4K Technician's Guide PDF

TECHNICIANS’ GUIDE
INSPECTION AND ANALYSIS OF THE

ALLISON 4000 & B 500
PRODUCT FAMILIES
GN4065EN
(5/05)
ALLISON 4000 / B 500 PRODUCT FAMILIES
Glossary Of Terms . . . . . . . . . . . 2 Control Module . . . . . . . . . . 16-21

Introduction To Torque Converter
Inspection & Analysis . . . . . . . . 3 Module . . . . . . . . . . . . . . . . . 22-27
Torque Converter
General Inspection Housing Module . . . . . . . . . 28-30
Guidelines for
Standard Rear Cover and
Q Cast Parts & Machined P3 Planetary Module . . . . . 31-38
Surfaces . . . . . . . . . . . . . . . . . . 4
Retarder Module . . . . . . . . . 39-42
Q Gears . . . . . . . . . . . . . . . . . . . . 5
Close Ratio Main
Q Splines . . . . . . . . . . . . . . . . . . . 6 Shaft Module . . . . . . . . . . . . . . 43
Q Bearings . . . . . . . . . . . . . . . . 7-8 Wide Ratio Main
NOTICE: This guide is intended Shaft Module . . . . . . . . . . . . . . 44
for use by technicians skilled
Q Bushings . . . . . . . . . . . . . . . . . 9
P2 Planetary Module . . . . . 45-46
in diagnosis and repair of Q Retaining Rings . . . . . . . . . . 10
P1 Planetary Module . . . . . 47-48
automatic transmissions. Q Thrust Washers . . . . . . . . . . . 11
Contact an authorized Allison Front Support & Oil
Q Clutch Plates . . . . . . . . . . 12-13 Pump Module . . . . . . . . . . . 49-52
Transmission service outlet for
further information or Q Springs . . . . . . . . . . . . . . . . . 14 Rotating Clutch Module . . . 53-58
clarification if required. All Q Valves and Valve Bores . . . . 15 C3/C4 Clutch Module . . . . . 59-64
specifications provided in this
Main Housing . . . . . . . . . . . 65-66
manual are subject to change
without notice. C6 Adapter Housing . . . . . . 67-69
Wear Limits and
Spring Data . . . . . . . . . . . . . 70-77
ALLISON TRANSMISSION TECHNICIANS’ GUIDE i

 2005 General Motors Corporation.
GLOSSARY OF TERMS
Abrade - Scrape off Metal Transfer - Metal from one

component embedded in a mating
Battering - Wear or damage due to component
hard usage or repeated blows
Nick - Small notch
Brinelling - Permanent deformation
of a bearing surface where rollers or Pit - Local areas where material has
balls contact a race; Results from been removed
excessive load or impact;
Characterized by indentations Porosity - Porous area where air,
on a bearing surface fluid, or light may pass through
Burr - Sharp metal extending Score - Deep scratch

beyond normal surface Scuff - Wear due to two moving
Chipped - Having a small piece parts coming together with no
broken off lubricant
Cone - A shape whose base is a Spalled - Damage characterized by

circle and whose sides taper up metal flaking or breaking down on
to a point a wear surface; Similar to pitting
damage
Crimped - Pinched or pressed
together tightly Stripped - Threads broken or
damaged so part will not hold
Crocus cloth - Fine grit cloth torque
Discoloration - Change in color TAN - Total Acid Number;
Oil acidity should not change by
Distortion - Change from original more then 3 from the new fluid
shape TAN when oil sampling is used to
Erosion - Gradual uneven removal determine oil change intervals
of material Twisted - Bent from original shape
Fracture - A break or crack
Gall - Wear between parts such

that metal transfer occurs
Grooves - Long narrow
depressions
Inadequate - Not enough
Light Stoning - Using a

medium India oilstone to
remove material
2 ALLISON TRANSMISSION TECHNICIANS’ GUIDE

INTRODUCTION TO INSPECTION & ANALYSIS
The Technicians’ Guide is

intended to provide additional
guidance with the inspection and
analysis of transmission parts.
This guide should be used by
technicians who overhaul Allison
4000/B 500 automatic
transmissions in conjunction with
the 4000/B 500 Service Manual
(SM2457EN) when inspecting parts
to determine their serviceability
and reuse.
General Rework Guidelines

Replace parts that cannot be
re-worked as outlined in this
manual and Service Manual
SM2457EN. A soft stone or crocus
cloth can be used to attempt
removal of “high spots” from
transmission parts. After the
attempted rework, the part must
meet specification if it is going to
be reused. Some seal surfaces (for
example the output yoke sealing surface
and the converter pump hub sealing
surface) cannot be reworked.
Both of these seal surfaces have a
controlled finish that can result in a
fluid leak if the part is altered by
rework.
ALLISON TRANSMISSION TECHNICIANS’ GUIDE 3

GENERAL INSPECTION GUIDELINES FOR
CAST PARTS & MACHINED SURFACES
A. Housings
B. Machined
Surfaces
A. Cast
Part
C. Fluid
Passages
A. Replace housings or other cast D. Replace housings that have

parts that are cracked or broken. splines worn beyond wear limits. D. Splines
Inspect clutch housing sealing Refer to the Wear Limits Table
surfaces for imperfections that (7-1) in Service Manual SM2457EN.
could damage the piston seals or
NOTE: Some parts have Spiralock®
interfere with mating parts.
threaded holes . A standard tap will
Inspect threaded holes for bad
eliminate the locking feature
threads. Clean damaged threads requiring the reworked part to be
with the correct size tap. replaced. For repair, use a
B. Inspect all machined surfaces Spiralock® tap to repair Spiralock®
for damage that could cause fluid threaded holes. As of this printing,
the following parts have Spiralock®
leakage. Inspect mounting faces
threaded holes: C. Fluid
and bores for damage.
Passages
Q Torque converter front cover
C. Inspect all fluid passages for flexplate adapter bolt holes and
obstructions, porosity, broken lockup clutch backplate bolt
lands, cracks and land surface holes.
imperfections.
Q Output shafts using a single bolt
for flange or yoke retention.
GEARS
A. Gear
Teeth
Check gears for

damaged or
missing teeth. B. Thrust Face
Surface
A. Inspect gears for damaged or

broken teeth. Inspect gear teeth for
wear that has changed the original
tooth shape. If this condition is noted,
replace the gear. Inspect gears for load
pattern and signs of distress. Any
signs of distress indicate the gear may
fail during operation. Reusing
distressed gears is an individual
customer decision based on
experience. Backlash cannot be used
to establish critical gear wear. Pits,
scuffs, scores or galling are typically
evident long before backlash exceeds
specification.
B. Inspect the thrust face of gears
A. Gear for damage. If these defects cannot
Teeth be removed with a soft stone, replace
the gear.
SPLINES
A. Splines
Inspect splined parts

for burrs, damage
and excessive wear.
A. Inspect splined parts for 0.38 mm (0.015 inches) if not

damage. Remove burrs with a soft otherwise listed in Wear Limits
stone. Spline wear is not considered Table 7-1 in Service Manual
harmful except where it affects the SM2457EN. Do not reuse a splined
fit of the splined parts. Spline wear part that exceeds the published
is determined by comparing feeler maximum spline wear. Backlash
gauge thickness with the thickness cannot be used to establish critical
of the worn area on the spline. spline wear. Accurate backlash
Replace parts having excessive measurement requires the mating
spline wear. The maximum parts to be concentrically located.
movement allowed at the splines is

