2–3. Invalid for Display Messages b. Consistency of Readings. Always check the fluid
level reading at least twice using the following Cold
Display Code DDR Message Check and Hot Check procedures. Consistency (re-
OL SETTLING TIME X peatable readings) is important to maintaining proper
OL ENGINE SPEED LOW fluid level. If inconsistent readings persist, check the
transmission breather to be sure it is not clogged. If
OL ENGINE SPEED HIGH
readings are still inconsistent, contact your nearest Al-
OL SELECT N (NEUTRAL) lison distributor or dealer.
FULL
HOT
HOT
DO NOT fill above “COLD CHECK” band if the RUN
BAND
transmission fluid is below normal operating
temperatures. During operation an overfull DIMENSION A
(SEE CHART BELOW)
transmission can become overheated, leading to
HOT
ADD
transmission damage.
COLD
FULL
COLD
DIMENSION B CHECK
(SEE CHART BELOW) BAND
b. Cold Check Procedure 86.6 mm
(3.41 in.)
DIMENSION C
1. Park the vehicle on a level surface, chock the
COLD
(SEE CHART BELOW)
ADD
wheels, and apply the parking brake.
2. Run the engine at idle (500–800 rpm) for about TRANSMISSION
CONTROL MODULE 5.9 mm REF DIMENSION D
one minute. Shift to D (Drive) and then to SPLITLINE (0.23 in.) (DETERMINED BY
INSTALLATION)
R (Reverse) to clear the hydraulic system of
OIL TRANSMISSION SUMP DIMENSION DIMENSION DIMENSION
air. Then shift to N (Neutral) and allow the en- SUMP DESCRIPTION A B C*
gine to remain at idle (500–800 rpm). 4 INCH DEEP SUMP
101.6 mm 63.5 mm 45.7 mm
(4.00 in.) (2.50 in.) (1.80 in.)
3. With the engine running, remove the dipstick 2 INCH SHALLOW SUMP
101.6 mm
(4.00 in.)
73.7 mm
(2.90 in.)
50.8 mm
(2.00 in.)
from the tube and wipe clean. 7 INCH STANDARD**
101.6 mm 63.5 mm 45.7 mm
(4.00 in.) (2.50 in.) (1.80 in.)
4. Insert the dipstick into the tube until it stops * Reference only dimension. Actual dimension determined by installation.
** 3700 SP have 7.00 in. oil sump.
and remove. Check the fluid level. Repeat the V01832.01.00
4. Insert the dipstick into the tube until it stops 3. When choosing the optimum viscosity grade of
and remove. Check fluid level. Repeat the fluid to use, duty cycle, preheat capabilities,
check procedure to verify the reading. and/or geographical location must be taken
into consideration. Table 2–4 lists the
5. If the fluid level is not within the “HOT RUN” minimum fluid temperatures at which the
band, add or drain as necessary to bring the transmission may be safely operated. Preheat
fluid level to within the band. Safe operating with auxiliary heating equipment or by running
level is within the “HOT RUN” band on the the equipment or vehicle with the transmission
dipstick (refer to Figure 2–1). in neutral for a minimum of 20 minutes before
attempting range operation.
2–5
3000 PRODUCT FAMILIES SERVICE MANUAL—ALLISON 4 th GENERATION
LUBE
MAIN
WARNING!
Avoid contact with the hot fluid or the sump
when draining transmission fluid. Direct contact
with the hot fluid or the hot sump may result in
bodily injury.
CAUTION: NOTE:
Do not use the bolts to draw filter covers to the Whenever metallic particles larger than those nor-
sump. This can damage the covers, seals, or sump. mally found in filters are present on plug 12, the
transfer case must be disassembled to find and re-
3. Install filter 1 and cover 5 assemblies into the pair the source of the contamination.
filter compartment. Index each filter/cover as-
sembly to the holes in the channel plate/sump. 2. Tighten drain plugs to 25–32 N·m (18–24 lb ft)
Push the filter/cover assemblies in by hand to after inspection is completed.
seat the seals.
3. After refill, check the fluid level (refer to Para-
4. Install six bolts 6 into each cover 5 and tighten graphs 2–6 and 2–7).
them to 51–61 N·m (38–45 lb ft).
NOTE:
d. Refill Transmission When the transmission is not completely disassem-
bled or when just filters or fluid is changed, some
1. For all models, except the 3700 SP and, and if fluid will remain in the transmission so that refill
removed, inspect drain plug assembly 9 quantity will be less than for a dry unit.
(Figure 2–2) and replace O-ring 7 or plug 8 as
required. For 3700 SP models, remove and in-
4. Refer to Table 2–7 for typical initial fill (dry
spect drain plug assemblies 7 and 10 (Figure
unit) and for fluid amounts required to fill cool-
2–3) and replace O-rings 8 and 11 or plugs 9
ers and the remote retarder accumulator.
and 12 as required.
Table 2–7. Fluid Fill Quantities
Item Being Filled Initial Fill*
27.0 liters
LUBE
MAIN
5 2–13. BREATHER
6 LUBE
MAIN V05557.02.00
a. Location and Purpose. The breather is located
on top of the transmission converter housing. It serves
to prevent air pressure buildup within the transmission
Figure 2–3. 3700 SP Filter Change and must be kept clean and open.
NOTE: MAIN
Determine if there are diagnostic codes set which C2
LU C4
are related to the transmission difficulty you are
evaluating. Proceed to make mechanical prepara- BOTTOM VIEW C1
tions for measuring clutch pressures after codes
have first been evaluated. 3700 SP TRANSFER CASE
T-CASE MAIN
CAUTION: C7
Be sure that the hydraulic fittings have the same
thread as the plugs removed (7⁄16-20 UNF-2A).
Fittings must be straight thread, O-ring style. T-CASE
Failure to do this will result in damage to the CONNECTOR
control module.
FRONT VIEW V01834.01.01
7. Bring the transmission to normal operating transmission sump fluid temperature, main hy-
temperature of 71–93ºC (160–200ºF). Inspect draulic pressure, and clutch pressures in the
for fluid leaks in the added pressure gauge/ ranges where a problem is suspected.
transducer lines. Repair leaks as needed. Be
sure that fluid level is correct. c. Comparing Recorded Data to Specifications
2. Consult Table 2–8 and locate the transmission 6. Return the transmission to its original configu-
model that you are testing. ration. (Remove instrumentation and install
any components removed for pressure testing.
3. Operate the transmission at the conditions Pressure tap plugs should be reinstalled and
shown in Table 2–8 and record engine speed, tightened to 10–13 N·m; 7–10 lb ft.)
2–12
Main Press. Range Clutch Lock Up Clutch D’ box Main
Transmission Model/ Engine Clutches Spec. Press. Spec.* Pres. Press. Spec
Test Type rpm Range Applied kPa / [psi] kPa / [psi] kPa / [psi] kPa / [psi]
3000 Product 580–620 Neutral 1515–2035 1440–2035 10–35 1440–2035
C5
Family—Idle Main Mod OFF [220–295] [210–295] [1–5] [210–295]
Neutral 1310–1725 1235–1725 10–35 1235–1725
C5
Main Mod ON [190–250] [180–250] [1–5] [180–250]
Reverse 1450–2035 1375–2035 10–35 1375–2035
C3 C5
Main Mod OFF [210–295] [200–295]. [1–5] [200–295].
Reverse 1170–1585 1095–1585 10–35 1095–1585
C3 C5
Main Mod ON [170–230] [160–230] [1–5] [160–230]
Low C 3000 1240–1725 1165–1725 10–35 1165–1725
7-Speed Main C3 C6 [180–250] [170–250] [1–5] [170–250]
Mod OFF
Low C 3000 870–1340 795–1340 10–35 795–1340
7-Speed Main C3 C6 [125–195] [115–195] [1–5] [115–195]
Mod ON
1C 1240–1725 1165–1725 10–35 1165–1725
C1 C5
Main Mod OFF [180–250] [170–250] [1–5] [170–250]
1C 870–1340 795–1340 10–35 795–1340
2–13
Table 2–9. Sump Fluid Temperature Same as in Table 2–4 (cont’d)
2–14
Main Press. Range Clutch Lock Up Clutch D’ box Main
Transmission Model/ Engine Clutches Spec. Press. Spec.* Pres. Press. Spec
Test Type rpm Range Applied kPa / [psi] kPa / [psi] kPa / [psi] kPa / [psi]
3000 Product Family— 2080–2120 1550–1690 0–70 (C1) 310–410 310–410
High Speed (cont’d) [225–245] [0–10] [45–60] [45–60]
1C C1 C5
0–40 (C5)
[0–5.8]
1550–1690 0–70 (C1) 310–410 310–410
[225–245] [0–10] [45–60] [45–60]
2C C1 C4
0–40 (C4)
[0–5.8]
1100–1240 0–70 (C1) 310–410 310–410
[160–180] [0–10] [45–60] [45–60]
2L C1 C4 LU
0–40 (C4)
[0–5.8]
1100–1240 0–70 (C1) 310–410 310–410
[160–180] [0–10] [45–60] [45–60]
3L C1 C3 LU
0–40 (C3)
[0–5.8]
1100–1240 0–70 (C1 & C2) 310–410 310–410
4L C1 C2 LU
[160–180] [0–10] [45–60] [45–60]
10. Reduce engine speed to idle and shift the trans- 2–16. FLUID LEAK DIAGNOSIS
mission to neutral.
Most fluid leaks can be located and repaired by visu-
11. Raise engine speed to 1200–1500 rpm for two ally finding the leak and replacing or repairing the nec-
minutes to cool the transmission fluid. At the essary parts. On some occasions, a fluid leak may be
end of two minutes, record converter out (to difficult to locate or repair. The following procedure
cooler) temperature may help in locating and repairing most leaks.
2. If the transmission fluid does not cool within 2. Operate the vehicle to reach normal operating
two minutes, the cause could be a stuck torque temperature and park the vehicle. After a few
converter stator or an issue with the transmis- minutes look for dripping fluid to identify the
sion cooler, lines, or fittings. approximate location of the leak.
3. Operate the vehicle under normal operating • Converter leak in weld area
conditions. • Damaged or missing converter O-ring seal
4. Visually inspect the suspected area and trace • Porous casting
the leak path over the white powder surface to
the source. 4. Fluid comes out vent or fill tube:
c. Black Light and Dye Method • Overfilled—incorrect dipstick
• Plugged breather
NOTE:
• Water or coolant in fluid—fluid will appear
A dye and black light kit is available for finding milky
leaks. Refer to the manufacturer’s directions when
using the kit. Refer to kit directions for the color of • Incorrect electronic fluid level indication
the fluid and dye mix.
• Drain-back holes plugged
3. Direct the black light toward the suspected • Improperly tightened fasteners or dirty/
area. The dyed fluid will appear as a brightly damaged threads
colored path leading to the source.
• Warped flanges or sealing surface
d. Possible Points of Fluid Leaks
and Their Causes • Scratches, burrs, or other damage to a
sealing surface
1. Transmission mating surfaces:
• Damaged or worn gasket
• Attaching bolts not correctly tightened
• Cracked or porous casting
• Improperly installed or damaged gasket
• Mounting face damaged • Improper sealant used (where applicable)
2
3
1
2 6
3
2 8
13 9
3
12 11
10
V05558.03.00
Figure 2–5. Output Flange and Oil Seal—3000 Product Family (Except 3700 SP)
4. Insert bolt 10 through retainer plug 11. Figure 2–6. Output Flange and Oil Seal—3700 SP
120 cm
(48 in.)
200 cm
(78 in.) OIL DRAIN STEEL TOP
TROUGH
60 cm 16-GAUGE SHEET STEEL
(24 in.) 35 mm (11Ú2 in.) DEEP
35 mm (11Ú2 in.) WIDE
OIL DRAIN
(BOTH SIDES) 5x15 cm
(2x6 in. BOARD)
FOR TOP FRAME
10x10 cm AND LEG BRACKETS
(4x4 in. LEGS)
V00660.02
• Retaining ring pliers • Clean, lint-free shop cloths (do not use
waste cloths)
• Micrometer (metric preferred)
• Containers for parts
• Depth micrometer (metric preferred)
• Supply of wood blocks
• Dial indicator set (metric preferred)
• Petrolatum
• Metric headless guide bolts set
• Container of mineral spirits for cleaning
• M10 eye bolt
parts
• M16 eye bolt
CAUTION:
• Suitable hoist—500 kg (1000 lb) capacity
Caustic cleaning compounds will damage some
• A 12 N·m (100 lb in.) torque wrench transmission parts. Use only mineral spirits to
clean transmission parts.
• A 350 N·m (250 lb ft) torque wrench
WARNING!
• A press for disassembly and assembly of
spring-loaded clutches and interference-fit Use appropriate safety equipment such as safety
parts glasses, safety shoes, and gloves.
J 35926 J 29109
V05613.02.00
2 3
6A 6 9 10
10A
7
6C 8
10B
7C
7B 8E 8A
6B 8B
11 13 7A 19
13B 13C 8C
17 8D
13A
16
20
12 14 15
18 30
x
–
9 +
–
8 6 =
5 3
7 2 R
4 TE
EN
1
0
23
25
23B 28
23C 25B
29
23A
25A
NOTE: Objects are not shown to scale V05559.04.01
3–5. CLEANING AND INSPECTION installation. Observe the following rules to provide
maximum bearing life:
a. Dirt Causes Malfunction. All parts must be • Do not unwrap new bearings until they are
clean to permit effective inspection. Do not allow dirt to be installed.
or foreign material to enter the transmission during as-
• Do not remove the grease in which new
sembly. Even minute particles can cause close-fit
bearings are packed until they are to be in-
parts, such as valves, to malfunction.
stalled.
b. Cleaning Parts • Do not lay bearings on a dirty bench. Place
1. Clean all metallic transmission parts, except bearings on clean, lint-free paper.
bearings and friction-faced clutch plates, by • If a bearing is not installed immediately,
steam-cleaning or with volatile mineral spirits. wrap or cover the lubricated bearing with
Do not use caustic soda solution for steam- clean paper or lint-free cloth to keep out
cleaning. Clean friction-faced clutch plates and dust.
bearings with mineral spirits only.
e. Inspecting Bearings
2. Dry all parts, except bearing assemblies, with 1. Inspect bearings for rough rotation. Replace a
compressed air. To prevent rust, lubricate bearing if its rotation is still rough after clean-
steam-cleaned parts as soon as they are dry. ing and lubrication.
3. Clean fluid passages by working a piece of soft 2. Inspect bearings for scored, pitted, scratched,
wire through the passages and flushing them cracked, or chipped races, and for excessive
with mineral spirits. Dry the passages with roller or ball wear. Replace the bearing if any
compressed air. defects are found.
4. Examine parts, especially fluid passages, after 3. Inspect a defective bearing’s bore and mating
cleaning to make certain they are entirely shaft for grooved, burred, or galled conditions
clean. Re-clean parts if necessary. that indicate the bearing has been turning in the
bore or on the shaft. If the damage cannot be
c. Cleaning Bearings repaired with crocus cloth, replace the defec-
tive part.