BEARINGS
B. Bearing
C. Retainer
Race
C. Retainer
A. Rollers
C. Retainer B. Bearing
Race
A. Replace the bearing if any bearing. Replace the bearing if races

rollers/balls are rusted. Replace the are discolored from heat, lack of
bearing if balls/rollers have a feeling lubrication or debris lapping in the
of looseness in the retainer or race race. Replace the bearing if the
compared to a new bearing. Replace races are worn, galled or abraded.
the bearing if balls/rollers are Replace the bearing if it catches or
discolored from heat, lack of feels rough after being thoroughly
lubrication or debris lapping in the cleaned.
balls/rollers. Replace the bearing if C. Replace the bearing if any
the balls/rollers are worn, galled or retainer or retainer clip is
abraded. Replace the bearing if it fractured, bent, dented or missing.
catches or feels rough after being Replace the bearing if any retainer B. Bearing Race
thoroughly cleaned. is rusted. Replace the bearing if
there is a feeling of looseness
B. Replace the bearing if any between the retainer and ball/roller
races are rusted. Replace the compared to a new bearing. Replace
bearing if the bearing balls/rollers the bearing if it catches or feels
have a feeling of looseness in the rough after being thoroughly
raceway compared to a new cleaned. (continued)

GENERAL INSPECTION
GUIDELINES FOR BEARINGS
(continued)
General Bearing Handling When immersing in solvent, place

& Storage bearings in a wire basket so there is
plenty of space for cleaner to reach
Dirt is the greatest single enemy all parts. Tanks should have a
of any antifriction bearing. screened false bottom to prevent
Cleanliness - using clean tools in a settled debris from being stirred up Fractured races - a fractured race
clean environment - is at the top into the bearings. Agitate the can be caused by forcing a cocked
of the list of good service basket frequently until grease, oil or bearing on or off a shaft. An
techniques. Keep bearings sealed in sludge is thoroughly loosened and excessively tight press fit can also
original containers. Do not allow can be flushed out. Blow solvent cause a race to fracture.
anyone to open boxes and handle out of bearings using dry, filtered
bearings. A new bearing, if not Worn, galled or abraded
air. Be careful not to spin the surfaces - worn, galled or abraded
protected, can quickly pick up bearing using air pressure.
enough dust even in an apparently surfaces on a bearing may be the
Lubricate bearings immediately result of a loose fit on a shaft or in a
clean place to seriously affect its life after drying to avoid rust.
and operation. Minimize the housing. A locked bearing spinning
possibility of rusting or lubricant NOTE: Wear eye protection and on a shaft or in a housing can also
aging in storage by using the oldest follow the appropriate safety create this type of damage.
bearings in stock first. guidelines when using solvents to General feeling of roughness -
clean components. inspect for a general feeling of
If any part of a bearing assembly
has been compromised, replace all Badly discolored rollers and races roughness which remains
detail parts in the assembly are usually a sign of inadequate unchanged by thorough cleaning.
(example - races, retainers and the lubrication. Replace badly This condition generally indicates
bearing itself). Most bearings fail discolored bearings. Moderately damage to raceways or rollers
from preventable causes. Follow a discolored rollers, cages and races caused by dirt, pitting, brinelling or
regular system for inspection. Look do not necessarily mean that the corrosion.
for bearings with obvious damage bearing needs replacement. Catchy feeling - inspect for a
first. catchy feeling at one or more points
Technicians should always try to
determine the root cause of failure which repeated flushing will not
General Bearing Inspection when inspecting failed components. remove. This condition generally
It’s important the root cause be indicates a spalled or fatigued spot
Do not try to judge the condition of on the race. Thorough flushing is
identified and repaired to avoid the
a bearing until after cleaning. Do necessary to be sure the catchy or
same failure in the future. Bearings
not spin bearings while cleaning rough feeling is not caused by
should be replaced for the
them. Rotate them slowly while foreign debris in the bearing.
following reasons:
washing. Do not spin any bearings
with air pressure. Put bearings Rusted rollers, balls or Excessive looseness - inspect for
under axial pressure while rotating raceways - rusted rollers, balls or excessive looseness which indicates
to bring the balls and races firmly in raceways are usually caused by lapping by dirt or an abrasive
contact with each other. For single water passing worn or defective contaminate in the lubricant. If in
row angular contact bearings, seals, or by condensation inside the doubt, compare the end play
pressure must always be applied on housing. against the end play of an identical
thrust faces. new bearing. The races, balls and
rollers will appear dull gray when
lapped by dirt.

BUSHINGS
Bushing wear is strongly

influenced by the
quantity and condition
of the lubricant.
A. Bushing
A. Inspect bushings for wear General Bushing Information Some bushings are susceptible to
beyond service limits. Replace any material leaching. This can be
Mechanically, bushings are the
bushing which is excessively worn. caused by oxidized oil that has
simplest type of journal bearing and
Inspect bushings for discoloration turned acidic combined with heat
are often referred to as “plain”
and surface damage due to lack of and mechanical loading. The TAN
bearings. A bushing is simply a
lubrication. Replace any bushing (Total Acid Number) of the
sleeve of bearing material, such as
which is damaged. transmission oil should not change
bronze or aluminum, in which a
by more than 3 from the baseline
component rides. Bushing wear is
(new fluid) TAN. Changing
strongly influenced by the quantity
transmission oil per recommended
and condition of the lubricant.
change intervals or based on a
Bushing bearing surfaces are
successful oil sampling program
sometimes grooved to better
will help prevent material leaching.
distribute lubrication across the
bearing surface.

RETAINING RINGS
A. Retaining
Rings
A. Inspect retaining rings for Examine retaining

damage, distortion and excessive rings for damage,
wear. Replace retaining rings if distortion or
excessive wear.
damage cannot be repaired using a
soft stone or crocus cloth.

THRUST WASHERS
Thrust
Washers
A. Replace thrust washers if they

are worn beyond service limits.
A. Thrust Replace thrust washers if they are
Washers galled, abraded or distorted.
Replace thrust washers if they are
damaged due to a lack of
lubrication.