1. Bearings that have been in service should be
thoroughly cleaned in volatile mineral spirits. 4. When removing a bearing, do not apply pres-
sure across the balls. This can cause brinelling
2. Soak particularly dirty bearings or ones filled and bearing failure.
with hardened grease in mineral spirits before
5. If a bearing must be removed or installed with-
trying to clean them.
out the proper tool, press only on the race
which is adjacent to the mounting surface. If a
WARNING! press is not available, carefully seat the bearing
Never dry bearings by spinning them with com- with a drift and hammer.
pressed air. A spinning bearing can disintegrate,
allowing balls or rollers to become lethal flying f. Inspecting Cast Parts
projectiles. Also, spinning a bearing without lu- and Machined Surfaces
brication can damage the bearing. 1. Inspect bores for wear, scratches, grooves, and
dirt. Remove scratches and burrs with crocus
3. Before inspection, lubricate the bearings with cloth. Clean the part. Replace parts that are
transmission fluid. deeply scratched or grooved.
d. Keeping Bearings Clean. Ball or roller bearing 2. Inspect all fluid passages for obstructions. If an
failures are usually caused by dirt or grit in the obstruction is found, remove it with
bearing. Keep bearings clean during removal and compressed air, or by working a soft wire back
cloth. Thoroughly clean all residue from the retaining ring must snap tightly into its groove to
piston before assembly. function properly.
i. Inspecting Gears m. Inspecting Springs. Inspect springs for signs of
1. Inspect gears for scuffed, nicked, burred, or overheating, permanent set, or wear due to rubbing ad-
broken teeth. If a defect cannot be removed jacent parts. Replace the spring if any one of these de-
with a soft stone, replace the gear. fects are found. (Refer to Spring Data, Table 7–2 in
Section 7.)
2. Inspect gear teeth for wear that has changed
the original tooth shape. If this condition is n. Inspecting Clutch Plates (Figure 3–4)
found, replace the gear. 1. Inspect friction-faced clutch plates (internal-
3. Inspect the thrust face of gears for scores, splined plates) for burrs, embedded metal par-
scratches, and burrs. Remove such defects with ticles, severely pitted faces, loose faces, exces-
a soft stone. If scratches and scores cannot be sive wear, cone, cracks, distortion, shallow oil
removed with a soft stone, replace the gear. groove depth, or damaged spline teeth. Re-
move burrs using a soft honing stone. Replace
4. Inspect gears for load pattern and signs of dis- plates which have any defects.
tress. Any sign of distress indicates that a gear
failure during operation is possible. Reusing 2. Inspect steel plates (external-tanged plates) for
distressed gears is an individual customer deci- burrs, scoring, excessive wear, excessive cone,
sion based on experience. Backlash cannot be distortion, imbedded metal, galling, cracks,
used to establish critical gear wear. Backlash breaks, or damaged tangs. Remove burrs and
tolerances are of such nature that a gear usually minor surface irregularities using a soft stone.
pits, scuffs, scores, or galls long before gear Replace plates which have any defects.
wear becomes critical.
3. The amount of clutch plate cone is determined
j. Inspecting Splined Parts by measuring the distance between the inside
diameter of the plate and a level surface (Fig-
1. Inspect splined parts for stripped, twisted,
ure 3–4). Discard plates having excessive cone.
chipped, or burred splines. Remove burrs with
(Refer to Wear Limits, Section 7).
a soft stone. Replace the part if other defects
are found. Spline wear is not considered harm- 4. Determine oil groove depth with a depth mi-
ful except where it affects the fit of the splined crometer or by measuring the smooth surface
parts. (total) thickness of the plate, measuring the
thickness of the steel part of the plate at the oil
2. Spline wear is determined by comparing feeler
groove, and subtracting this measurement from
gauge thickness with the thickness of the worn
the total thickness. Replace plates not having
area on the spline. Replace parts having
the minimum oil groove depth. (Refer to Wear
excessive spline wear. (Refer to Wear Limits,
Limits, Section 7).
Section 7.)
3. Backlash cannot be used to establish critical
spline wear. Accurate backlash measurement
requires the mating parts to be concentrically CLUTCH PLATE
LEVEL SURFACE
located.
k. Inspecting Threaded Parts. Inspect threaded
parts for burred or damaged threads. Remove burrs MEASURE HERE FOR CONE
with a soft stone or fine file. Replace damaged parts. V00493.01
b. Grease Used for Assembly. During assembly use 2. The circumference of some seals is precoated
oil-soluble grease with a low melting point (petrola- with a dry sealant. The sealant is usually
tum) to temporarily retain parts, butt-joint sealrings, colored for easy identification. Precoated seals
scarf-cut sealrings, and hook-type sealrings. do not require any additional sealant before
installation.
c. Sealing Compounds and Nonsoluble Greases.
h. Butt-Joint Sealrings
Do not use gasket-type sealing compounds, fibrous
greases, or nonsoluble vegetable-base cooking com-
pounds inside the transmission or where they could be CAUTION:
flushed into the transmission hydraulic system. If humidity is allowed to penetrate and expand a
butt-joint sealring, the sealring can be damaged
d. Clutches and Pistons during installation. A damaged sealring will leak
1. Soak each friction-faced clutch plate (two- fluid from the clutch piston cavity and cause
minute minimum) in transmission fluid before clutch slippage. Do not open the sealed package
final assembly. until you are ready to install the sealring.
supported race.
RETARDER
TEMPERATURE
j. Electrical Components. For inspection and re- SENSOR
pair of electrical components, refer to the Allison 4th
Generation Controls Troubleshooting Manual
TS3989EN.
WARNING!
Avoid contact with the hot fluid or the sump REMOTE SUMP
when draining transmission fluid. Direct contact TACHOGRAPH PROVISION
NOTE: Metric series threads
MANIFOLD
with the hot fluid or the hot sump may result in V07394.02.00
XXX
Wo
rld
L NO.
XXX
Divisio
Tra
Manu
n of
nsmi
factur
ssion
Genera
Indiana
ed
l Motors
polis,
By
Corpor
Indiana
ation
speed sensor, the output speed sensor, the
O BIL E A E R O SPACE
UAW
AND A
G
R ICU
PART
L T U R A L I M P L E MENT
933
U TO M
MODE
A
TED
UNI
NO.
A
RIC
R K E R S O F AME WO
NO. L
XX XXX
5
1 2
3
4
6
7
16
26 14
8
25 16 9
14
23 24 16
20 13
22 14
19
21 18 12 11
17
10
15
V07379.03.00
7
4
3
8
1
9
10
11
2
5
6
10
11 2
1 1
V07378.04.00
J 35926 3 3 4
6
V07364.03.00
J 38572
Figure 4–5. Control Module Removal
WARNING!
The control module assembly weighs approxi-
1 mately 25 kg (56 lb). Handle carefully to avoid
5
personnel injury or control module damage. The
control module assembly used in a 3700 SP
4
2 weighs approximately 29 kg (65 lb).
J 38564
VIEW A
VIEW B
LOCKUP
PRESSURE
TAP
BOTTOM VIEW
j. Removal of Converter Housing Module 2. Thread a M10 eye bolt into the retarder output
(Figure 4–7) shaft 7 (Foldout 11,A) and lift the retarder
module 5 from main housing 49.
WARNING!
The retarder module assembly weighs approxi- V07370.01.00
1
1
2
2
3
4
5
8 7 6 V05569.01.00
V07375.01.00
Figure 4–7. Converter Housing Module Removal Figure 4–9. Transfer Case Adapter Housing Removal
1
5
C5
2
3
3
V05616.02.00
1 (3000 PRODUCT
FAMILY) V05617.01.00
2
3
1
1 (3500 MODEL)
1 (3700 SP)
V05565.01.01
V05618.01.00
Figure 4–11. Main Shaft Module Removal Figure 4–13. P1 Module Removal
V05621.01.00
V05620.01.00
Figure 4–15. Rotating Clutch Module Removal Figure 4–16. C3/C4 Clutch Module Removal
cover against a flat surface. Remove OD 3. Install thrust washer 23 (Foldout 5) and thrust
sealring 11 from the lockup clutch piston. plate 22 onto stator 27.
Measure the thickness of the lockup clutch
piston. Minimum thickness allowed is 5.71 4. Install retaining ring 21.
mm (0.225 inch).
5. Lube star washer 19, and install it on the stator.
18. Remove thrust bearing 16.
19. Inspect the ID of converter cover bushing 8. 6. If removed, press a new bushing 8 into the bore
Maximum allowable bushing ID is 61.51 mm of cover 7 using J 38566 bushing installer and
(2.422 inch). If replacement is necessary, re- J 8092 drive handle. Insert turbine assembly 17
move the bushing using a hammer and a chisel. onto the new bushing and check for freedom of
rotation. After the trial fit, remove the turbine
20. Remove inner sealring 9 from the converter from the front cover.
cover.
7. Install thrust bearing 16 in converter cover
21. If replacement is necessary, remove thrust
assembly 6.
washer 32 from the pump.
22. If bolt replacement is necessary, remove dam- 8. Install lockup piston seal ring 9 on the hub of
aged bolt(s) 34 from the OD of torque con- converter cover 7 and sealring 11 on the OD of
verter pump 33. lockup clutch piston assembly 10. Install the
lockup clutch piston.
23. Examine torque converter pump assembly 31
for cracks, missing vanes, or a loose torus ring. 9. Install lockup clutch/damper 12 into cover 7.
b. Assembly (Foldout 5)
10. Install lockup clutch backplate 13.
1. Install stator race 24 into stator and cam as-
sembly 27. 11. Install thirty bolts 14. Tighten bolts to 30–35
N·m (22–26 lb ft).
2. Install thirteen springs 25 and rollers 26 into
stator and cam assembly 27. Be sure springs 12. Install thrust bearing 18 onto turbine 17, if it
and rollers are installed in the cam pockets as was removed.
shown in Figure 5–1. Lube the rollers.
13. Install sealring 15 onto turbine 17 and install
SPRING (End of spring Roller to be installed in turbine 17 into converter cover assembly 5.
may be up or down) small end of cam pocket
14. Install stator assembly 20 onto turbine 17.
STATOR CAM
15. Install selective shim 28, removed in
Paragraph 5–3a(9), and thrust bearing 29 onto
the stator.
E00214.00.01
17. Install O-ring 30 onto converter cover 7. With go back to Paragraph 5–3a and disassemble the
balance marks or scribe mark aligned, place converter and install the correct shim at
converter pump assembly 31 over the top of Step b(15). Repeat Steps b(16)–b(23). If
converter cover assembly 5. dimension C equals the “NO STEP”
dimension, clearance is correct, go on to
18. Install four nuts 4, evenly spaced, onto four bolts
Step (24).
34. Tighten the nuts to 30–35 N·m (22–26 lb ft).
19. Using a depth micrometer, measure from the 24. Install the remaining thirty-two nuts 4 onto
top of the converter hub to the thrust surface of converter pump bolts 34. Tighten all the nuts to
turbine assembly 17. This is dimension A (Fig- 30–35 N·m (22–26 lb ft).
ure 5–2).
20. Insert tool J 38548 into the converter cover and 5–4. TORQUE CONVERTER
place on a flat surface. Repeat the same mea-
HOUSING MODULE
surement as in Step (19). This is dimension B.
(Models Without PTO Provision)
21. Subtract dimension B from dimension A to get
dimension C. a. Disassembly (Foldout 6,A)
22. Refer to Table 5–1 for correct shim selection.
1. If not previously removed, remove input
23. If dimension C does not equal the “NO STEP” speed sensor retaining bolt 6, sensor retaining
dimension of 0.08–0.35 mm (0.003–0.014 inch), bracket 5, input speed sensor assembly 3, and
O-ring 4. The input speed sensor should have 5. Remove bearing retainer assembly 3 and PTO
a resistance of 300 ± 30 Ohms. gear assembly 9. If necessary, use jack bolts to
loosen the bearing retainer assembly.
CAUTION:
6. Inspect the bearing bore of converter housing
Use the correct wrench size to avoid crushing the 22 for damage. Measure the bearing bore—
breather. maximum ID permitted is 140.03 mm
(5.513 inch).
2. Remove breather assembly 9.
b. Disassembly of the Bearing Retainer
b. Assembly (Foldout 6,A)
1. Be sure O-ring 4 is in place and install input 1. Remove sealring 8 from bearing retainer 7. Re-
speed sensor assembly 3. Hold bracket 5 in move oil seal 4 using tool J 24171-A.
place and install retaining bolt 6. Tighten the
bolt to 24–29 N·m (18–21 lb ft). 2. Inspect bushing 6 for damage or wear and re-
move if replacement is necessary. Maximum
bushing ID permitted is 75.23 mm (2.962 inch).
CAUTION:
Use the correct wrench size to avoid crushing the 3. Inspect the bearing bore of bearing retainer 7
breather. for damage. Measure the bearing bore—maxi-
mum ID permitted is 140.06 mm (5.514 inch).
2. Install breather 9. Tighten the breather to
12–16 N·m (9–12 lb ft). c. Disassembly of the PTO Gear Assembly
1. If not previously removed, remove input 3. Remove sealrings 10 and 16. If replacement is
speed sensor retaining bolt 21, sensor re- required, remove bearings 11 and 14 from PTO
taining bracket 20, input speed sensor as- gear 12.
sembly 18, and O-ring 19. The input speed
sensor should have a resistance of 300 d. Assembly of the PTO Gear Assembly
± 30 Ohms.
1. If removed, press bearings 11 and 14 onto PTO
gear 12, using tool J 38565.
CAUTION:
Use the correct wrench size to avoid crushing the 2. Install oil pump drive hub 13 into PTO gear 12.
breather. Install retaining ring 15 onto hub 13.
2. Remove breather assembly 28 or breather 3. Refer to Paragraph 3–6h. Insert two butt-joint
adapter 29. sealrings 10 and 16 into the sealing bore of
3. If present, remove PTO cover(s) 25 by remov- converter housing 22 and measure the end gap
ing ten bolts 26 for each cover. Remove PTO with feeler gauges. Maximum allowable seal-
cover(s) 25 and gasket(s) 24. ring end gap is 1.15 mm (0.045 inch).
4. Remove ten bolts 2 holding bearing retainer 4. Remove the two sealrings 10 and 16 from the
assembly 3 and PTO gear assembly 9 into converter housing and install them onto PTO
converter housing 22. gear 12.
3. Remove eight bolts 6 that retain pump housing Figure 5–3. Measuring Gear-Cavity Depth
assembly 7 to front support assembly 15. In The Pump Housing
PUMP HOUSING
STAKED
BUSHING
INSTALL REMOVE
14.5 mm
(0.57 in.)
FRONT SUPPORT
T.I.R. MAX SLEEVE 20
0.30 mm (0.012 in.) MIN OD PIN 19
98.83 mm (3.891 in.)
PIN 19
E FRONT
SUPPORT
SECTION EE BOTTOM 21
VIEW A VIEW B
To install, align flat on
ground sleeve with arrow
on front support
GROUND SLEEVE
16 or 17
VIEW C
Numbers in this illustration coincide
with callout numbers on Foldout 7,A V01367.00.03
J 35923-4
J 35923-4
J 28467-34
J 28467-34
FLAT WASHER
FLAT WASHER
J 35923-1
BEARING J 35923-2
BEARING
J 35923-3
VIEW A VIEW B
J 35923-4
LUBE ORIFICE
VIEW C
VIEW D ALIGNMENT SLOTS
V00221.03.00
b. Assembly (Foldout 7,B) with any lube orifice on the rotating clutch hub,
1. If removed during disassembly, install install C1 piston 24 into the center of C2 piston
bushing 13 into rotating clutch hub 14 using 20. With a soft mallet, lightly tap C1 piston un-
tools J 35922-2 and J 8092. til it is fully seated.