CLUTCH PLATES
Oil grooves Spline teeth battered D. Spline
appear shallow and worn - may be an Teeth
or worn away - indication of driveline A. Contact
measure plate issues. Replace Surface
thickness and clutch plates and
C. Oil
groove depth. check driveline.
Groove
Depth
A. Inspect friction plate contact C. Measure friction plate oil stone or crocus cloth. Replace the
faces and splines for excessive groove depth. Replace any plates clutch plate if spline teeth are
wear, damage and coning. Inspect that are not within Service Manual broken or missing.
the plates for burrs, pitted faces, minimum groove depth NOTE: Anti-freeze (glycol) and/or
cracks, distortion and damaged specification. water can adversely affect the
spline teeth. bonding agent between the friction
D. Inspect spline teeth for
excessive wear and battering. material and steel core. Replace any
B. Measure friction plate friction plates which have been
thickness and coning. Reference Replace the clutch plate if damage
cannot be repaired using a soft exposed to water and/or glycol.
the Service Manual for minimum (continued)
thickness and maximum coning
specifications. Do not reuse friction B. Clutch Plate
plates that do not meet published Thickness and
specifications. If reused plates are Coning Coned Plate
slightly coned (within
Check Using
specification), make sure each plate
Feeler Gauge
is stacked with the cone facing the Flat Plate
same direction.
Thickness

(continued) CLUTCH PLATES
Acceptable
discoloration -
reuse plates.
Excessive scoring -
replace plates.
B. Thickness
& Coning
(see prior
page graphic) Broken tangs -
A. Contact replace plates.
Surfaces
C. Tangs
NOTE: The current clutch friction plates Allison Transmission. Do not intermix A. Inspect reaction plates for
were implemented April of 2000 starting both former and current friction plates in excessive wear, warping, coning
with s/n 6610062126. Current clutch a clutch pack. and surface damage. Replace any
friction plates will have two or more plate with wear exceeding service
missing splines. Former friction plates The P3 ring gear changed to a harder ring
gear on s/n 6610027070. The current P3 limits or with damage which
will either have one spline missing or
none missing. Any 4000/B 500 model ring gear identifier is a groove machined cannot be repaired using a soft
transmission may be updated from former around the outer diameter of the gear. stone or crocus cloth..
C5 friction plates to current C5 frictions The P3 ring gear with a groove identifier
requires the C5 friction with two missing
B. Measure reaction plate
without recalibrating the transmission thickness and coning. Reference
ECU. The rest of the clutches in the main splines if updating from former C5
frictions. If any 4000/B500 series model the Service Manuals for minimum
housing (C1 through C4) must be
without the harder ring gear (no groove thickness and maximum coning
updated with current friction plates if
any other individual clutch besides C5 is on O.D.) is being updated with current specifications. Do not reuse plates
updated from former to current friction C5 frictions, then it will require the C5 that do not meet published
plates. Any update from former frictions friction that has three missing internal specifications. If reused plates are
to current frictions in C1 through C4 for splines. The C5 friction plate missing slightly coned (within
a 4000 Series or B500 with a WTEC II three splines will exhibit spline wear if specification), make sure each plate
ECU will require a new ECU calibration used with the current P3 ring gear with a is stacked with the cone facing the
groove identifier on the O.D. The former
from Allison Transmission. Any update same direction.
from former frictions to current frictions P3 ring gear (no groove on O.D.) will
in C1 through C4 for a 4000 Series or exhibit premature wear if used with the C. Inspect reaction plate tangs
B500 with a WTEC III ECU with a current C5 friction with two missing for damage. Replace the plate if
calibration prior to October 25, 1999 will internal splines. No ECU calibration is damage cannot be repaired using a
require an updated ECU calibration from necessary for updating C5 clutch plates. soft stone or crocus cloth.

SPRINGS
A. Springs
Reference the Service Manual

Spring Data Charts for spring
identification and specifications.
A. Inspect springs for permanent

set and wear due to rubbing
adjacent parts. Replace the spring if
any of these defects are identified or
if the spring fails to meet published
service limits. Reference the Spring
Data Charts in Service Manual
SM2457EN for spring identification
and service limit specifications.
Inspect springs for signs of

overheating, permanent set
or wear due to rubbing
adjacent parts.

VALVES & VALVE BORES
A. Valves
Valves should move freely in

their bores, when dry, under
their own weight.
A. Valves must be free of nicks,

burrs and scoring and operate
smoothly in their bores without
sticking. Dry valves must move
freely in their bores by their own B. Valve
weight. Replace damaged valves. A Bores
soft stone or crocus cloth can be
used in an attempt to repair slight
irregularities.
B. Valve bores must be free of
nicks, burrs and scoring. No honing
of any kind is allowed. A soft stone
or crocus cloth can be used in an
Valve bores must
attempt to repair slight
be free of nicks,
irregularities.
burrs and scoring.

CONTROL MODULE
B. Solenoid
Separator Plate
C. Suction
Filter
Assembly
A. Channel
Plate D. Internal
Wiring
Harness
H. Oil Level
Sensor E. Rotating
Clutch Body
Assembly
G. Stationary Clutch F. Main Valve
Valve Body Assembly Body Assembly
A. Inspect the channel plate for B. Inspect both

damage. All passages must be clear separator B. Separator Plate
of debris. Inspect all machined plates for dents,
surfaces for burrs, nicks or scoring. nicks, burrs and
Light stoning and crocus cloth may other damage or
be used to eliminate minor high distortion.
spots. If a channel plate cannot be Replace the
repaired so that all machined plate if it has
surfaces can seal correctly to their damage which
mating parts, or if thread damage cannot be
cannot be repaired, replace the repaired using a
channel plate. soft stone or
crocus cloth. All
NOTE: Do not use impact guns (air
passages must
wrenches, electric impact be clean and
wrenches, etc.) when working with debris free.
aluminum threads or when torque Separator plate and gasket installed
(continued)
sequencing bolts. on channel plate.

(continued) CONTROL MODULE
Identification Detail:
Internal Wiring Harness
Feed
Through
Stand-Off
Sump Temperature
Dust
Sensor (TID 2, 3)
Seal
O-Ring
C3 Pressure Seal Feed
Switch Through
Harness
A Solenoid
(C1)
F Solenoid G Solenoid
(Lockup) (C2 Latch)
B Solenoid D Solenoid (C4)

(C2)
C Solenoid (C3)
Oil Level
E Solenoid Sensor
(C5)
C. Replace the suction filter NOTE: Transmissions built prior to differ between the former and
assembly during overhaul. S/N 6610014067 used the former current designs. Be sure to use the
design sump temperature sensor. correct resistance specification
D. Replace or repair the control Sensor resistance specifications chart for the sensor being checked.
module wiring harness if the (continued)
wires, terminals or
connectors are visibly Current TID2 / TID3 Former TID1
damaged. Inspect the Harness Harness
molded harness channel
for cracks or breaks. TID 2, 3
Replace the harness if Sump Temp.
the molded channel is Sensor
damaged. Check sump
temperature resistance
following the guidelines
and specifications listed TID1 Sump
in the Service Manual Temp. Sensor
and Troubleshooting
Manual.