2. Install piston seals 17 and 18 into rotating 5. Place the assembly on tool base J 35923-4. In-
clutch hub assembly 12. Lube sealrings. stall C1 spring assembly 25.
3. Install a new OD sealring 19 in C2 piston 20. 6. Install a new sealring 27 on balance piston 26.
Lubricate C2 clutch piston inside bore and OD Lube the sealring.
of the sealring. Install C2 piston 20 into the ro-
tating clutch hub assembly 14. Lightly tap until 7. Place balance piston 26 on rotating clutch as-
it is fully seated. sembly 14, aligning the notch on C1 piston 24
with the cast bump on balance piston 26.
4. Install a new OD sealring 23 into C1 piston 24.
Lube the inside bore and OD sealring on the 8. Install tool J 35923-1 over rotating clutch as-
C1 piston 24. Aligning slot in C1 piston 24 sembly 14 along with bearing, washer, and
10. Carefully release C1 spring 25 and remove all 22. Install C2 clutch plates—six friction plates 38
tools from the assembly. and six steel reaction plates 37. Install clutch
plates alternately, starting with a steel reaction
11. Install C1/C2 assembly into rotating clutch plate 37.
drum 11.
23. Install C2 backplate 39. Install C2 retaining
12. Install C2 spring assembly 21 with the stepped ring 40.
end down. Make sure the spring assembly
24. If removed, install bushing 43 using tools
properly aligns with the drum and hub splines.
J 35922-2 and J 8092.
13. Place the assembly on tool base J 35923-4 so
25. Install P1 sun-gear drive hub assembly 401 In-
that the rotating drum is supported by tool
stall retaining ring 44.
tangs (Figure 5–9, View C). Install tools
J 35923-3 and J 35923-2 (Figure 5–9,
View B), bearing, washer, and handle. Com- 5–8. C3/C4 AND MAIN HOUSING
press C2 spring assembly 21 and install retain- MODULE
ing ring 22 (Foldout 7,B). Remove tools
J 35923-3 and J 35923-2. a. Disassembly (Foldout 8,A)
6. Remove C3 clutch pack—five friction plates 7 17. Inspect C4 clutch housing 18 for damage.
and four steel reaction plates 8.
7. Measure the thickness of each friction plate 7. b. Assembly (Foldout 8,A)
Minimum thickness allowed is 3.25 mm
(0.128 inch). Measure the oil groove depth of 1. Install piston 17 into C4 housing 18. Install
each friction plate. Minimum allowable groove spring retainer assembly 16.
depth is 0.20 mm (0.008 inch). Maximum cone
permitted is 0.40 mm (0.016 inch). 2. Install piston return plate spring retainer as-
sembly 16.
8. Measure the thickness of each steel reaction
plate 8. Minimum thickness allowed is 3. Install C4 clutch pack. Starting with a friction
2.41 mm (0.095 inch). Maximum cone allow- plate, alternately install five friction plates 15
able is 0.40 mm (0.016 inch). and five steel reaction plates 14.
9. Remove piston return plate assembly 9 with 4. To install new C3 housing wear plates, position
four return spring assemblies attached. Mea- the C3 housing on the bed of an arbor press
sure the thickness of return plate 9. Minimum with the wear plate mounting surface facing up
thickness permitted is 3.41 mm (0.135 inch). (Figure 5–10).
Maximum cone allowed is 0.40 mm (0.016
inch). 5. Align the post on the back of a wear plate with
10. Remove C3 housing assembly 14. one of three chamfered wear plate mounting
holes in the C3 housing.
11. Inspect three wear plates 12 in clutch housing
13. Measure the wear plates at the contact sur- 6. Lightly press the wear plate until it is flush or a
face. Minimum thickness allowed is 2.81 mm 0.070 mm (0.0027 inch) gap exists between the
(0.111 inch). Check flatness of backplate 4 and back of the wear plate and the C3 housing.
the wear plates. Maximum allowable distortion
is 0.15 mm (0.006 inch). If replacement is nec- 7. Repeat Steps (4) through (6), for each of the
essary remove the wear plates by gently prying two remaining wear plates.
the wear plate from the backplate.
8. Lube seal surfaces of C3 clutch piston 10, and
12. Remove C4 clutch pack—five friction plates
install the C3 clutch piston into C3 clutch
14 and five steel reaction plates 15.
housing 13.
13. Measure the thickness of each friction plate 19.
Minimum thickness allowed is 3.25 mm 9. Install C3 clutch housing assembly 13 with
(0.128 inch). Measure the oil groove depth of clutch piston 10 on top of the assembled C4
each friction plate. Minimum groove depth al- clutch housing (items 14–18). Make sure the
lowable is 0.20 mm (0.008 inch). Maximum index tangs on the clutch housings are aligned.
cone permitted is 0.40 mm (0.016 inch).
10. Install piston return plate spring retainer as-
14. Measure the thickness and cone of each steel sembly 9.
reaction plate 14. Minimum thickness allowed
is 2.41 mm (0.095 inch). Maximum allowable 11. Install P1 ring gear 6.
cone is 0.40 mm (0.016 inch).
12. Install C3 clutch pack. Starting with a friction
15. Remove piston return plate 16 with four return
plate, alternately install five friction plates 7,
spring assemblies attached. Measure the
and four steel plates 8.
thickness of return plate 16. Minimum
thickness permitted is 3.41 mm (0.135 inch). 13. To install new C3 backplate wear plates, posi-
Maximum allowable cone is 0.40 mm tion the C3 backplate on the bed of an arbor
(0.016 inch). press with the wear plate mounting surface fac-
16. Remove piston 17 from the C4 housing 18. ing up.
THRUST PLATE (3) 19. If removed, install nameplate 24 and screw 25.
NOTE:
• For 3000 Product Family models, except 3500,
3700 SP models, proceed to Paragraph a.
• For 3500 model skip Paragraphs a and b and
proceed to Paragraph c.
• For the 3700 SP model, skip Paragraphs a–d and
proceed to Paragraph e.
1. Install P3 sun gear 8 onto main shaft 9. 6. Inspect C6 bushing journal OD on main
shaft 8. Minimum allowable OD is 35.92 mm
2. Install bearing spacer 7. (1.414 inch). Inspect P3 bushing journal OD.
3. Install thrust bearing 5. Minimum OD allowed is 52.98 mm
(2.086 inch).
4. Install P2 sun gear 6.
7. Measure the front main shaft pilot. Minimum
5. Install spiral retaining ring 4. Compress the pilot OD permitted is 19.98 mm (0.787 inch).
spiral retaining ring to lock it into place. Inspect and measure main shaft journal OD for
P2 planetary bushing. Minimum journal OD
6. Proceed to Paragraph 5–10.
allowed is 42.97 mm (1.692 inch).
c. Module Disassembly (3500 Transmission
Model) (Foldout 9,A) f. Module Assembly (3700 SP Transmission
Model) (Foldout 9,B)
1. Remove spiral retaining ring 4.
1. Install thrust bearing 1.
2. Remove P2 sun gear 5 and thrust bearing 6.
2. Install P3 sun gear 7.
3. Remove spacer 7.
3. Install spacer 6.
4. Inspect and measure main shaft pilots.
Minimum pilot OD permitted is 19.98 mm 4. Install P2 sun gear 5 and thrust bearing 4.
(0.787 inch). Inspect and measure main shaft
5. Install spiral retaining ring 3. Compress the
journal OD for P2 planetary bushing.
spiral retaining ring to lock it into place.
Minimum allowable main shaft journal OD is
42.97 mm (1.692 inch).
d. Module Assembly (3500 Transmission Model) 5–10. P1 PLANETARY MODULE
(Foldout 9,A)
a. Disassembly (Foldout 10,A)
1. Remove retaining ring 2 from P2 ring gear 14.
NOTE:
2. Remove P2 ring gear 14.
Do not install thrust bearing 2 or selective shim 1
until final transmission assembly. Measurement for 3. Check P1 planetary pinion end play in P1 car-
selective shim 1 is performed during final buildup. rier assembly 4. Pinion end play should not ex-
ceed 0.94 mm (0.037 inch). Check all six
pinion gears.
1. Install spacer 7 and thrust bearing 6.
4. Remove retaining ring 5 and indexing ring 6.
2. Install P2 sun gear 5 and spiral retaining ring 4. Inspect indexing ring 6 for minor wear, flip
Compress the spiral retaining ring to lock it over worn indexing ring and reuse. This will
into place. expose a new surface of the index flat to pre-
vent spindle rotation (Figure 5–11). If both ar-
3. Proceed to Paragraph 5–10.
eas of the indexing flat are worn, replace the
e. Module Disassembly (3700 SP Transmission indexing ring.
Model) (Foldout 9,B) 5. Remove six spindles 7 from P1 carrier 8.
1. Remove spiral retaining ring 3. 6. Slide pinion gear 10, thrust washers 9 and 12,
and two bearing sets 11 from the side of P1
2. Remove P2 sun gear 5 and thrust bearing 4. planetary carrier 8. Repeat the procedure with
3. Remove spacer 6. the five remaining pinion gears.
INDEXING FLAT
5. Install P1 planetary carrier assembly 4 into P2
ring gear 14.
6. Install retaining ring 2 into P2 ring gear 14, re-
taining P1 planetary carrier assembly 4 in the
NO WEAR P2 planetary ring gear.
7. Install two thrust bearings 3 and 13 one on
each side of P1 planetary carrier assembly 4.
ABNORMAL WEAR
6.50
6.00 Max Ohms
5.50 Min Ohms
5.00
4.50
4.00
3.50
-4 32 68 104 140 176 212 248 284 Degrees F
-20 0 20 40 60 80 100 120 140 Degrees C
Temperature V09264.00.00
SPANNER
SPANNER TOOL
TOOL SPANNER
SPANNER TOOL
TOOL
(J 35925-1)
(J 37347) (J 35925-2)
(J 37025-2)
BREAKER
BREAKER TORQUE WRENCH
TORQUE WRENCH
BAR TOOL
BAR TOOL
COUNTER-
COUNTER-
STATIONARY
STATIONARY CLOCKWISE
CLOCKWISE
FORCE
FORCE ROTATION
ROTATION
TOP
TOPVIEW
VIEW
V04620.00.02
V04620.00.04
1. Remove fours bolts 89 retaining remote mani- 10. Remove bearing retainer 60 using special tool
fold 88 to retarder housing 46. J 35925-2 and J 47347 (Figure 5–13). Remove
belleville spring washer 61.
2. Remove remote manifold 88 and gasket 86.
3. If not already removed, remove output speed 11. Support retarder housing 49 so that P3 plane-
sensor bolt 42, retainer 41, output speed sensor tary carrier assembly 6 can be removed from
assembly 39, and O-ring 40 from the retarder the retarder housing. Place special tool J 47347
housing. Output speed sensor resistance should against the threaded shoulder of the P3 plane-
be 300 ± 30 Ohms. tary carrier (Figure 5–14). Drive on J 47347
with a hydraulic press or a mallet until the P3
4. If not already removed, remove temperature planetary carrier is separated from the retarder
sensor bolt 38, bracket 37, temperature sensor housing.
assembly 35, and O-ring 36 from the retarder
housing. Check the resistance of the
temperature sensor and replace the sensor if it NOTE:
is defective (Figure 5–12).
Perform Steps (12) and (15) only if roller bearing 62
5. Remove nine bolts 52, cover 51 and gasket 50 and cup 45 need to be replaced.
from the bottom of retarder housing 49.
RESISTANCE-TEMPERATURE
CHARACTERISTIC CHART
1,000,000
100,000
SENSOR RESISTANCE (‰)
10,000
1,000
100
10
1
— 40 14 68 122 176 230 284 338 392
12. Remove roller bearing 63 from the retarder 2. If replacement is necessary, remove bearing as-
housing. sembly 13.
13. Remove three bolts 33 to allow removal of
3. Measure pinion end play of all four pinions.
retarder stator assembly 20 from retarder
Pinion end play should not exceed 0.94 mm
housing 49. Remove gasket 30 which seals
(0.037 inch).
between retarder stator 27 and the retarder
housing 49.
14. Remove rotor 31 and sealring 32. Insert hook- NOTE:
type sealrings 29 and 32 into their mating The spindles and pinions do not need to be removed
bores and measure the ID of each sealring. before removing output shaft assembly 7.
Replace the sealrings if the ID exceeds
95.67 mm (3.767 inch).
15. Remove bearing cup 45 using bearing tool 4. Remove retaining ring 10. Remove indexing
J 3940. ring 11. Remove four pinion spindles 15.
c. Disassembly of P3 Planetary 5. Slide pinion gear 17, thrust washers 16 and 19,
Carrier Assembly (Foldout 11,A) and two bearings 18 from the side of P3 plane-
tary carrier 12. Repeat the procedure with three
1. Remove retaining ring 14. Remove output remaining pinion gears.
shaft assembly 7. Inspect bushing 8 inside the
end of output shaft 9 for wear or damage. Mea- 6. Measure the thickness of all thrust washers 16
sure the ID of the output shaft bushing. Maxi- and 19. Minimum thickness permitted is
mum ID allowed is 20.19 mm (0.795 inch). 1.39 mm (0.054 inch).
2. Install O-ring seal 84 and pressure tap plug 83. b. Disassembly of the P3 Planetary
Tighten plug to 10–13 N·m (7–10 lb ft). Carrier Assembly (Foldout 11,B)
3. Install valve 75, spring 74, lubed O-ring 73, and 1. If damaged, or if removing bearing
plug 72. Tighten plug to 24–29 N·m (18–21 lb ft). assembly 13, or if replacing output speed sig-
nal wheel 33, remove pin 11.
4. Install valve 66, spring 67, lubed O-ring 69, and
plug 70. Tighten plug to 24–29 N·m (18–21 lb ft). 2. If replacement is necessary, remove bearing
assembly 13.
5. Install solenoid separator plate 63, on re-
3. Measure pinion end play of all four pinion
tarder control body 65.
gears. Pinion end play should not exceed 0.94
6. Install retarder control body assembly 64, nine mm (0.037 inch).
bolts 81 and retain it to retarder housing assem-
bly 46. Tighten bolts to 24–29 N·m (18–21 lb ft). NOTE:
Spindles and pinions do not need to be removed to
5–13. REAR COVER MODULE
remove output shaft assembly 6.
a. Disassembly (Foldout 11,B)
4. Remove retaining ring 9. Remove indexing
1. If not previously removed, remove retaining ring 10. Remove four planetary spindles 16. In-
bolt 32, retainer 31, output speed sensor as- spect indexing ring 10 for abnormal wear
sembly 29, and O-ring 30. The output speed where spindles 16 contact (Figure 5–11). If ab-
sensor should have a resistance of 300 normal wear is present, flip over and reuse. If
± 30 Ohms. both corners are worn, replace indexing ring.