CONTROL MODULE (continued)
Supersession Information Supersession Information

Oil Drain Plug Redesign - Oil Level Sensor Redesign -
SIL 5-WT-98, Rev. A SIL 19-WT-99
Current
Former
Current plug is
backward compatible Kit must be used when
with all control replacing former sensor
modules. with current sensor.
E, F, G. Valves, valve body bores Inspect all threaded holes for Valve stops and retention pins
and oil passages must be free of damage and debris. Replace the must not be damaged or battered.
debris, nicks, burrs, scoring and valve body if the thread damage Replace valve stops or pins which
galling. Valves should move freely cannot be repaired. have damage that cannot be
in their bores, when dry, under removed using a soft stone or
NOTE: Do not use impact guns (air
their own weight. Repair or replace crocus cloth.
valves and/or valve bodies failing to wrenches, electric impact
meet these requirements. wrenches, etc.) when working with Replace solenoids if they are visibly
aluminum threads or when torque damaged. Proper solenoid
Valve body machined surfaces sequencing bolts. resistance is 3 to 4 ohms measured
must be free of debris, nicks, burrs between the two solenoid
and scoring. Light stoning of these Replace valve springs which are terminals. Check resistance
machined surfaces is permitted to broken, permanently set or worn between each solenoid terminal and
correct minor defects. Replace any due to rubbing adjacent parts. the solenoid body. Replace the
valve body that cannot be repaired. Reference the Spring Data Charts in solenoid if resistance measures less
the Service Manual for spring than 100k ohms.
specifications and identification. (continued)

2” Channel
Plate
4” Channel
Plate
Supersession Information
Suction Filter Redesign - SIL 1-WT-00
Replace the C3 pressure switch if
Replace the it is visibly damaged. Resistance
assembly between the two switch terminals
during
should measure 20k ohms or higher
overhaul.
when the switch is open (and no
pressure is present). Resistance
between the two terminals should
not exceed 2 ohms when the switch
Former
is closed (159 kPa-255 kPa or 23-37
Current psi present).
H. Replace the optional oil level
sensor if it is determined it is not
functioning correctly.
(continued)

CONTROL MODULE (continued)
Identification Detail: Rotating Clutch Valve Body Assembly

Solenoid
Regulator Solenoid
Valves Regulator Rotating
Springs Clutch Valve
Body
B Solenoid
(C2)
Accumulator
Relay Valve
F Solenoid C3
(Lockup) Pressure
Switch
A Solenoid
(C1)
Identification Detail: Stationary Clutch Valve Body Assembly
Overdrive Knock
Down Valve Stationary
Valve Body
D Solenoid
(C4)
C Solenoid
(C3)
Solenoid Solenoid
Regulator Regulator
Valves Springs
E Solenoid
(C5) (continued)
Identification Detail: Main Valve Body Assembly
Lube Regulator
Valve Spring
Lockup
Lube Regulator Valve Spring
Valve
Converter
Converter Lube Regulator
Regulator Lockup
Regulator Valve Stop
Converter Spring Valve
Valve
Regulator Lockup
Valve Stop Valve Stop
C1 Latch Main
Valve Spring Regulator
Valve Stop
C1 Latch
Valve Stop C1 Latch Valve
Exhaust Main Regulator Valve

Backfill Valve Main Regulator
Valve Spring
Exhaust
Backfill Control Main
C2 Latch C2 Latch Main Valve Control Main

Valve Stop Valve C2 Latch Body Control Valve Spring
Spring Valve Main Valve G Solenoid
Converter Regulator Valve Stop Redesign -
SIL 12-WT-99
Current Former
Stop Stop
(continued)

TORQUE CONVERTER MODULE
B. Drive
A. Converter
Hub
Pump Exterior
B. Drive Hub
Model
Identifiers Inspect the pump hub tangs for cracks,
(see chart) impact damage and broken tangs.
A. Inspect the converter pump NOTE: Do not use crocus cloth on pump bushing failure and ground
exterior for dents and sealing the converter pump hub. Polishing sleeve wear is often caused by poor
surface damage. Replace the the hub with crocus cloth can cause transmission fluid condition due to
converter pump if damage cannot improper input seal performance improper maintenance intervals.
be remove with a soft stone or resulting in fluid leakage. Observation of proper fluid change
crocus cloth. intervals is key to optimum
NOTE: Pump hub tang breakage or
B. Inspect the converter pump deformity accompanied by charging transmission life. (continued)
hub for damage and excessive wear.
Minimum pump hub diameter is 4000 Product Family Torque Converter Identification Chart
88.99 mm (3.504 inch). Inspect the Torque Converter Model TC-521 TC-531 TC-541 TC-551 TC-561
pump hub tangs for cracks, impact Designation
damage or broken tangs. Maximum Front Cover Sticker and Green Pink Blue Orange Yellow
allowable tang step wear is 0.31 mm Converter Paint Dot Color
(Exterior Marker)
(0.012 inch). On PTO-equipped
Engraved Letter Identifiers E D C B A
models, check the splines inside (Torus Ring of Converter
the hub for wear and damage. Pump) Ink Stamped Letter
Maximum spline wear is 0.38 mm (Exterior of Converter Pump)
(0.015 inch). Number of Stator Blades 19 19 19 19 19
Paint Dot Color on Stator None None None None None

Supersession Information ALLISON 4000 / B 500 PRODUCT FAMILIES
Converter Plug and Front TORQUE CONVERTER MODULE
Cover Update SIL-21-WT-98
(continued)
Current Converter Turbine Shaft

Plug Retaining Bolt Selective Shim
The current front cover has a
threaded pilot to accept the
current converter plug. Plugs
are not interchangeable E. Ring
Gear
Model Identifiers (see

chart previous page)
F. Flexplate
D. Pilot Adapter
C. Front
Cover
Mounting
Face
C. Inspect the torque converter E. Inspect the engine starter ring NOTE: The flexplate adapter bolt
front cover mounting faces for gear for chipped, worn or broken holes use Spiralock® threads. A
damage. Inspect the flexplate teeth. Spiralock® tap must be used when
adapter bolt holes for stripped or repairing damaged threads. Using a
damaged threads. F. Inspect the flexplate adapter standard tap will destroy the
mounting faces for surface damage. locking feature. If this occurs, the
D. Inspect the front cover pilot Replace the adapter if damage torque converter front cover must
for damage and wear. Maximum cannot be repaired using a soft be replaced.
pilot diameter is 61.77 mm (2.432 stone or crocus cloth. Inspect the (continued)
inches). Inspect the torque flexplate adapter bolt holes fro
converter end plug and the stripped or damaged threads. Clean
retaining bolt for stripped or damaged threads using the correct
damaged threads. Verify that the size tap. Replace the adapter if
correct turbine shaft selective shim damage cannot be repaired.
is installed following the Service
Manual procedures.