2. If not previously removed, remove oil seal 5. Slide pinion gear 18, thrust washers 17 and 20,
assembly 38 using seal removal tool and two bearings 19, from the side of P3 plane-
J 24171-A. If present, remove plug 39 and tary carrier 12. Repeat the procedure with the
washer 40. three remaining pinion gears.
3. Remove bearing retainer (spanner) nut 37 us- 6. Measure the thickness of thrust washers 17 and
ing special tool J 35925-2 and J 47347. 20. Minimum thickness allowed is 1.39 mm
(0.054 inch).
4. Remove belleville spring washer 36.
5. Place blocks under rear cover 28 or 41 so that 7. Remove retaining ring 15 and spacer 14.
the P3 carrier assembly is above the work 8. If not done previously, remove output shaft as-
surface far enough to allow disassembly from sembly 6.
the rear cover. Place special tool J 47347
against the threaded shoulder of the P3 carrier 9. Inspect bushing 7 inside the end of output
assembly. Drive on special tool J 47347 with a shaft 8 for replacement. Measure the ID of the
press or a mallet until the P3 carrier assembly output shaft bushing. Maximum allowable ID
is separated from the rear cover. is 20.19 mm (0.795 inch).
d. Assembly of Rear Cover (Foldout 11,B) 3. If removed, press bushing 7 inside the end of
output shaft 8 using installer J 35922-1 and
1. Install bearing cup 27 using bearing tool drive handle J 8092.
J 35922-1.
4. If removed, install output shaft assembly 6 into
2. Install inner sealring 26 onto C5 clutch P3 planetary carrier 12.
piston 24. Install outer sealring 25 onto C5
clutch piston 24.
5. Install spacer 14 and retaining ring 15.
CAUTION:
Over-tightening bearing retainer nut 37 will 5–14. ADAPTER HOUSING AND
damage bearing rollers and cone 13 and 35. If the P3 OVERHAUL
torque wrench and breaker bar positions in Fig-
ure 5–13 are reversed, the output spanner nut a. Disassembly (Foldout 16,B)
will be overtorqued. Be sure wrenches are posi-
tioned ONLY as shown in Figure 5–13. 1. Place adapter housing assembly 14 on tool
base J 35923-4 with output end down.
5. Install and tighten bearing retainer nut 37 using 2. Install tool J 35923-2 along with its washer,
special tools J 47347 and J 35925-2. Place the bearing, and handle.
NOTE:
P3 carrier disassembly is covered in Steps (12)
J 35925 through (16).
6. Using a soft face mallet, loosen C5 clutch pis- 1. If removed, press bushing 6 inside carrier 5,
ton 17. Remove C5 piston from adapter hous- using installer J 38569 and drive handle
ing 20. J 8092.
7. Remove square cut outer sealring 18 and inside 2. Install two bearings 10 into the center of pinion
lip-type sealring 19 from the piston. gear 9. Install thrust washers 8 and 11 in P3
planetary carrier 5. Align the thrust washer
8. Inspect seal bore areas in the housing for nicks tangs with the slot in the carrier and retain
and wear. them with oil-soluble grease. Slide the pinion
9. Remove plug 22 from the lower left side of the gear and bearing sets into the side of the P3
housing. planetary carrier between the thrust washers.
Repeat the procedure with the three remaining
10. Remove O-ring 23 from the plug. pinion gears.
11. Remove filter screen 24 from housing 20. This 3. Install four pinion spindles 7 so the lower step
screen filters main sump fluid before it enters is positioned for proper installation of indexing
the transfer case lube pump. ring 3.
9. Lube adapter housing seal bores. 11. Remove four bolts 19 from pump assembly.
12. Remove pump cover 14, gear set 15, and thrust
10. Install C5 piston17, aligning the cast tab on the
washer 16 from pump body 17.
piston with the notch in the housing. Lightly
seat the piston using a soft face mallet. 13. Measure the thickness of thrust washer 16.
Minimum allowed thickness is 2.47 mm
11. Install C5 spring retainer 16, aligning the notch (0.097 inch).
in the housing with the tab on the retainer.
14. If thrust washer 16 is worn, damaged, or does
12. Place adapter housing 20 on the base of tool not meet specifications, replace thrust
J 35923-4 with input side up. washer 16.
13. Install J 35923-2 along with its washer, bear- 15. Measure the thickness of pump cover 14. Min-
ing, and handle. Tighten the handle to com- imum allowed thickness is 6.75 mm
press spring retainer assembly 16. Make sure (0.265 inch).
that spring retainer tab indexes with the notch 16. If pump cover 14 is worn, damaged, or does
in the housing. not meet specifications, replace pump
cover 14.
14. Install retaining ring 15.
17. Measure the pump body gear-cavity depth
15. Release spring force and remove tools (Figure 5–17). Maximum allowed depth is
J 35923-2 and J 35923-4. 15.215 mm (0.599 inch).
V08534.00.00
V08538.00.00
Figure 5–19. Measuring Scavenge Pump Figure 5–20. Measuring Scavenge Pump Gear Tooth
Gear Side Clearance Clearance
WARNING!
Figure 5–21. Measuring Scavenge Pump Driven Gear
To Pump Body Diametrical Clearance The transfer case module assembly weighs ap-
proximately 270 kg (595 lb). Use proper lifting
b. Assembly (Foldout 17,C) and handling equipment to prevent injury.
2. Install bearings 9 and 10 to a depth of 3 mm 1. If not previously done, install transfer case as-
(0.118 inch). sembly 1 on the transmission overhaul stand.
Position the transfer case so that the front out-
3. Install new O-rings 5 and 6 onto shaft 4. put is upward. Begin the transfer case disas-
sembly by loosening front output shaft nut 42
4. Install thrust washer 16 into pump body 17. installed on front output shaft 57. Loosen the
nut by installing a large reaction tool (for lever-
5. Lubricate pump gear set 15 and install the gear
age) and an impact wrench. Leave the nut in-
set into pump body 17.
stalled on the front output shaft.
6. Position pump cover14 on pump body 17 and in-
2. Remove fifteen bolts 45. Remove front output
stall four bolts 19. Tighten bolts 19 to 24–29 N·m
housing 49 by lifting with a chain hoist and eye
(18–21 lb ft).
bolts in output yoke 44. Remove gasket 50.
7. Align the flats on the driven gear hub with the 3. Remove C7 clutch housing assembly 58.
flats on the inner gear set. Slide driven gear as-
sembly 8 into pump assembly 13. 4. Rotate the fixture so that the rear output end is
upward.
8. Install a NEW gasket 18, pump assembly 13,
and driven gear assembly 8 into pump
housing 3. NOTE:
Refer to Foldout 14 for Steps (5) through (11).
9. Retain the pump assembly to the pump housing
with three bolts 7. Tighten bolts 7 to 24–29 N·m
(18–21 lb ft). 5. Loosen rear output shaft nut 81 by following
the same procedure explained in Step (1).
10. Install thrust washer 12 into pump housing 3. Leave the nut installed on the rear output shaft.
6. Remove six bolts 75 and nine bolts 82. Re- 18. Remove driven gear 80, idler gear 39, and
move rear output housing 74 by lifting with a drive gear 19 (Foldout 13).
chain hoist and eye bolts. Remove gasket 73.
19. Rotate the remaining assembly, front output
7. Remove P4 carrier assembly 57. end upward.
8. Remove fifteen bolts 23 and two bolts 24. Re- 20. Remove eight bolts 4, and then remove lube
move C6 clutch housing assembly 17. Remove charging pump 5.
C6 housing gasket 22. Note where the different
21. Remove shim pack A. Shim pack A is critical
length bolts were removed so that reassembly
to drive gear end play; keep the shim pack in-
will be correct.
tact for assembly.
9. Remove five bolts 50, holding rear idler
22. Remove eight bolts 71 and manifold
cover 49 onto the transfer case. Remove rear
assembly 72.
idler cover 49, gasket 47, and O-ring 48. Use
small pry bars at locations provided in order to 23. Remove shim pack C and keep it intact for as-
remove the cover. sembly. Shim pack C is used to set up driven
gear end play.
10. Remove controls cover 43 after removing ten
bolts 44. Remove gasket 42. Removing the 24. Remove five bolts 22, then remove front idler
controls cover provides access to the control cover 23, O-ring 24, shim pack B (keeping it
valve body 29 and its wiring. intact), and gasket 28. Use pry bars as in
removal of rear idler cover.
11. Remove the bolts securing the rear transfer
case to transfer case holding fixture J 38572. 25. Remove nut 88, securing electrical harness
connector 31 to connector plate 29. Remove
four bolts 32, holding connector plate 29 to the
NOTE: transfer case. Remove connector plate 29, fol-
Refer to Foldout 12,B for Steps (12) through (14). lowed by the harness and gasket 30.
26. Remove the suction hose fitting (not shown)
12. Remove fifteen bolts 17, fastening rear transfer from the transfer case. The fitting is sealed
case cover 8 to front transfer case housing 7. with an O-ring, and provides a pilot for the
13. Thread an eye bolt in the center of rear transfer screen which filters the fluid returning to the
case cover 8, to lift it. main transmission sump from the transfer case
sump. Replace the filter screen during the over-
14. Use a soft face mallet to separate the rear and haul.
front transfer cases. Pry points at opposite ends
of the case halves are also provided to accom- 27. Inspect bearing cups 17, 37, and 78 on front
plish separation. transfer case 14 for wear and damage; like-
wise, inspect bearing cups 21, 41, and 82
15. Lift and remove the rear transfer case; removal (Foldout 13) on rear transfer case 2
of the rear transfer case exposes drive gear 19 (Foldout 14).
(Foldout 13), idler gear 39, driven gear 80, and
control valve body 29 (Foldout 14). Remove 28. If the bearing cups must be replaced, drive
gasket 16 (Foldout 13) and replace it during as- them out by using a hammer and a drift.
sembly. 29. During the cup installation, temporarily install
16. Remove the output speed sensor and solenoid the lube charging pump or the manifold with
wiring harness connectors. Remove two the appropriate shim pack to locate the cup in
bolts 46 and output speed sensor 45 the housing. Since the cup does not have an
(Foldout 14). actual seat in the housing, locating the cup
correctly is essential for proper gear end play.
17. Remove control valve assembly 29 after re-
moving six bolts 41 holding the control valve 30. Install the cups in the housing. For the drive
body on the transfer case. and driven gear cups, use special tools
5. Install NEW external sealring 15 and internal 7. Measure the C7 clutch housing bushing and
sealring 16 in piston 14. For internal replace bushing 68 if required. The maximum
sealring 16, use proper lip position. Lube inter- allowable bushing ID measurement is
nal and external sealring bores in the C6 clutch 47.26 mm (1.861 inch).
housing, and also lube the sealrings on the pis-
ton. 8. Inspect pressure-relief ball 69 and make sure
that the ball moves freely; minimum required
6. Install piston 14 into housing 19; use soft face movement is 1.00 mm (0.040 inch).
mallet to seat the piston.
9. Remove three sealrings 70 from C7 clutch
7. Inspect spring retainer assembly 13 for missing housing 67.
or broken springs. Refer to Section 7 for the
spring specifications. Replace spring e. Assembly of C7 Clutch Housing (Foldout 13)
assembly 13 if specifications are not met. 1. Inspect C7 clutch housing 67 for damage to
8. Install spring assembly 13. sealring groove and piston seal surfaces, and
housing spline wear. Replace the C7 clutch
9. Install retaining ring 12 after using tools housing if it is damaged.
J 38573-1 and J 38573-3 to compress spring
assembly 13. Remove special tools. 2. Install three new sealrings 70 into C7 clutch
housing 67.
10. Install C6 clutch hub 7 into the C6 housing.
3. If bushing 68 was removed, install the bushing
11. Install five reaction plates 11, and five friction using tools J 38569 and J 8092.
plates 10 alternately, starting with a reaction
plate 11, and finishing with a friction plate 10. 4. Install ball 69 if it was removed. Make sure
that it moves freely.
12. Install backplate 9.
5. Inspect piston 64 for sealring groove damage
13. Install retaining ring 6. and burrs.
d. Disassembly of C7 Clutch (Foldout 13)
CAUTION:
1. Remove retaining ring 60.
Incorrect lip-type sealring installation can cause
2. Remove the C7 clutch hub 59 along with C7 improper transmission operation or failure.
clutch pack. The C7 clutch pack consists of
backplate 61, five friction plates 62, and five 6. Install new sealrings 65 and 66 into C7
steel reaction plates 63 stacked in alternating piston 64. Be sure that sealring lips are prop-
order. erly positioned. Lube the sealring areas on the
piston, and seal bore areas in C7 clutch hous-
3. Inspect C7 friction plates 62 for minimum al- ing 67.
lowable thickness—2.21 mm (0.087 inch),
minimum oil groove depth allowed—0.20 mm 7. Install piston 64 into C7 clutch housing 67. Be
(0.008 inch), and maximum cone permitted— sure it is properly seated.
0.25 mm (0.010 inch).
8. Inspect C7 clutch hub 59 splines for wear and
4. Inspect C7 reaction plate 63 for minimum allow- damage. Replace hub if damage is not repair-
able thickness—2.11 mm (0.083 inch), maxi- able. Install C7 clutch hub 59 into C7 clutch
mum cone permitted—0.25 mm (0.010 inch). housing 67.
5. Inspect backplate 61 for minimum thickness 9. Install five friction plates 62 and five reaction
allowed—8.67 mm (0.341 inch), wear, flat- plates 63 into housing 67 in alternating order,
ness, and damage. starting with a reaction plate 63 and finishing
with a friction plate 62.
6. Remove C7 piston 64. Remove internal and ex-
ternal sealrings 66 and 65 from piston 64. 10. Install backplate 61 into C7 clutch housing 67.
8. Install pump front cover 83, aligning the holes 7. Inspect spindle 59 for wear and damage. Make
with the locating pins in housing 87. Drive lo- sure that the fluid holes are free of obstruc-
cating pins 9 into the cover from the back of tions.
the pump housing. Use a small punch to
slightly countersink the pins. 8. Install spindle 59 into P4 carrier 57, aligning
the setscrew pilot on the spindle with the hole
9. Install pressure relief valve 6, and spring 7 into in the housing.
bore in the pump housing.
9. Install one of three setscrews 58, and tighten to
10. Install a NEW washer onto plug 8, then install 25–35 N·m (18–26 lb ft). Swage set screw
the plug and tighten it to 12–14 N·m (9–10 lb ft). bore, using a chisel and a hammer.
10. Repeat Steps (6) through (9) to install the re- 5. Inspect bearing cups 48 and 55 for pitting,
maining two pinion gears 61. scoring, and damage. If the bearing cup(s)
needs replacement, remove it by using a ham-
11. Install sun gear 63 into P4 carrier assembly 57. mer and a drift or a hammer and tool J 3940.
j. Disassembly of Drive, Idler, and Driven Gears 6. Remove shims 51, 52, or 53, and output bear-
(Foldout 13) ing spacer 54 from output shaft 57.
1. Inspect bearings 18, 20, 38, 40, 79, and 81 per 7. If bearing 56 on output shaft 57 is damaged,
guidelines explained in Paragraph 3–5e. If any remove bearing 56. To remove bearing 56, in-
of bearings 18 and 20 installed on drive stall a split bearing puller on the bearing, and
gear 19, bearings 38 and 40 installed on idler position the bearing and the puller on a press
gear 39, or bearings 79 and 81 installed on table. Press the output shaft out using an ap-
driven gear 80 require replacement, use the propriate press.
procedure in the next step.
m. Assembly of the Front Output Housing
2. To remove bearing 18 from drive gear 19, in- and Front Output Shaft (Foldout 13)
stall a large split bearing puller on the bearing.