TORQUE CONVERTER MODULE (continued)
A. Converter
Pump Interior
Vanes
B. Torus
Ring
C. Seal Ring
Area
A. Inspect the converter pump

interior. Replace the assembly if
the vanes are damaged, cracked or
loose.
Replace the assembly if the vanes are
B. Replace the converter pump
damaged, cracked or loose.
assembly if the torus ring is loose
or cracked.
C. Inspect the seal surface C. Front Cover-to-
between the converter pump Converter Pump
assembly and the front cover. Sealing Surface
Light stoning is permitted to
remove slight irregularities.
(continued)

Turbine hub ALLISON 4000 / B 500 PRODUCT FAMILIES
sealring groove -
Sealring installed. TORQUE CONVERTER MODULE
(continued)
D. Turbine Hub
B. Torus
Ring
C. Rivets
E. Splines
Turbine
Assembly
A. Converter Exterior
Turbine
Assembly Turbine F. Thrust
Interior Blades Bearing
A. Inspect the converter turbine E. Inspect the hub splines for F. Inspect the thrust bearing
assembly. Replace the assembly if damage and wear. Spline movment following the “General Inspection
the blades are cracked, broken or between the lockup damper and Guidelines for Bearings” section of
loose. turbine hub cannot exceed 0.38 this manual. Replace any thrust
mm (0.015 inch). Replace the bearing failing these inspection
B. Inspect the torus ring. Replace turbine assembly if splines are procedures.
the turbine assembly if the torus excessively worn. (continued)
ring is loose or cracked.
C. Inspect the rivets. Replace the
turbine assembly if the rivets are
loose or cracked.
D. Inspect the converter turbine
hub. Replace the converter turbine
assembly if the hub is worn beyond
limits. Minimum allowable hub
diameter is 66.69 mm (2.626
inches). Inspect the sealring groove
for damage. Inspect the hub splines and rivets for damage and wear.

TORQUE CONVERTER MODULE (continued)
B. Bushing
A. Sealring Lockup Clutch Damper Assembly
Bore Update SIL-4-WT-00, Rev. B
Front
Cover
E. Lockup
Damper
Current damper is backward

compatible with all torque
converter assemblies. ECU
recalibration is not necessary.
C. Lockup
Clutch
Piston
F. Thrust D. Backplate
Bearing
A. Torque converter lockup C. Inspect the lockup clutch E. Replace the lockup clutch
clutch components fit inside the piston for damage. Minimum damper if the friction surfaces are
front cover. Install a new turbine allowable piston thickness is 6.53 worn beyond service limits.
sealring in the converter cover bore mm (0.257 inch). Minimum allowable friction surface
then measure the sealring inside thickness is 8.51 mm (0.335 inch).
D. Inspect the lockup clutch
diameter. Replace the cover Maximum allowable damper
backplate for damage, scoring and
assembly if diameter exceeds 61.77 distortion is 0.51 mm (0.020 inch).
overheating. Minimum allowable
mm (2.432 inch). Maximum allowable movement
plate thickness is 11.79 mm
between the damper and converter
B. Inspect the converter cover (0.464 inch).
turbine splines is 0.38 mm (0.015
bushing for damage. Replace the
NOTE: If the backplate is within inch). Replace the damper if any of
bushing if damage cannot be
thickness limits but has surface these measurements are beyond
removed with crocus cloth.
damage due to metal transfer allowable limits.
Maximum allowable bushing inside
between the backplate and lockup
diameter is 66.91 mm (2.634 inch). F. Inspect thrust bearing
damper, the plate may be reused by
following the “General Inspection
turning it over so that the lockup
Guidelines for Bearings” section of
damper has a new contact surface.
this manual. Replace any thrust
bearing failing these inspection
procedures. (continued)

(continued) TORQUE CONVERTER MODULE
E. Front Stator I. Roller

Thrust Washer Stator
Pockets
F. Thrust
Bearing
D. Star
Plate
A. Stator
G. Stator Race
Thrust Plate H. Stator Cam
and Assembly
C. Stator
Roller
B. Stator
K. Shim Spring
L. Retaining
Ring J. Tanged Thrust
Bearing Race
A. Inspect the stator race for inch) or more. If it is within service temperatures may be high enough to
damage. Replace the race if damage limits, the thrust washer can be release the cam assembly from the
cannot be repaired using a soft stone turned over and the un-worn surface stator.
or crocus cloth. can be used. I. Inspect the stator roller
B. Inspect the stator springs for F. Inspect the thrust bearings pockets for wear and damage. Verify
correct spring height following per following the “General Inspection correct spring-to-roller orientation.
the Service Manual. Replace any Guidelines for Bearings” section of Inspect the bottom of the cam
spring which has a free length below this manual. Replace any thrust pocket for wear. Replace the stator
17.8 mm (0.700 inch). bearings failing these inspection and cam assembly if it is worn 0.40
C. Inspect the stator rollers for procedures. mm (0.010 inch) or more in the
damage. Rollers should be smooth, G. Inspect the stator thrust plate bottom of the pocket.
round and defect-free. Replace for damage and wear. Replace the J. Inspect tanged thrust bearing
damage or worn rollers. plate if damage cannot be removed race for damage. Replace any
D. Inspect the star plate for using a soft stone or crocus cloth. damaged race.
excessive wear. Replace the star Minimum allowable plate thickness K. Inspect shim for damage.
plate if damage cannot be repaired is 9.45 mm (0.372 inch). Replace any damaged shims. Use
using a soft stone or crocus cloth. H. Inspect the stator and cam procedure for shim selection in 4000
E. Inspect the front stator thrust assembly for damage. Replace the Series Service Manual.
washer for wear beyond service stator and cam assembly if damaged. L. Inspect the retaining ring for
limits. Replace the stator thrust NOTE: Use care when cleaning the damage and distortion. Replace any
washer it is worn 0.40 mm (0.010 stator and cam assembly. Hot tank distorted or damaged retaining rings.

TORQUE CONVERTER HOUSING MODULE
B. Breather
C. Speed
Sensor &
Bore
B. Breather
A. Torque
Converter
Housing (PTO) A. Torque
Converter
Housing
(Non-PTO)
A. Inspect for torque converter speed sensor if it does not meet the
housing damage. High spots may be service limit.
removed with crocus cloth or a soft
stone. Inspect threaded holes for D. On PTO-equipped models,
debris and thread damage. Replace inspect the converter housing
the torque converter housing if it is bearing bore for wear. Maximum
cracked, if it leaks from a damaged allowable bearing bore inside D. Bearing
machined surface, or if it has thread diameter is 180.05 mm (7.088 Bore
damage which cannot be repaired. inches). Replace the housing if
damage cannot be repaired using a
B. Inspect the breather for soft stone or crocus cloth. E. Retainer
damage and obstructions. Replace Mounting
the breather if it is damaged. Clean E. Inspect the PTO bearing Surface
the breather if it is blocked with retainer mounting face surface
debris. and threads for damage. Replace
the housing if surface damage
C. Replace the input speed sensor cannot be repaired using a soft
if the sensor body or electrical stone or crocus cloth. Replace the
terminals are damaged. Speed housing if thread damage cannot be
sensor resistance is 300 ohms (plus repaired.
or minus 30 ohms). Replace the
(continued) TORQUE CONVERTER HOUSING MODULE
M. PTO Drive
Gear Bearings
L. Splines
F. PTO Drive J. Bearing

Assembly Surfaces
Bearing
Retainer
H. Oil
Pump
Drive
Hub I. PTO Gear
Teeth
F. On PTO-equipped models, G. Inspect the retainer housing I. Inspect the PTO drive gear
inspect the PTO drive bearing bushing for damage and wear. teeth for chips, pitting and
retainer housing bore for damage. Replace the bushing if damaged. excessive wear. Replace the gear if
Replace the retainer if damage Maximum allowable bushing inside damage cannot be repaired using a
cannot be repaired using a soft diameter is 89.19 mm (3.511 inches). soft stone or crocus cloth.
stone or crocus cloth. Replace the Replace the bushing if it is worn
NOTE: Some axial movement of the
retainer housing if the bushing has beyond service limits.
spun in the bushing bore. gear is normal, but movement
should not exceed 3.175 mm (0.125
H. Inspect the oil inch). Replace the PTO bearings if
G. Bushing
F. Retainer pump drive hub. axial movement exceeds service
Bore Replace the drive hub limit.
if damage cannot be
NOTE: Normal operating backlash
repaired using a soft
stone or crocus cloth. after PTO is installed is 0.1 mm to
0.66 mm (0.004 to 0.026 inch).
(continued)

TORQUE CONVERTER HOUSING MODULE (continued)
K. Splines
I. PTO
Gear
Teeth
J. Inspect the PTO drive hub K. Inspect the drive hub splines L. Inspect the PTO drive gear
tangs for step wear, deformation for wear. Replace the drive hub if bearings following the “General
and cracks. Replace the drive hub if spline wear exceeds 0.38 mm Inspection Guidelines for Bearings”
tang step wear exceeds 0.38 mm (0.015 inch). section of this manual. Replace
(0.015 inch) or if either tang is either bearing as needed.
deformed or cracked.
NOTE: Drive hub tang breakage or
deformity accompanied by charging Examine the
pump bushing failure and ground oil pump
sleeve wear is often caused by poor drive tangs
transmission fluid condition due to for excessive
improper maintenance intervals. battering.
Observation of proper fluid change
intervals is key to optimum
transmission life.

STANDARD REAR COVER &
P3 PLANETARY MODULE
A. Output
Speed
Sensor
C. Piston
B. Rear Cover
E. Retaining
Ring
D. Spring
Pack
F. Clutch Plates
A. Inspect the output speed damage to any machined surface D. Inspect the C5 clutch spring
sensor for damage. Replace any cannot be repaired using a soft pack for damage due to rubbing
sensor that has body, terminal or stone or crocus cloth. Replace the adjacent parts and cracked or
connector seat damage. Allowable rear cover if it is cracked. broken pieces. Check springs for
output speed sensor resistance is wear, breakage and damage.
300 ohms plus or minus 30 ohms. C. Inspect the C5 clutch piston Reference the Spring Data Charts in
following the “General Inspection the Service Manual SM2457EN
B. Inspect the rear cover Guidelines for Cast Parts and for spring specifications and
following the “General Inspection Machined Surfaces” section of this identification.
Guidelines for Cast Parts and manual. Replace the piston if it fails
E. Replace the C5 retaining
Machined Surfaces” section of this to meet the inspection guidelines.
ring if it is bent or distorted.
manual. High spots on machined Inspect the C5 piston tang for
surfaces can be removed using a excessive wear. (continued)
soft stone or crocus cloth. Inspect
the slot on the back side of the
housing where the C5 piston tang
indexes. Replace the rear cover if

P3 PLANETARY MODULE (continued)
C5 Friction Plate Update -
SIL 4-WT-00, Rev. B and SIL 12-WT-03
Current C5
Friction Plate -
missing two
splines.
Former C5 Friction
Plate - one or no
missing splines.
F. Clutch
Plates Clutch plate identification is made by
counting the number of missing teeth.
F. Inspect the C5 friction clutch Inspect the C5 reaction clutch missing. Any 4000/B 500 model
plates following the “General plates following the “General transmission may be updated from
Inspection Guidelines for Friction Inspection Guidelines for Reaction former C5 friction plates to current
Plates” section of this manual. Plates” section of this manual. C5 frictions without recalibrating
Discard any plates that do not meet Discard any plates that do not meet the transmission ECU. The rest of
the guidelines. Minimum allowable
the guidelines. Minimum allowable the clutches in the main housing
thickness for reuse is 2.41 mm
thickness for reuse is 3.48 mm (0.095 inch). Maximum cone for (C1 through C4) must be updated
(0.137 inch). Minimum oil groove reuse is 0.25 mm (0.010 inch). with current friction plates if any
depth for reuse is 0.20 mm (0.0008 other individual clutch besides C5
inch). Maximum cone for reuse is NOTE: The current clutch friction is updated from former to current
0.25 mm (0.010 inch). plates were implemented April of friction plates. Any update from
2000 starting with s/n 6610062126. former frictions to current frictions
NOTE: Battered and worn spline Current clutch friction plates will in C1 through C4 for a 4000 Series
teeth may be an indicator of have two or more missing splines. or B500 with a WTEC II ECU will
driveline issues. Replace the clutch
Former friction plates will either require a new ECU calibration from
plates and check the driveline.
have one spline missing or none Allison Transmission. Any update
(continued)

(continued) P3 PLANETARY MODULE
P3 Ring Gear Update -

SIL 12-WT-03
IDENTIFICATION
GROOVE
FORMER (NON-HARDENED) HARDENED

P3 RING GEAR P3 RING GEAR
Use C5 friction Use C5 friction

plate missing plate missing
3 internal teeth. 2 internal teeth.
from former frictions to current 4000/B500 series model without

Oil Passage
Detail
frictions in C1 through C4 for a the harder ring gear (no groove on
4000 Series or B500 with a WTEC O.D.) is being updated with current
III ECU with a calibration prior to C5 frictions, then it will require the
October 25, 1999 will require an C5 friction that has three missing
updated ECU calibration from internal splines. The C5 friction
Allison Transmission. Do not plate missing three splines will
C5 Pressure intermix both former and current exhibit spline wear if used with the
friction plates in a clutch pack. current P3 ring gear with a groove
identifier on the O.D. The former P3
The P3 ring gear changed to a ring gear (no groove on O.D.) will
harder ring gear on s/n 6610027070. exhibit premature wear if used with
The current P3 ring gear identifier the current C5 friction with two
is a groove machined around the missing internal splines. No ECU
outer diameter of the gear. The P3 calibration is necessary for
ring gear with a groove identifier updating C5 clutch plates.
requires the C5 friction with two
(continued)
missing splines if updating from
former C5 frictions. If any