Using appropriate tool(s) and fixture(s), re- 1. Inspect front output housing 49 for scoring and
move the bearing by pressing out the gear. burrs.
3. To remove bearings 20, 38, 40, 79, or 81, fol- 2. If removed, install new bearing cups 48 and 55.
low the procedure in Step (2). To install the bearing cups, use tool J 38568-3
and a press. Press each bearing cup until it bot-
k. Assembly of Drive, Idler, and Driven Gears toms in the output housing.
(Foldout 13)
3. Position bearing 47 in output housing 49.
1. Inspect drive gear 19, idler gear 39, and driven
gear 80 for tooth wear and damage. Refer to 4. Install output seal 46 in the output housing us-
Paragraph 3–5i for gear inspection guidelines. ing tools J 38547 and J 35921-1.
5. Inspect output yoke 44 for scoring of seal sur-
2. If removed, install bearing 18 on drive gear 19
face. Minimum seal surface diameter allowed
using tool J 38579-1 and press. Repeat the
is 76.20 mm (3.00 inch). If the yoke does not
same procedure to install bearing 20 on drive
meet the required specification, replace the
gear 19, or bearings 79 and 81 on driven
yoke.
gear 80.
6. Inspect output shaft 57 for spline damage and
3. If removed, install bearing 38 on gear 39 using scoring. If necessary, replace the output shaft.
tool J 38579-2 and appropriate press. Repeat
the same procedure to install bearing 40 on 7. If removed, install bearing 56 on output
gear 39. shaft 57. To install the bearing, use tool
J 38579-2. Position the bearing and tool
l. Disassembly of the Front Output Housing and J 38579-2 on the press table, and then carefully
Front Output Shaft (Foldout 13) press the output shaft 57 into the bearing until
1. Remove front output shaft nut 42 and it is fully seated.
washer 43. 8. Place output yoke 44 on a press table.
2. Press front output shaft 57 out of front output 9. Position output housing 49 on the yoke.
yoke 44.
10. Place bearing spacer 54 and shims 51, 52, or
3. Remove output seal 46 by using a hammer and 53 on output shaft 57; the number of shims
a chisel or tool J 24171-A. Be careful not to could be one or more.
damage the seal bore area.
11. Install output shaft 57 into front output
4. Remove output shaft bearing 47. housing 49 through bearing 47, output seal 46,
12. Install output washer 43 and output nut 42. 5. Inspect output yoke 79 seal area for nicks, burrs,
and damage. Measure yoke seal surface; mini-
13. Perform the bearing preload procedure as ex- mum allowable seal journal OD is 76.20 mm
plained in Paragraph 5–16p which uses the (3.00 inch). If the yoke does not meet the re-
rear output housing as an example. quired specification, replace the yoke.
n. Disassembly of the Rear Output Housing 6. Place output yoke 79 on a press table.
(Foldout 14)
7. Position output housing 74 on the yoke.
1. Remove retaining ring 64 to remove P4 ring
gear 65. 8. Inspect rear output shaft 66 for spline damage
and scoring, and if required, replace the rear
2. Remove P4 ring gear 65 from rear output hous- output shaft.
ing 74.
9. If removed, install new bearing 67 on output
3. Remove output nut 81 and washer 80. shaft 66. To install bearing 67, use tool
J 38579-2. Position the bearing and tool
4. Remove rear output shaft 66 by pressing it out J 38579-2 on the press table, and then carefully
of rear output yoke 79. press output shaft 66 into the bearing until it is
fully seated.
5. Remove yoke 79. Check yoke sealing area for
nicks, burrs, or damage. 10. Install bearing spacer 69, and shims 70, 71, or
72 onto output shaft 66.
6. Remove output seal 78 by using tool
J 24171-A. Be careful not to damage the seal 11. Press rear output shaft 66 into yoke 79 passing
bore areas. through bearing 77 and output seal 78, making
sure that the output housing 74 spins freely.
7. Remove output shaft bearing 77 if it is dam-
aged. 12. Install washer 80 and output shaft nut 81 but
do not tighten.
8. Inspect bearing cups 76 and 68 for pitting,
scoring, and damage. If the bearing cups need 13. Place P4 ring gear 65 in housing 74.
replacement, remove each bearing cup by us-
ing tool J 3940 or a hammer and a drift. 14. Install retaining ring 64.
9. Remove shims 70, 71, or 72, and bearing 15. Follow bearing preload procedure explained in
spacer 69 from output shaft 66. Paragraph 5–16p.
10. If bearing 67 on shaft 66 is damaged, replace it. p. Output Housing Bearing Preload Procedure
To remove bearing 67, position the bearing on (Foldout 14)
the press table and install split bearing puller. 1. Install rear output housing 74 on the rear trans-
Using a press, press out rear output shaft 66. fer case half 2.
o. Assembly of the Rear Output Housing
2. Remove output shaft nut 81.
(Foldout 14)
3. Install washer 80 on the output shaft after coat-
1. Inspect rear output housing 74 for scoring and
ing both sides with sealant.
burrs.
4. Lube the threads on the output shaft.
2. If removed, install bearing cups 76 and 68 into
rear output housing 74 by using tool J 3940 or 5. Install output shaft nut 81 and tighten it to 610–
a hammer and a drift. 815 N·m (450–600 lb ft).
6. Install a dial indicator to read up and down 3. Replace solenoid O-rings 36 and 37 during
shaft movements. overhaul.
7. You may need to place a shim or a smooth 4. Insert solenoid 35 into valve body 30.
washer on the output shaft to get true readings.
5. Insert valve 31, followed by spring 32 and
8. Bottom the output shaft by applying downward valve stop 33.
force while slightly rotating the output yoke.
6. Push in on stop 33 to compress spring 32 and
9. The shaft is bottomed when the dial indicator insert a small cylindrical punch through the top
shows no more down movement. Zero the dial hole in body 30 to hold these parts in position.
indicator at this point.
7. Install pin 34 by starting it in the hole opposite
10. Using a chain hoist and a scale, apply an up- where the punch has been inserted. Tap the pin
ward force of 734–778 N (165–175 lbs) on the into position. The punch will be displaced as
output shaft. While force is applied, slightly the pin is installed.
rotate the yoke.
8. Install pin 40 which retains solenoid 35. Insert
11. Check the dial indicator for movement. the smooth (not ridged) end of the pin into the
mating hole at the bottom face of body 30. Tap
12. If the indicator readings are not within the spec- the pin into position flush with the bottom of
ified limits, add or remove shims and check pre- body 30. Use a small diameter punch to
load again. End play must be 0.025–0.127 mm slightly countersink pin 40.
(0.001–0.005 inch).
s. Assembly of Transfer Case Module
13. If the indicator readings are within the speci-
(Foldouts 12, 13, 14)
fied limits, coat both sides of washer 80 with
sealant and install the washer. Repeat Step (5) 1. Lube bearing cups 17, 37, and 78 (Foldout 13),
from above. installed in front transfer case housing 14.
q. Disassembly of C7 Control Valve Body 2. One side of drive gear 19 has a shorter shoul-
(Foldout 14) der than the other side. Install drive gear 19 so
1. Begin C7 valve body disassembly by removing that the side with the shorter shoulder is toward
pins 34 and 40 securing the C7 signal valve so- the front of the transmission.
lenoid 35 and C7 control valve 31 in body 30. 3. Install idler gear 39 with its threaded hole to-
Remove the pins by driving them out from the ward the front of the transmission.
top toward the bottom (machined face).
4. Install driven gear 80 into front transfer case 14
2. Remove stop 33, spring 32, and valve 31 from in the same orientation as it was removed.
body 30.
5. Install output speed sensor 45 (Foldout 14).
3. Remove solenoid 35 and O-rings 36 and 37.
6. Install two bolts 46 and tighten them to
4. Remove solenoid regulator valve 38. 24–29 N·m (18–21 lb ft).
5. Check the valves and bores for wear, scoring, 7. Install C7 control valve body assembly 29.
and damage.
8. Install six bolts 41, and tighten them to
r. Assembly of C7 Control Valve 24–29 N·m (18–21 lb ft).
Body Assembly (Foldout 14)
9. Install new transfer case gasket 16
1. Insert solenoid regulator valve 38 in the bore of (Foldout 13).
body 30 and inspect for smooth movement.
10. Install rear transfer case 2 (Foldout 14) onto
2. Inspect solenoid filter screen for damage or de- the front transfer case. If necessary, use soft
bris. face mallet to seat the case half.
V09556.00.00
d. Disassembly of C6 Control Valve Body 3. Remove solenoid retention pin 114 from bot-
(Foldout 15) tom of control valve body.
2. Lift Main control valve body and set on flat 10. Remove stop 109, spring 108, and main regula-
work space. tor valve 107.
12. Remove clip 113, spring 112, and control main 1. Install converter regulator valve 133,
valve 111. spring 134, and stop 135.
18. Install solenoid retention pin 114 through bot- 12. Install bracket 56 with diagnostic pressure
tom of main valve body assembly. switch 55. Check switch for glycol contamina-
tion, reference SIL TR-18-98. Maximum resis-
19. Install solenoid separator plate 96 on top of
tance of pressure switch 55 must not exceed
main body assembly 118.
two Ohms. Minimum resistance of pressure
i. Assembly of C6 Control Valve Body switch (open) must be at least 20,000 Ohms.
(Foldout 15) The switch should close between 159–255 kPa
(23–37 psi).
1. Install spring 175, valve 174, two rings 173
and 172, C6 enable solenoid 171, nut 169 and 13. Install twelve bolts 57. Install two bolts 48.
solenoid retention pin 176 into C6 valve
body 177. k. Installation of Electrical
Components and Sensors (Foldout 15)
2. Install spring 180, valve 181, two O-rings 183
and 184, solenoid 182, bracket 185, and secure 1. Install 24-way internal connector feedthrough
to C6 valve body 177 with screw 186. connector 13 with wire harness assembly 8.
Secure connector assembly 13 with three
3. Install spring 178, accumulator 179 into valve bolts 50. Connect all connectors. Tighten
body 177. Install bracket 168 and four bolts 50 to 1.3–2.7 N·m (12–24 lb in.).
bolts 167. Tighten the bolts to 10–13 N·m
(7–10 lb ft).
2. Reconnect all connectors.
j. Assembly of the Solenoid Valve Body
(Foldout 15) 3. If present install two bolts 136 and oil level
sensor (OLS) assembly 137. Tighten bolts to
1. Install solenoid 90, two O-rings 91 and 92. 10–13 N·m (7–10 lb ft).
2. Install spring 89, valve 88, O-rings 86 and 87 4. Install two bolts 93 and turbine speed
and solenoid 85. sensor 94. The turbine speed sensor should
have a resistance of 300 ± 30 Ohms.Tighten
3. Install spring 84, valve 83, two O-rings 81 and
bolts to 10–13 N·m (7–10 lb ft).
and 82, and solenoid 80.
4. Install valve 78, and spring 79. Insert tool l. Installation of Filters (Foldout 15)
J 47942 tool into slot to push in valve and in-
stall clip77. 1. Install suction filter 5 and gasket 7 and face
seal 6. Install three bolts 3. Tighten bolts to 10–
5. Install spring 66, valve 65, and solenoid 62 13 N·m (7–10 lb ft).
with two O-rings 63 and 64.
2. Install two filters 162, two O-rings 161, two
6. Install spring 71, valve 70, and solenoid 67 O-rings 160, two gaskets 159, and two filter
with two O-rings 68 and 69. covers 158.
7. Install spring 76, valve 75, and solenoid 72
with O-rings 73 and 74. 3. If present and not previously installed, install
oil level assembly 161 and two bolts 160.
8. Install three face seals 49. Tighten bolts to 10–13 N·m (7–10 lb ft).
NOTES
b. Procedures. When a procedure does not apply to 1. Rotate the repair stand so the input end of the
your specific model, go to the next applicable proce- main housing is up.
dure. 2. Using a hoist and an M16 eye bolt, insert rotat-
c. Illustrations. Illustrations will not always show ing clutch module 1 in the front of the main
your model, but when an operation is identical for all housing.
models, the correct procedure is shown. c. Installation of the Front Support/Charging
d. General Information. Refer to Section 3 for gen- Pump Module (Figure 6–3)
eral information as follows:
1. Lower front support and charging pump mod-
Paragraph Description ule 3 over the top of the turbine shaft.
3–2 Tools, Equipment
3–3 Replacement Parts 1
NOTE:
All parts must be cleaned and lubricated before
assembly.
V05621.01.00
3. Mesh the P1 pinion gears with the P1 ring gear Figure 6–4. P1 Planetary Module Installation
inside the C3/C4 clutch assembly.
e. Installation of the P2 Planetary Module
(Figure 6–5)
1. Install P2 planetary module 1—consisting of 1
the P2 carrier and the P3 ring gear.
C5
2. Mesh the P2 pinions with the P2 ring gear dur- 2
3
ing installation.
f. Installation of the C5 Clutch Pack (Figure 6–5).
Install the C5 clutch pack in the main housing—eight
steel reaction plates 2 and seven friction plates 3,
stacked alternately, starting with a steel reaction plate.
Stack all plates so plate cone faces the same direction.
Steel plates mesh with the main housing and reaction V05617.01.00
plates mesh with the P3 ring gear.
g. Installation of the Main Shaft (Figure 6–6). In- Figure 6–5. P2 Planetary Module and
stall main shaft 1 as assembled in Section 5, without C5 Clutch Pack Installation
selective shim 2 and thrust bearing 3 (does not apply to
3700 SP models).
1 (3000 PRODUCT
FAMILY)
2
3
2
3
1
1 (3500 MODEL)
1 (3700 SP)
V05619.01.00 V05565.01.01
1. Place a straight edge across the retarder or rear 5. Measure dimension D, from top of the straight
cover mounting surface of the main housing. edge to the mounting gasket.
6. Measure dimension E from the top of the
2. Measure dimension A, from top of the straight straightedge to the thrust bearing contact sur-
edge to the selective shim thrust surface on the face on the P3 planetary carrier. Subtract di-
main shaft bearing spacer. mension E from dimension D—the remainder
3. Measure dimension B, thickness of straight is dimension F.
edge. Subtract dimension B from dimension 7. Dimension G is the remainder of C minus F
A—the remainder is dimension C. and determines the thickness of the selective
4. Place the retarder or rear cover module output shim.
end down (facing the bench top). Install an 8. Install the proper thickness selective shim and
uncompressed gasket on the retarder the thrust bearing.
BEARING AND
STRAIGHT EDGE SHIM REMOVED STRAIGHT EDGE
DIM. E
GASKET
INSTALLED
DIM. A DIM. B
DIM. C DIM. F
DIM. D
NON-
RETARDER RETARDER
MODEL MODEL
MAIN SHAFT MODULE
PROCEDURE:
• FORMULA (C) – (F) = G
DIM. G USE P/N SHIM ID
4.574–4.843 mm
29503218 1 NOTCH
0.180–0.190 in.