I. Output Shaft
External
Retaining Ring
H. Output
Shaft
C. Indexing Spacer
A. P3 Carrier
Ring Assembly
(Non-Retarder)
F. Pinion
Gear
G. Pinion
Roller
Bearing D. P3 Planetary
Spindle
B. Tapered
Roller
Bearing
E. Thrust
Washer J. Output Shaft
A. Verify a proper press fit spindle has more than 0.051 mm

between the P3 carrier and rear (0.002 inch) clearance in the bore.
cover or retarder housing by Inspect for thread damage on the
inverting the carrier over a table or carrier hub. Replace the carrier if
workbench. If the P3 carrier falls threads are damaged.
out of the rear cover or retarder
housing without using a press or B. Inspect the tapered roller Bearing races
mallet, the press fit between the bearings and races following the located in rear
tapered bearings and P3 carrier no “General Inspection Guidelines for cover.
longer exists and the carrier must Bearings” section of this manual.
be replaced. Replace any bearings failing to meet indexing ring if it is broken or if it
the inspection guidelines. Bearing has excess step wear or damage
Inspect the P3 carrier for spline races are located in the rear cover which cannot be repaired using a
wear. Replace the carrier if spline housing and should also be soft stone or crocus cloth. Indexing
wear exceeds 0.38 mm (0.015 inch). inspected for wear and damage. rings with acceptable wear can be
Inspect the pinion spindle bores in flipped during reassembly so that a
the carrier and the pinion thrust C. Inspect the P3 indexing ring
for step wear in the area where it new contact surface is used.
surfaces for excessive wear and
damage. Replace the P3 carrier if a contacts the spindle. Replace the (continued)


P3 Carrier Update - Planetary Spindle and
SIL 25-WT-01 Indexing Ring Updates -
SIL 10-WT-00
P1 P2 P3
Planetary spindles and indexing rings are

backward compatible. Current spindles are
Current P3 carriers use a drill point stamped with the number “2.” Indexing rings
hole and a Belleville spring washer. are stamped with the identifier “HD5.”
D. Inspect planetary spindles for G. Inspect the pinion roller

wear and damage. Discoloration is bearings following the “General
only a concern if spindle surface Inspection Guidelines for Bearings”
damage exists. section of this manual. Replace any
bearings which fail these inspection
E. Inspect the pinion gear thrust procedures.
washers for damage, distortion and
signs of excessive wear. Minimum H. Replace the output shaft
allowable thrust washer thickness spacer if it is bent, cracked or if it
is 1.39 mm (0.054 inch). Replace is distorted in any way. An attempt
damaged or worn thrust washers. can be made to repair some minor
damage using a soft stone.
F. Inspect the pinion gears
following the “General Inspection I. Inspect the output shaft
Guidelines for Gears” section of this external retaining ring. Replace
manual. Replace any gears which the retaining ring if it is distorted
fail these inspection procedures or or fits loosely on the shaft.
if the damage cannot be repaired (continued)
using a soft stone.

Flange / Yoke Retaining Bolt Update - Reference SIL 1-WT-99
Single Bolt
design
increases
clamp load.
J. Inspect the output shaft

bushing for damage.
Output spacers
are not
interchangeable
between the
former and
current designs.
J. Output Shaft
J. Inspect the output shaft Service Kit for Two-Bolt Ouput - SIL 15-WT-98
following the “General Inspection Kit Part Number: 29535910
Guidelines for Cast Parts and
Machined Surfaces” and the
“General Inspection Guidelines for * Note: Kit contains
Splines” sections of this manual. Belleville washers and
Replace the output shaft if it fails 2 allen-head bolts to
replace original locking
these inspection procedures.
tab and hex-head bolts.
Inspect the output shaft bushing
Guidelines for Bushings” section of
this manual. Replace the bushing if
it fails these inspection procedures.
Maximum allowable bushing inside
diameter is 36.14 mm (1.423 inch).
(continued)

4000 Series
Close Ratio
P3 Carrier
Assembly
4000 Series
Wide Ratio
P3 Carrier
Assembly
K. Replace the output bearing

locknut retainer whenever the
locknut is removed.
L. Inspect the Belleville spring
washer for damage. Replace the
L. Belleville
washer if it is distorted or the M. Output
Spring
tang is worn. Bearing
Locknut
M. Replace the output bearing
locknut if it is cracked, distorted, Former output bearing
has damaged threads. The current locknut and retainer
locknuts have three buttons in the
threaded area. This nut should be
replaced if it does not have a
minimum of 10 N.m (7.5 ft. lb.) of K. Locknut
running torque when threading Retainer
the nut.
(continued)


Bearing Retainer Locknut Output Seal Update -
Update - Reference Reference SIL 4-WT-03
SIL 25-WT-01
Two seals are
currently available -
to fit former and
current rear covers.
Current They are NOT
bearing interchangeable.
retainer
locknuts
include Former
three Output Seal
locking
buttons.
Current Output Seal (current Current Output Seal (former

standard/ retarder housing) for standard/ retarder housing)
S/N starting with 6610116108 for S/N prior to 6610116108

Output Yoke/Flange Update - Rear Cover Update - Reference SIL 4-WT-03
Reference SIL 4-WT-03
Former: No cut relief Current: Cut relief on

the exterior for a wrap
around slinger.
Not all yoke / slinger combinations Current rear cover has interior cut relief to accommodate
can be used with all transmis- 5-ridge output seal. Former rear cover has interior cut relief to
sions. Rear cover design deter- accommodate 4-ridge output seal (reference Output Seal Update
mines yoke / slinger combination. Supersession Information).

Retarder Exhaust Backfill Valve Update -
Reference SIL 14-WT-02 ALLISON 4000 / B 500 PRODUCT FAMILIES
Current
Retarder
Exhaust
Former
Retarder
Exhaust
RETARDER MODULE
Backfill Backfill
The current stop is backward

compatible with all 4000/B 500 retarder - F. Retarder Temp
equipped transmissions. Sensor Assembly
G. Output Speed
Sensor
B. Retarder Stator
Housing
A. Retarder
Housing
D. P3 Carrier C. Retarder
Assembly Rotor
(Retarder)
E. Autoflow Valve,
Spring & Plug
A. Inspect the retarder housing inside diameter is greater than Inspect the slot on the back side
following the “General Inspection 139.72 mm (5.501 inches). A bearing of the housing where the C5 piston
Guidelines for Cast Parts and race fits into the housing and tang indexes for excessive wear.
Machined Surfaces” section of this should be inspected for damage. Replace the stator housing if
manual. High spots on machined damage to any machined surface
B. Inspect the stator housing
surfaces can be removed using a following the “General Inspection cannot be repaired using a soft
soft stone or crocus cloth. Replace Guidelines for Cast Parts and stone or crocus cloth. Replace the
the retarder housing if it is cracked Machined Surfaces” section of this stator housing if it is cracked.
or if machined surface damage manual. Some light housing
cannot be removed using a soft C. Inspect the retarder rotor
imperfections can be removed using
stone or crocus cloth. following the “General Inspection
a soft stone. Discard and replace the
housing if damage is excessive. Guidelines for Cast Parts and
Install a “known good” rotor Machined Surfaces” section of this
sealring in the retarder housing and NOTE: Transmissions built prior to manual. Check for loose, cracked or
measure sealring inside diameter. If January 1998 included two small broken rivets. Replace the rotor if
the retarder housing is slightly check balls and retainers located in movement exists between the
grooved or worn, place the sealring the retarder stator housing. center hub and the vaned assembly.
directly in the grooved or worn Minimum allowable check ball Inspect the rotor splines for wear.
area. Replace the housing if sealring movement is 0.50 mm (0.020 inch). (continued)