4.844–5.113 mm
29503219 2 NOTCHES
0.192–0.201 in.
5.114–5.383 mm
29503220 3 NOTCHES
0.202–0.212 in.
5.384–5.653 mm
29503221 4 NOTCHES
0.213–0.223 in.
5.654–5.923 mm
29503222 5 NOTCHES
0.224–0.233 in.
5.924–6.193 mm
29503223 6 NOTCHES
0.234–0.244 in.
6.194–6.463 mm
29503224 7 NOTCHES
0.245–0.254 in. V06748.01.00
Figure 6–7. Main Shaft Selective Shim Measurement (Close Ratio Models)—3000 Product Family
Except 3700 SP
i. Main Shaft Selective Shim Measurement surface and place a straight edge across the P3
(Wide Ratio Models) (Figure 6–8) planetary carrier.
1. Place a straight edge across the retarder or rear 5. Measure dimension D from top of the straight
cover mounting surface of the main housing. edge to the rear cover mounting gasket.
6. Measure dimension E from the top of the
2. Measure dimension A, from top of the straight straightedge to the thrust bearing contact sur-
edge to the selective shim thrust surface on the face on the P3 planetary carrier. Subtract di-
main shaft bearing spacer. mensions E from dimension D—the remainder
3. Measure dimension B, thickness of straight is dimension F.
edge. Subtract dimension B from dimension 7. Dimension G is the remainder of C minus F
A—the remainder is dimension C. and determines the thickness of the selective
4. Place retarder or rear cover output end down shim.
(facing the bench top). Install an uncompressed 8. Install the proper thickness selective shim and
gasket on the retarder or rear cover mounting the thrust bearing.
BEARING AND
STRAIGHT EDGE SHIM REMOVED STRAIGHT EDGE
DIM. E
GASKET
INSTALLED
DIM. A DIM. B
DIM. C DIM. F
DIM. D
NON-
RETARDER RETARDER
MODEL MODEL
MAIN SHAFT MODULE
PROCEDURE:
• FORMULA (C) – (F) = G
DIM. G USE P/N SHIM ID
4.574–4.843 mm
29503226 1 NOTCH
0.180–0.190 in.
4.844–5.113 mm
29503227 2 NOTCHES
0.192–0.201 in.
5.114–5.383 mm
29503228 3 NOTCHES
0.202–0.212 in.
5.384–5.653 mm
29503229 4 NOTCHES
0.213–0.223 in.
5.654–5.923 mm
29503230 5 NOTCHES
0.224–0.233 in.
5.924–6.193 mm
29503231 6 NOTCHES
0.234–0.244 in.
6.194–6.463 mm
29503232 7 NOTCHES
0.245–0.254 in. V06747.01.00
Figure 6–8. Main Shaft Selective Shim Measurement (Wide Ratio)—3500 Model
GASKET DIM. E
INSTALLED DIM. F
DIM. B
DIM. D
DIM. C
PROCEDURE:
A A
(38–45 lb ft). Also four M10 x 1.5 x 192 mm MARKED A
A A
bolts, gasket 94, jumper manifold 95 or mani-
fold 96 (Foldout 11,A). Tighten M10 bolts to A A
1
5
WARNING!
The transfer case module assembly weights ap- 4
proximately 270 kg (595 lb). 2
7
4. Use hoist and J 38572 to lift transfer case 3.
3
5. Install transmission shaft adapter 5 into trans- V07368.04.00
fer case 3.
Figure 6–13. Transfer Case Module Installation
6. Install transfer case 3 into the main transmis-
sion, and install nineteen bolts 2. o. Installation of the Converter Housing Module
(Figure 6–14)
7. Install bolt 27 or 28 (Foldout 16B, bolt 7 in
1. Place transmission input end up. Install a new
Figure 6-13) passing through C6 housing into
converter housing gasket 2 on main housing
the adapter housing. Tighten bolt 27 or 28 to
module 4.
51–61 N.m (38–45 lb ft).
2. Install guide bolts to ease converter housing 1
8. Tighten bolts 2 to 51–61 N . m (38–45 lb ft). installation and keep gasket 2 in place.
7
8
J 38564
VIEW A VIEW B
J 38548
Figure 6–15. Torque Converter Module Installation and Selective Shim Measurement
WARNING! 2
Transmissions installed in overhaul stands must
be positioned vertically before installing control
module. Failure to do so could result in personal 1 1
injury.
WARNING!
The control module assembly weighs approxi- 3 3 4
mately 25 kg (56 lb). The control module assem-
bly used in the 3700 SP weighs approximately 29 V07364.03.00
kg (65 lb).
Figure 6–16. Control Module Installation
2. Install a new control module gasket 2 over the r. Installation of Power Takeoff(s)
dowel pins on control module 1. (Figure 6–17)
3. Guide control module 1 onto the main housing 1. If removed, install PTO studs 4.
using the dowel pins. Install one bolt 163
(Foldout 15) in the top center bolt hole. 2. Install PTO gasket 3 and PTO assembly 2. In-
sert bolt 1 into each of the 6 o’clock and
4. Install two filter covers 158 (Foldout 15), two
12 o’clock positions. Install the remaining six
gaskets 159, two O-rings 160, two O-rings
bolts. Tighten bolts to 51–61 N·m (38–45 lb ft).
161, and two filters 162. Install remaining
thirty-one bolts 163 and/or 164. Tighten all s. Installation of Integral Oil Cooler
bolts to 51–61 N·m (38–45 lb ft). (Foldout 17,A)
NOTE:
Main and lube filters are interchangeable. However, NOTE:
the filters for a two inch sump are a different length • For units without retarder, go to Step (1).
than those for a four inch sump. The filters in the • For units with retarder, skip Steps (1)–(5) and go
seven inch sump are the same as in the two inch sump. to Step (6).
3
1
4
3
1
V07369.01.00
1. Install two M10 guide bolts at rear of main hous- 5. Install two bolts 24 and seventeen bolts 25
ing where cooler housing attaches. Slide gasket 5 (two will replace the guide bolts). Tighten
and cooler housing 7 onto the guide bolts. Be the two bolts 24 to 90–110 N·m (66–81 lb ft)
sure the housing and gasket are properly aligned. and the seventeen bolts 25 to 51–61 N·m
(38–45 lb ft).
2. Install nine bolts 15 (two will replace the guide
bolts) and nine washers 16 which fasten the 6. Install two M10 guide bolts at rear of retarder
cooler housing to the main housing. Tighten housing where cooler housing attaches. Slide
the bolts to 51–61 N·m (38–45 lb ft). gasket 6 and cooler housing 7 onto the guide
3. Install plate assembly 27 with four lubed bolts. Be sure the housing and gasket are prop-
O-rings 28 in place. Push the plate assembly in erly aligned.
until the O-rings are seated in their mating
bores in the cooler housing. 7. Install bolt 12, washer 11, six bolts 15 and six
washers 16 which fasten the cooler housing to the
4. Install two O-rings 26. Install two guide bolts retarder housing. Tighten the bolts to 51–61 N·m
at rear of cooler housing where cover 23 at- (38–45 lb ft). Install three bolts 13 and three
taches. Slide gasket 22 and cover 23 into posi- washers 14. Tighten the three bolts 13 to
tion over the guide bolts. 100–120 N·m (74–88 lb ft).
t. Installation of Integral Retarder Sump Oil 15. Install the remaining fourteen M10 x 1.5 x 60
Cooler (Foldout 17,B) bolts 1.
1. Rotate the transmission so that the retarder is 16. Evenly tighten sixteen M10 x 1.5 x 60 bolts 43
facing up. to 51–61 N·m (38–45 lb ft).
2. Install two headless guide bolts into the re- 17. 1nstall six bolts 5. Tighten bolts to 30–35 N·m
tarder housing. (23–25 lb ft)
3. Install gasket 4 over the headless guide bolts. 18. Install water inlet and outlet hoses.
4. Install cooler manifold 16 over the headless 19. If used, install the retarder accumulator hose
guide bolts. onto the fitting on cooler manifold 16.
5. Install three M12 x 1.75 x 218 bolts 8. Tighten u. Installation of Speed Sensors
bolts to 100–120 N·m (74–88 lb ft).
13. Install two gaskets 3. 4. Install input speed sensor assembly 18 (Fold-
out 6,B), O-ring 19, retainer 20, and bolt 21
14. Align and install two inlet or outlet hose into the converter housing module. Tighten
adapters 2. bolt 21 to 24–29 N·m (18–21 lb ft).
5
1 2
3
4
6
7
16
26 14
8
25 16 9
14
23 24 16
20 13
22 14
19
21 18 12 11
17
10
15
V07379.03.00
11
NOTE:
If you have a 3700 SP model transmission, complete 2
5
Steps (13) and (14). Refer to Figure 6–19.
6
13. Replace gasket 9 (thin coated metal type), and 10
install scavenge pump 7. Install nine bolts 8. 11
Tighten bolts 8 to 51–61 N.m (38–45 lb ft).
14. Install O-ring 4 and fitting 3 into scavenge
pump 7. Tighten jam nut to 100–120 N·m
(74–88 lb ft).
w. Removal of Transmission From Repair Stand V07378.04.00
NOTE:
WARNING!
Refer to Mechanic’s Tips MT4015EN for preparing
Transmission dry weights are as follows:
the transmission for installation and installing the
transmission into the vehicle. • Base transmission 243 kg (535 lbs)
• With Retarder 279 kg (615 lbs)
J 29109
J 35926
J 38572
J 35926
VIEW A VIEW B
3000 PRODUCT FAMILY 3700 SP
V07377.02.00
NOTES
Wear Limit
Illustration Description mm (inches)
Foldout 5 TORQUE CONVERTER MODULE
9 Cover Bushing, Maximum ID 61.51 2.422
11 Piston, Minimum Thickness 5.71 0.225
13 Lockup Clutch Friction Plate Flatness, Maximum Distortion 0.51 0.020
13 Lockup Clutch Friction Plate, Minimum Thickness 8.05 0.317
13, 18 Turbine-To-Damper Spline Wear, Maximum Movement 0.38 0.015
14 Backing Plate Wear Surface, Minimum Thickness 8.58 0.338
16 Turbine Hub Hook-Type Sealring, Maximum ID When Installed In 56.75 2.234
Cover 7 Bore
18 Turbine Hub, Minimum OD 61.34 2.415
23 Stator Thrust Plate, Minimum Thickness 11.68 0.460
34 Converter Pump Hub, Minimum OD 74.999 2.9527
Foldout 8,B TORQUE CONVERTER HOUSING MODULE — WITH PTO
6 Bearing Retainer Bushing, Maximum ID 75.23 2.962
7 Bearing Retainer Bearing Bore, Maximum ID 140.06 5.514
10, 17 Oil Pump Drive Hub Seals, When Installed in Sealing Bore, 1.15 0.045
Maximum End Gap
14 Oil Pump Drive Hub, Maximum Tang Wear 0.38 0.015
23 Converter Housing Bearing Bore, Maximum ID 140.03 5.513
Wear Limit
Illustration Description mm (inches)
Foldout 7,A FRONT SUPPORT AND CHARGING PUMP MODULE
8 Pump Housing Bushing, Maximum ID 75.23 2.962
9 Pump Housing Gear Cavity, Maximum Depth 17.93 0.706
9 Pump Housing Gear Cavity, Maximum ID 127.30 5.012
9, 10 Driven Gear-To-Pump Housing, Maximum Diametrical Clearance 0.36 0.014
10 Drive/Driven Gear, Maximum Gear Tooth Tip Clearance 0.20 0.008
10 Driven Gear, Minimum OD 126.95 4.998
10 Drive/Driven Gear, Minimum Width 17.81 0.701
10, 14 Gear-To-Plate Maximum Side Clearance 0.13 0.005
11 Pump Drive Gear Bushing, Maximum ID 57.30 2.256
14 Wear Plate, Minimum Thickness 4.70 0.185
16, 17 Ground Sleeve Oil Pump Bushing Journal, Minimum OD 57.04 2.246
20 Front Support Sleeve, Minimum Dimension 98.83 3.891
23 Front Support Seal, Maximum End Gap 1.44 0.057
Foldout 7,B ROTATING CLUTCH MODULE
7 Turbine Shaft Bushing ID, Maximum 20.19 0.795
10 Turbine Shaft Seal, Maximum End Gap 0.94 0.037
11 Drum, Maximum Spline Wear 0.38 0.015
13 Rotating Clutch Hub Bushing, Maximum ID 99.25 3.907
29 C1 Clutch Pressure Plate Flatness, Maximum Distortion 0.15 0.006
29 C1 Clutch Pressure Plate, Minimum Wear Surface Thickness 6.25 0.246
30, 37 C1, C2 Friction Plate, Maximum Cone 0.40 0.016
30, 37 C1, C2 Friction Plate, Minimum Thickness 2.21 0.087
30, 37 C1, C2 Friction Plate, Minimum Oil Groove Depth 0.20 0.008
31, 36 C1, C2 Steel Reaction Plate, Maximum Cone 0.40 0.016
31, 36 C1, C2 Steel Reaction Plate, Minimum Thickness 2.41 0.095 *
33, 35 C1, C2 Drive Hub, Maximum Spline Wear 0.38 0.015
38 C2 Clutch Pressure Plate, Maximum Cone 0.45 0.018
38 C2 Clutch Pressure Plate, Minimum Thickness 6.25 0.246
42 P1 Sun Gear Drive Hub Bushing, Maximum ID 68.22 2.685
Wear Limit
Illustration Description mm (inches)
Foldout 8,A MAIN HOUSING MODULE
4 Backing Plate Flatness, Maximum Distortion 0.15 0.006
5, 16 C3, C4 Wear Plate Flatness, Maximum Distortion 0.15 0.006
5, 16 C3, C4 Wear Plate, Minimum Thickness At Wear Point 2.81 0.111
7 P1 Ring Gear, Maximum Spline Wear 0.38 0.015
8, 19, 28 C3, C4, C5 Friction Plate Cone, Maximum Distortion 0.40 0.016
7, 15 C3, C4 Friction Plate, Minimum Thickness 2.21 0.087
C3, C4 Friction Plate, Maximum Friction Material Erosion Around
7, 15 4.00 0.157
Lubrication Slots
7, 15 C3, C4 Friction Plate, Minimum Oil Groove Depth 0.20 0.008
8, 14, 28 C3, C4, C5 Reaction Steel Plate Cone, Maximum Distortion 0.40 0.016
8, 14 C3, C4, C5 Reaction Steel Plate, Minimum Thickness 2.41 0.095
28 C5 Reaction Steel Plate, Minimum Thickness 3.25 0.123
9, 16 C3, C4 Piston Return Plate Cone, Maximum Distortion 0.40 0.016
9, 16 C3, C4 Piston Return Plate, Minimum Thickness 3.41 0.135
17, 24 C3, C4 Clutch Housing Flatness, Maximum Distortion 0.15 0.006
27 Main Housing Clutch Plate Splines, Maximum Wear 1.15 0.045
28 C5 Friction Plate, Minimum Thickness 2.90 0.114
28 C5 Friction Plate, Minimum Oil Groove Depth 0.20 0.008
Foldout 8,B
MAIN SHAFT MODULE (3000, 3500,)
and 9,A
NA Main Shaft Spines Maximum Wear 0.38 0.015
9, 8 Main Shaft Pilot, Minimum OD 19.98 0.787
9, 8 Main Shaft P2 Bushing Journal, Minimum OD 42.97 1.692
Foldout 9, B MAIN SHAFT MODULE (3700 SP)
NA Main Shaft Spines Maximum Wear 0.38 0.015
8 Main Shaft Pilot (Front), Minimum OD 19.98 0.787
8 Main Shaft P2 Bushing Journal, Minimum OD 42.97 1.692
8 Main Shaft C6 Bushing Journal, Minimum OD 35.92 1.414
8 Main Shaft P3 Bushing Journal, Minimum OD 52.98 2.086
Wear Limit
Illustration Description mm (inches)
Foldout 10,A P1 PLANETARY MODULE
9, 12 P1 Pinion Thrust Washer, Minimum Thickness 1.39 0.054
10 Pinion, Maximum End Play 0.94 0.037
14 P2 Ring Gear, Maximum Spline Wear 0.38 0.015
Foldout 10,B P2 PLANETARY MODULE
6 P2 Carrier Bushing, Maximum ID 43.20 1.701
7, 10 P2 Pinion Thrust Washer, Minimum Thickness 1.39 0.054
9 Pinion, Maximum End Play 0.94 0.037
14 P3 Ring Gear, Maximum Spline Wear 0.38 0.015
Foldout 11,A;
RETARDER AND P3 PLANETARYMODULE
11B,
8 Output Shaft Bushing, Maximum ID 20.19 0.795
16, 19 P3 Pinion Thrust Washer, Minimum Thickness 1.39 0.054
17 Pinion, Maximum End Play 0.94 0.037
29, 31 Retarder Rotor Sealring, Maximum ID 56.75 2.234
Foldout 11,B REAR COVER AND P3 PLANETARY MODULE
7 Output Shaft Bushing, Maximum ID 20.19 0.795
17, 20 P3 Pinion Thrust Washer, Minimum Thickness 1.39 0.054
18 Pinion, Maximum End Play 0.94 0.037
Foldout 13 C7 CLUTCH HOUSING
44 Yoke Journal Seal Wear, Minimum Diameter 76.20 3.000
61 C7 Backplate, Minimum Thickness 8.67 0.341
62 C7 Friction Plate, Minimum Thickness 2.21 0.087
62 C7 Friction Plate, Minimum Oil Groove Depth 0.20 0.008
62 C7 Friction Plate, Maximum Cone 0.25 0.010
63 C7 Reaction Plate, Minimum Thickness 2.11 0.083
63 C7 Reaction Plate, Maximum Cone 0.25 0.010
68 Bushing, Maximum ID 47.26 1.861
69 Ball, Free Movement 1.00 0.040
Wear Limit
Illustration Description mm (inches)
Foldout 14 C6 CLUTCH HOUSING
9 Backplate, Minimum Thickness 7.90 0.311
9 Backplate, Maximum Cone 0.40 0.016
10 C6 Friction Plate, Minimum Thickness 3.68 0.145
10 C6 Friction Plate, Minimum Oil Groove Depth 0.20 0.008
11 C6 Reaction Plate, Minimum Thickness 2.41 0.095
11 C6 Reaction Plate, Maximum Cone 0.40 0.016
19 C6 Housing, Maximum Groove Wear 2.29 0.090
21 C6 Housing Bushing 36.18 1.424
Foldout 16,B TRANSFER CASE ADAPTER HOUSING AND P3 MODULE
6 P3 Carrier Bushing, Maximum ID 53.22 2.095
7, 10 P3 Pinion Thrust Washer, Minimum Thickness 1.39 0.054
9 Pinion, Maximum End Play 0.94 0.037
Foldout 17,C Scavenge Pump Thrust Washer, Minimum Thickness 2.47 0.097
7–6
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.
5 25 Stator 29500064 No Code N/A N/A N/A 17.8 3.3 0.7–1.6
Convoluted (0.70) (0.13) (0.16–0.36)
7,B 21 C2 Return 29503215 No Code 12* 2. 04* 13.00* 45.3** 37.0 4823–5379**
(0.080) (0.512) (1.78) (1.46) (1084–1209)
7,B 25 C1 Return 23045586 No Code 10* 2.19* 16.00* 45.2** 27.5 5763–6369**
(0.086) (0.630) (1.78) (1.08) (1296–1432)
8,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)
8,A 12 C3 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)
8,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)
8A 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)
11,A/11,B 23/23 C5 Retainer 29507780 No Code 9.5* 1.83* 14.35* 39.2** 25.0 3044–3364**
(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)
* Individual Springs
** For the complete Spring Assembly
Table 7–2. Spring Data (cont’d)
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.
11,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)
11,B 78 Retarder Control 29529300 White/ 8.52 1.27 13.46 33.02 16.51 34.22–37.86
Low, 54 psi Black Stripe (0.050) (0.530) (1.30) (0.650) (7.69–8.51)
11,B 78 Retarder Control 29529299 Yellow/ 9.25 1.04 12.19 37.8 16.51 23.44–25.94
Medium, 64 psi Red Stripe (0.041) (0.480) (1.49) (0.650) (5.27–5.83)
11,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)
11B/16,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)
C6 Spring Retainer 2109–
14 13 1.84 12.70 35.10 26.20
29501191 No Code 10 2331**
Assembly (0.072) (0.500) (1.382) (1.032)
(474–524)
15 71 A Trim 23049338 No Code 4 0.67 11.05 † 6.5 3.45 3.2–4.2
(0.026) (0.435) (0.26) (0.14) (0.72–0.94)
15 66 Lock Up 29542938 No Code 4 0.67 11.05 † 6.5 3.45 3.2–4.2
(0.026) (0.435) (0.26) (0.14) (0.72–0.94)
15 89 D Trim 29542936 No Code 4 0.67 11.05 † 6.5 3.45 3.2–4.2
* Individual Springs
** For the complete Spring Assembly
† OD at larger end
7–7
Table 7–2. Spring Data (cont’d)
7–8
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.
15 104 Lube Regulator 23049327 Red 13 1.22 11.10 46.3 23.5 46.5–51.3
(0.048) (0.437) (1.82) (0.93) (10.5–11.5)
15 108 Main Regulator 29500963 Lt. Blue 15 2.87 22.0 98.5 54.6 305–337
(0.113) (0.866) (3.88) (2.15) (68.6–75.8)
15 112 Control Main 29542926 Orange 10 1.83 14.8 44.6 24.2 131–145
(0.072) (0.583) (1.76) (0.95) (29.5–32.6)
15 123 C2 Latch 29542929 Lt. Green 11 1.32 11.43 41.3 19.0 64.1–78.3
(0.052) (0.450) (1.63) (0.75) (14.4–17.6)
15 127 Exhaust Back 23049391 No Code 17 0.61 7.80 29.2 18.2 2.40–2.94
(0.024) (0.307) (1.15) (0.72) (0.54–0.66)
15 130 C1 Latch 29542929 Blue 12 1.37 16.26 46.2 29.2 16.7–18.9
(0.054) (0.640) (1.82) (1.15) (3.75–4.25)
15 134 Converter Regulator 29507456 Pink 10.2 1.53 11.00 30.3 22.8 53.7–59.3
(0.060) (0.433) (1.19) (0.90) (12.1–13.3)
2 — Converter turbine
3 — Converter pump
4 — Converter housing
5 — Front support
7 — C2 clutch
9 — C3 clutch
10 — P1 planetary module
11 — C4 clutch
12 — P2 planetary module
13 — C5 clutch
14 — P3 planetary module
16 — Output shaft
20 — C1 clutch
21 — Oil pump
22 — Ground sleeve
23 — Converter stator
24 — Turbine shaft
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15
24 23 22 21 20 19 18 17 16
V03348.03.00
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19
30 29 28 27 26 25 24 23 22 21 20
V07392.05.00
Foldout 2. 3000 Product Family Transmission (Except 3700 SP) with PTO Provision and Retarder—Cross Section
3000 PRODUCT FAMILIES SERVICE MANUAL—ALLISON 4 th GENERATION
2 — Converter turbine
3 — Converter pump
4 — Converter housing
5 — Front support
7 — C2 clutch
9 — C3 clutch
10 — P1 planetary module
11 — C4 clutch
12 — P2 planetary module
13 — C5 clutch
14 — P3 planetary module
16 — Output shaft
20 — C1clutch
21 — Oil pump
22 — Ground sleeve
23 — Converter stator
24 — Turbine shaft
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15
24 23 22 21 20 19 18 17 16
V04635.07.00
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18
29 28 27 26 25 24 23 22 21 20 19
V04637.07.01
1
2
1 — Converter end plug, threaded 24 — Torque converter stator race 6
7
2 — O-ring 25 — Torque converter stator spring (13)
8
5
3 — Torque converter module 26 — Torque converter stator roller (13) 9
3
4 — Nut, M8 (36), A 27 — Stator and cam assembly 10
33
31 34
V03940.04.00
B
1 — Converter housing module Torque N·m lb ft
4
1 3
28
5
26
2 6
25
29
24
7
8
10
3 1
11
12 9
5
17
4
7 13 18
8 6
19 20
14 21
15
16
10
22 23
30
27
11
13
12
11
13 12
24
25
26
V02001
V05570.01.00
Foldout 6,A. Converter Housing Module, Without PTO Provision—Exploded View Foldout 6,B. Converter Housing Module, With PTO Provision—Exploded View
3000 PRODUCT FAMILIES SERVICE MANUAL—ALLISON 4 th GENERATION
12 3
21 8 13
14
4 22
3 15
5 7
23 16
8 17
24 18
9 19
10 12
25 20
26
11
6 13 27
15
14 16 33 28
29
34 30
31
1 27 35
26 17 18
19
25 36
21
35
37
38 32
20
24
23
22
39
40
42
V01975
43
41
44
V03941.01.00
Foldout 7,A. Front Support and Oil Pump Module—Exploded View Foldout 7,B. Rotating Clutch Module—Exploded View
3000 PRODUCT FAMILIES SERVICE MANUAL—ALLISON 4 th GENERATION
A B
1 — C3/C4 clutch assembly 1 — Shim (selective), 0.27 mm (0.01 inch)
2 — Bolt, M10 x 1.5 x 90 (12), A 1 — Shim (selective), 0.54 mm (0.02 inch)
3 — C3 backplate assembly 1 — Shim (selective), 0.81 mm (0.03 inch)
4 — Clutch backplate 1 — Shim (selective), 1.08 mm (0.04 inch)
5 — Clutch wear plate (3) 1 — Shim (selective), 1.35 mm (0.05 inch)
6 — P1 ring gear 1 — Shim (selective), 1.62 mm (0.06 inch)
7 — C3 clutch friction plate (5) 1 — Shim (selective), 1.89 mm (0.07 inch)
8 — C3 clutch reaction plate (4) 2 — Thrust bearing
9 — Piston return plate 3 — Main shaft module
10 — C3 clutch piston 4 — Spiral retaining ring
11 — C3 clutch housing assembly 5 — Thrust bearing
12 — Clutch wear plate (3) 6 — P2 sun gear
13 — C3 clutch housing 7 — Bearing spacer
14 — C4 clutch reaction plate (5) 8 — P3 sun gear
15 — C4 clutch friction plate (5) 9 — Main shaft
16 — Piston return plate
17 — C4 clutch piston
18 — C4 clutch housing
19 — Bolt, M10 x 1.5 x 25 (3), A
20 — Converter shipping bracket (3)
21 — Main housing assembly
22 — Main housing
23 — Drain plug
24 — Nameplate
25 — Screw, #4 x 1⁄4
26 — Shipping Cover
27 — Bolt, M10 x 1.5 x 35 (12), A
28 — C5 clutch reaction plate (8)
29 — C5 clutch friction plate (7)
Torque N·m lb ft
A 51–61 38–45
B 5–8 4–5
2 3
4
5 6 4
1
5
7 11
8 12 2
13
9
3
14
15 10
20
6
19
16 7
17
18
9
24 25
26
28 29
22
21
27 V05571
23
V09502.01.00
Foldout 8,A. Main Housing Module—Exploded View Foldout 8,B. 3000 Product Family Main Shaft Module (Except 3500 and 3700 SP)—Exploded View
3000 PRODUCT FAMILIES SERVICE MANUAL—ALLISON 4 th GENERATION
3500
1 — Selective shim
2 — Thrust bearing assembly
3 — Main shaft module
4 — Spiral retaining ring
5 — P2 sun gear
6 — Thrust bearing assembly
7 — Bearing spacer
8 — Main shaft
3700 SP
1 — Thrust bearing assembly
2 — Main shaft module
3 — Spiral retaining ring
4 — Thrust bearing
5 — P2 sun gear
6 — Bearing spacer
7 — P3 sun gear
8 — Main shaft
3
4 2
4 5
1
1
6
2
3
5
6
V05572
V05573
Foldout 9, A. Main Shaft Module 3500—Exploded View Foldout 11,B. Main Shaft Module 3700 SP—Exploded View
3000 PRODUCT FAMILIES SERVICE MANUAL—ALLISON 4 th GENERATION
A B
1 — P1 planetary module 1 — P2 planetary module
2 — Internal retaining ring 2 — Internal retaining ring
3 — Thrust bearing assembly 3 — P2 planetary carrier assembly
4 — P1 planetary carrier assembly 4 — Carrier and bushing assembly
5 — Retaining ring 5 — P2 planetary carrier
6 — P1 indexing ring 6 — Bushing
7 — P1 planetary spindle (6) 7 — Thrust washer (4)
8 — P1 planetary carrier 8 — Roller bearing (8)
9 — P1 thrust washer (6) 9 — P2 pinion gear (4)
10 — P1 pinion gear (6) 10 — Thrust washer (4)
11 — Roller bearing assembly (12) 11 — P2 planetary spindle (4)
12 — P1 thrust washer (6) 12 — P2 indexing ring
13 — Thrust bearing assembly 13 — Internal retaining ring
14 — P2 planetary ring gear 14 — P3 planetary ring gear
2 1
1
3
13
2
14
4
5 3
14
4
8 5
6
7
12
13
9 7
10
8
11
9 11
12
10
V03473
Foldout 10, A. P1 Planetary Module—Exploded View Foldout 10, B. P2 Planetary Module—Exploded View
V04223.01.00
F OLDOUT 11,A
3
1 — Rear cover gasket 24 — C5 clutch piston
2 — Bolt, M12 x 1.7 x 45 (19), A 25 — Piston sealring, 281 mm (11.06 inch) dia
3 — Rear support bracket 26 — Internal sealring, 140 mm (5.51 inch) dia
4 — Rear cover and P3 planetary module 27 — Roller bearing cup
5 — P3 planetary carrier assembly 28 — Rear cover 1
6 — Output shaft assembly 29 — Speed sensor assembly
22
7 — Bushing 30 — O-ring 23
8 — Output shaft 31 — Speed sensor retainer 4
24
9 — Internal retaining ring 32 — Bolt, M8 x 1.25 x 20, B 21 2
10 — Indexing ring 33 — Output speed signal wheel
5 25
11 — Spring pin, 5 x 12 34 — Roller bearing cup
12 — P3 planetary carrier 35 — Cone and roller bearing assembly
13 — Cone and roller bearing assembly 36 — Belleville spring washer 26
14 — Output spacer 37 — Bearing retainer nut, M70 x 20, C 27
15 — External retaining ring 38 — Oil seal assembly 28
6
16 — P3 planetary spindle (4) 39 — Tachograph plug 7 31 32
17 — Thrust washer (4) 40 — Washer 8 9 30
18 — P3 pinion gear (set of four gears) 41 — Rear cover 10
19 — Roller bearing assembly (8) 42 — Shipping cover 11 29
12
20 — P3 thrust washer (4) 42
Torque N·m lb ft
21 — Rear cover assembly
A 90–110 66–81 16
22 — External retaining ring 13
B 24–29 18–21
23 — Spring and retainer assembly
C 74–88 55–65 14
41
15
17
18
40
19 39
20
33
34
35
36
37
38
V03946.02.00
A 15 — OD sealring
16 — ID sealring
Kent-Moore Tools
17 — Bolt, M10 x 1.5 x 100 (15), A
1 — J 38547
Forward/rear output seal installer
18 — Bolt, M10 x 1.5 x 40 (5), A
2 — J 38568
Bearing cup installers
19 — Idler cover
3 — J 38568-1
Drive/driven bearing cup installer
20 — Idler cover o-ring
4 — J 38568-2
Idler bearing cup installer
21 — Idler bearing retainer shim,
5 — J 38568-3
Forward/rear output bearing cup
0.254 mm (0.010 inch)
installer
22 — Idler bearing retainer shim,
6 — J 38569 P3 carrier/C6/C7 housing bushing
0.127 mm (0.005 inch)
installer
23 — Idler bearing retainer shim,
7 — J 38572 Transfer case holding fixture
0.076 mm (0.003 inch)
8 — J 38573 C6 spring compressor
24 — Idler cover gasket
9 — J 38579 Bearing installers
25 — Tapered roller bearing cup
10 — J 38579-1 Drive/driven bearing installer
26 — Tapered roller bearing cup
11 — J 38579-2 Forward/rear output and idler
27 — Output oil seal
bearing installer
28 — Tapered roller bearing cup
12 — J 38547 Front and rear output seal installer
29 — Output housing
13 — J 39623 Bearing end play checker
30 — Tapered roller bearing cup
31 — Bolt, M10 x 1.5 x 35 (8), A
B 32 — Manifold assembly
1 — Bolt, M10 x 1.5 x 55 (8), A 33 — Output bearing retainer shim,
2 — Oil pump assembly 0.254 mm (0.010 inch)
3 — Input bearing retainer shim, 34 — Output bearing retainer shim,
0.254 mm (0.010 inch) 0.127 mm (0.005 inch)
4 — Input bearing retainer shim, 35 — Output bearing retainer shim,
0.127 mm (0.005 inch) 0.076 mm (0.003 inch)
5 — Input bearing retainer shim, 36 — Tapered roller bearing cup
0.076 mm (0.003 inch) 37 — Tapered roller bearing cup
6 — Transfer case housing assembly 38 — Tapered roller bearing cup
7 — Transfer case housing 39 — Output housing
8 — Transfer case cover 40 — Tapered roller bearing cup
9 — Tapered roller bearing cup 41 — Output oil seal
10 — Tapered roller bearing cup 42 — Bolt, M10 x 1.5 x 100 (15), A
11 — C6 clutch housing assembly
12 — Internal retaining ring Torque N·m lb ft
A B
J 35921-1
3700 SP
1 J 38568-1
6 J 8092
1
31
J 38568-2 18
8 12
2 9 19 32
2
25
4
5
7 9 8 A(3,4,5) B(21,22,23)
10 6 20 C(33,34,35)
36 10
3 J 3940 7
38
26
VIEW C
13 40 D D
11 37 24
41
J 8092
39
J 24171 J 38568-3
NOTE: Objects are not shown to scale V05600.00.02 VIEW A
6
J 38573 28
27 D 17
42
12
VIEW E
J 35921-1
14 13 PART OF J 38547
15 16 J 38573
11 VIEW B VIEW D
E01845.02.01
Foldout 12,A. Transfer Case Special Tools—Exploded View Foldout 12,B. Transfer Case, Special Disassembly/Assembly Instructions—Exploded View
F OLDOUT 13
3
83 5
84
1 — Transfer case module 33 — Lube hole plug (2), C 69 — Ball, 6.35 mm (0.250 inch) dia 85
86 A
2 — Bolt, M10 x 1.5 x 40 (15), A 34 — Orificed plug (lube hole) (2), D 70 — Manifold sealring 87
11
4 10
3 — Transmission shaft adapter 35 — Plug assembly (2), D 71 — Bolt, M10 x 1.5 x 35 (8), A 12
4 — Bolt, M10 x 1.5 x 55 (8), A 36 — O-ring (9.25 ID) 72 — Manifold assembly 6
7 9
5 — Oil pump assembly 37 — Tapered roller bearing cup 73 — Manifold 22 8
6 — Pressure relief valve 38 — Tapered roller bearing cone 74 — Ball, 0.218 dia. 23
7 — Spring 39 — Idler gear (37T) 75 — Output bearing retainer shim 24 B
25
8 — Plug, D 40 — Tapered roller bearing cone 0. 254 mm (0. 010 in.) 26 2
9 — Spring pin 41 — Tapered roller bearing cup 76 — Output bearing retainer shim 27 32 88 13
10 — Input bearing retainer shim, 42 — Front output shaft nut, E 0.127 mm (0.005 inch) 29 14
30
31 1
0.254 mm (0.010 inch) 43 — Flat washer 77 — Output bearing retainer shim 28
11 — Input bearing retainer shim, 44 — Front yoke assembly (16 TYS) 0.076 mm (0.003 inch) 33 15
72
78 — Tapered roller bearing cup 34
0.127 mm (0.005 inch) 45 — Bolt, M10 x 1.5 x 40 (15), A 73 16 18
79 — Tapered roller bearing cone 17
12 — Input bearing retainer shim, 46 — Output oil seal 74 C
19
0.076 mm (0.003 inch) 47 — Tapered roller bearing cone 80 — Driven gear 75 33
71 76 34 20
13 — Transfer case housing assembly 48 — Tapered roller bearing cup 81 — Tapered roller bearing cone 77 36 21
14 — Transfer case housing 49 — Output housing 82 — Tapered roller bearing cup
15 — Dowel 50 — Output housing gasket 83 — Lube charging pump front cover
35
16 — Splitline gasket (front and rear 51 — Idler bearing retainer shim 84 — Lube charging pump drive gear
cases) 37
0.254 mm (0.010 inch) 85 — Lube charging pump driven gear 36 38
17 — Tapered roller bearing cup 52 — Idler bearing retainer shim 86 — Lube charging pump reversing 54 39
18 — Tapered roller bearing cone 0.127 mm (0.005 inch) ring 55 40
56 35 41
19 — Drive gear (30T) 53 — Idler bearing retainer shim 87 — Lube charging pump rear cover
20 — Tapered roller bearing cone 0.076 mm (0.003 inch) 88 — Connector nut, F 57 78
79
21 — Tapered roller bearing cup 54 — Output bearings spacer 80
Torque N·m lb ft 59
22 — Bolt, M10 x 1.5 x 40 (5), A 55 — Tapered roller bearing cup 81
A 60–75 44–55 60
23 — Idler cover 56 — Tapered roller bearing cone 61 82
B 5–8 4–6
24 — Idler cover o-ring 57 — Front output shaft C 24–29 18–21 42 62
25 — Idler bearing retainer shim, 58 — C7 clutch housing assembly D 12–14 9–10 43 44
63
0.254 mm (0.010 inch) 58
59 — C7 clutch hub E 610–815 450–600 46 45
26 — Idler bearing retainer shim, 60 — Internal retaining ring F 2.73–4.09 24–36 lb in. 47 64
0.127 mm (0.005 inch) 61 — C7 clutch backplate 48 65
49
27 — Idler bearing retainer shim, 62 — C7 friction plate 50 66
0.076 mm (0.003 inch) 63 — C7 reaction plate 68
67
51
28 — Idler cover gasket 64 — C7 piston 52
29 — Electrical connector plate 65 — External sealring 53 70
30 — Electrical connector gasket 66 — Internal sealring
31 — Electrical connector assembly 67 — C7 clutch housing 69
32 — Bolt, M8 x 1.25 x 25 (4), B 68 — Bushing, 53.10 mm (2.08 inch) dia
E01846.01
97 101
96
100 136
10 98 99
1 9 102 105
120 137
11
104
1 132 125 106
103 138
8 109
95 110
12 121 108
114
43 107
93 113
44 14 46
39 112
42 45 94
111
40 41 13
3 115
30 133 165
116
2 38 134 117
26 135 129
6 130 118
29
4 37 131
28 126
5 27 15
25 127 119 139
24 128
36 23 122
35 22 21
20 123 140
32 19 124
7 33 18
34 16
31 17
150 141
80 82 159
81 84 183
78 182
83 79 181 168 167
180 179 158
77 178
V09483.01.00 V07373.01.00
12
12
2 15
16 14
17
18 13
19
8
20
26
10 3
4
3
4 33
5
5
6
9
6
7 32
27
7
24
23 25 28
21 22 29
31 30
8
9
10
V05924.02.00 11 V07362
Foldout 16,A. Output Flange and Yoke—Exploded View Foldout 16, B. Transfer Case Adapter Housing—Exploded View
3000 PRODUCT FAMILY SERVICE MANUAL
A B
1 — Gasket 1 — Bolt, M10 x 1.5 x 60 (16), B
2 — Cover 2 — Adapter
3 — Cooler port manifold 3 — Gasket, manifold to Water
4 — Bolt, M10 x 1.5 x 28 (6), A 4 — Gasket, integral cooler
5 — Gasket (without retarder) 5 — Bolt, M8 x 1.25 x 25 (6), A
6 — Gasket (retarder) 6 — Gasket, manifold to cooler, 2
7 — Cooler housing 7 — Cooler, intergal
8 — Gasket (2) 8 — Bolt, M12 x 1.75 x 218 (3), C
9 — Connector (2) 9 — Bolt, M10 x 1.5 x 210 (8), B
10 — Bolt, M10 x 1.5 x 35 (8), A 10 — Manifold assembly, integral cooler
11 — Washer 11 — Plug assembly, shipping, SAE No. 16
12 — Bolt, M10 x 1.5 x 205 (used with retarder), A 12 — Shipping plug
13 — Bolt, M12 x 1.75 x 230 (3, with retarder), B 13 — O-ring
14 — Washer (3) 14 — Plug assembly, pressure tap
15 — Bolt, M10 x 1.5 x 70 (9, without retarder), A 15 — O-ring, 11.6 mm ID
Bolt, M10 x 1.5 x 225 (6, with retarder), A 16 — Manifold, integral, strapped
16 — Washer (9, or 6) 17 — Plug assembly, pressure tap
17 — Pressure tap plug assembly (2), C 18 — Plug, pressure tap
18 — Pressure tap plug 19 — O-ring, 8.9 mm ID
19 — O-ring 20 — Plug assembly, pressure tap
20 — Plug, 1⁄2-14, D 21 — Plug, pressure tap
21 — Elbow (2) 22 — O-ring, 8.9 mm ID
22 — Gasket 23 — Plug assembly, pressure tap
23 — Cover 24 — O-ring, 9.3 mm ID
24 — Bolt, M12 x 1.75 x 25 (2), E 25 — Plug assembly, pressure tap
25 — Bolt, M10 x 1.5 x 35 (17), A 26 — Plug, pressure tap
26 — O-ring (2) 27 — O-ring, 8.9 mm ID
27 — Plate assembly
Torque N·m lb ft
28 — O-ring (4) A 33 24
29 — O-ring B 63 47
Torque N·m lb ft C 113 79
A 51–61 38–45
B 100–120 74–88
C 10–13 7–10
D 22–27 16–20
E 90–110 66–81
1
2
2
3
9 3
8 10
11 12 4
5
7 13
26
4 27 15
14
10 25
6
23 16
11
8 28 24
27
9 17
14
13 12 19
26 18
9 22
19 28 21
18 8 20
17 6 5
29 16 15
10 19 24
18 17
26 6
25
7
21
22
V07029.03.00
23 24
V05576.01.00
Foldout 17,A. Oil Cooler—Exploded View Foldout 17,B. Integral Sump Cooler—Exploded View
3000 PRODUCT FAMILIES SERVICE MANUAL—ALLISON 4 th GENERATION
C D
1 — Scavenge pump module 1 — Parking brake, 12 x 4
2 — Pin 2 — Bolt, M16 x 2.0 x 40 (4), A
3 — Pump housing 3 — Brake drum
4 — Shaft
4 — Bolt, 3⁄8-24 x 3⁄4 (2), B
5 — O-ring, 12.4 mm (0.488 inch) ID
5 — Stud (2)
6 — O-ring, 12.4 mm (0.488 inch) ID
7 — Bolt, M8 x 1.25 x 30 (3), A 6 — PTO gasket
8 — Driven gear assembly 7 — bolt, M10 x 1.5 x 35 (8), C
9 — Roller bearing assembly 8 — PTO assembly
10 — Roller bearing assembly 9 — Stud (2)
11 — Driven gear 10— PTO gasket
12 — Thrust washer
11— Bolt, M10 x 1.5 x 35 (8), C
13 — Pump assembly
12— PTO assembly
14 — Pump cover
15 — Gear set Torque N·m lb ft
16 — Thrust washer A 228–266 168–196
17 — Pump body B 56–66 41–49
18 — Gasket C 51–61 38–45
19 — Bolt, M8 x 1.25 x 20 (3), A
Torque N·m lb ft
A 30–35 23–25
6 1
4 2
5 1
12 3
3 4
10 8
11
7
2
9
13
14
15 5
19 16 7
17
18
11
12
10
V08540.00.00
V05577.01.00
Foldout 17,C. Scavenge Pump—Exploded View Foldout 17,D. Support Equipment—Exploded View
F OLDOUT 18
LOCKUP
LUBE
CONVERTER OUT COOLER
FILTER
LUBE LUBE
CONVERTER IN
TORQUE
CONVERTER Orifice
EX EX
CONVERTER CONVERTER
FLOW REGULATOR EX
LUBE
REGULATOR
REAR
SPLITLINE
SS1
N/C
Pressure
Orifice EX Relief
***
PS1 EX
DIAGNOSTIC PCS6 EX
EX N/C SS2 MAIN
EX N/C REGULATOR
EX PUMP
6-Speed
Only EX EXHAUST
BACKFILL Accum-
ulator
MAIN SUCTION
EX MOD ** FILTER
EX N/C
C2 EX EX
LATCH EX
C1
LATCH SUMP
C1 C2 C3 C4 C5 C6
NOTES:
LEGEND:
* TCC Solenoid is generally ON from 2nd-range thru 6th-range
MAIN COOLER/LUBE
C1 C2 C3 C4 C5 C6 ** Main Mod Solenoid may be ON in Reverse, Neutral, Low (7-speed), CONTROL MAIN EX. BACKFILL
1st, or 2nd as determined by calibration. EXHAUST CONVERTER
*** PS1 = Diagnostic Pressure Switch SUCTION C5
= 7-Speed Transmissions only MAIN MOD
V09253.00.00