RETARDER MODULE (continued)
Retarder Sump Cooling Feature - Reference
SIL 25-WT-00, Rev. A
No Sump
Cooling
Feature
The sump cooling feature provides additional cooling Sump

when the retarder is active through either an additional Cooling
auxiliary cooler or the direct mount cooler for retarder Provision
transmissions. The direct mount cooler for retarder transmissions
works as both the main cooler and auxiliary cooler. Main
Control Main
To Retarder
From
Cooler
Fluid Flow
Detail Lube
Pressure
Retarder
Main C5 Pressure Out
Exhaust
Accumulator
Control Converter Out
To Cooler
Main From (To Cooler)
Cooler
Spline wear cannot exceed 0.38 mm weight. Replace or repair the 1 and post-TID 1 (TID 2 and TID 3).
(0.015 inch). Replace the rotor if it autoflow valve and/or retarder Resistance specifications vary
exceeds this wear limit. housing as necessary. Crocus cloth between the two sensor types. Be
can be used to remove slight high sure to use the correct
D. Reference the “Inspection and spots. Troubleshooting Manual chart for
Analysis of the Standard Rear the sensor being tested. Replace the
Cover” section of this manual for P3 Inspect the autoflow valve spring temperature sensor if its measured
planetary carrier assembly details. for defects and permanent set. resistance is not within
Reference the Spring Data Charts in Troubleshooting Manual
NOTE: Inspect retarder P3 carriers
Service Manual SM2457 for spring specifications.
for excessive step wear on the specifications and identification.
splines of the P3 carrier hub. Replace the spring if it fails any G. Inspect the output speed
Replace those P3 carriers that inspection procedures. sensor for damage. Replace the
exhibit step wear. sensor if it has body, terminal or
F. Inspect the retarder connector seat damage. Allowable
E. Inspect the retarder autoflow temperature sensor exterior for
valve for wear and damage. The output speed sensor resistance is
defects. Replace the temperature 300 ohms plus or minus 30 ohms.
autoflow valve must move freely in sensor if it is damaged. There are
its bore, when dry, under its own (continued)
two temperature sensor types - TID

(continued) RETARDER MODULE
D. Valve
Plug & C. Retarder Control
Retaining Valve Spring
Ring
A. Retarder
B. Retarder Valve
Control Body K. Wiring
Valve Harness
G. Retarder
Solenoid
E. Channel L. Solenoid
Plate Cover
H. Exhaust
Backfill I. Exhaust J. Exhaust
Valve Backfill Backfill Valve
F. Separator
Valve Stop & Pin
Plate
Spring
A. Inspect the retarder control removal of slight irregularities. E. Inspect the channel plate
valve body following the “General Valves must move freely in their following the “General Inspection
Inspection Guidelines for Cast bores, when dry, under their own Guidelines for Cast Parts and
Parts and Machined Surfaces” weight. Machined Surfaces” section of this
section of this manual. All passages manual. Replace the channel plate if
must be clean and debris free. Valve C & I. Replace the retarder it fails any of these inspection
bores must be free of nicks, burrs control valve spring or exhaust procedures or if it has damage
and scoring. Crocus cloth or a soft backfill spring for damage or which cannot be repaired using a
stone can be used to attempt permanent set. Reference the soft stone or crocus cloth.
removal of slight irregularities, Spring Data Charts in the Service All passages must be clean and
however no honing of any kind is Manual for spring specifications debris free.
permitted. and identification. (continued)
B & H. Inspect the retarder D. Inspect the valve plug for

control valve and exhaust backfill damage. Replace the plug if damage
valve for nicks, burrs, scoring and cannot be repaired using a soft
other damage. A soft stone or stone or crocus cloth.
crocus cloth can be used to attempt

RETARDER MODULE (continued)
Retarder Pocket Retarder

Pressure Pressure Exhaust
Main Pressure
Exhaust Pressure
Pressure Main Pressure
Main
(Feed)
Pressure
(to Flow
Valve) Main
Pressure
Retarder
Pressure
Pocket
Exhaust
Pressure Exhaust
Backfill
Pressure
Exhaust
Control Pressure
Main Retarder
Control Main
Pressure
Pressure
F. Inspect the separator plate for J. Inspect the exhaust backfill L. Inspect the solenoid cover
nicks, burrs, scoring and distortion valve stop for damage. Replace the following the “General Inspection
(flatness). Replace the plate if stop if damage cannot be repaired Guidelines for Cast Parts and
damage cannot be repaired using a using a soft stone or crocus cloth. Machined Surfaces” section of this
soft stone or crocus cloth. Inspect the exhaust backfill valve manual. Replace the housing if it
pin for damage. Replace the pin if it fails any of these inspection
G. Replace the retarder solenoid is bent or has damage. procedures.
if the body, connector or terminals
show visible signs of damage. K. Replace or repair the wiring
Solenoid resistance should be 3 to 4 harness if the wires, terminals or
ohms measured between the two connectors are visibly damaged.
solenoid terminals. Check Check the installed harness for
resistance between each solenoid tight bends or crimps which might
terminal and the solenoid body. damage harness wires.
Replace the solenoid if either
reading is less than 100k ohms
resistance.

CLOSE RATIO MAIN SHAFT MODULE
B. Main
Shaft
C. Journal Pilots
Close Ratio Main

B. Main
Shaft Module Shaft
Pilots
G. Selective
F. Bearing Shim
E. P2 Sun Spacer A. Main Shaft
Gear
D. Thrust
Bearing
H. P3
I. Spiral Sun
Retaining Gear
Ring
A. Inspect the main shaft journal diameter is less than 52.98 and Machined Surfaces” and
following the “General Inspection mm (2.085 inch). “General Inspection Guidelines for
Guidelines for Gears” and “General D. Inspect the thrust bearings Splines” sections of this manual.
Inspection Guidelines for Splines” following the “General Inspection Replace the spacer if it fails any of
sections of this manual. Replace the Guidelines for Bearings” section of these inspection procedures.
main shaft if it fails any of these this manual. Replace any bearing G. Inspect the selective shim for
inspection procedures. that fails any of these inspection damage. Replace the shim if it is
B. Inspect the front and rear procedures. distorted or if damage cannot be
main shaft pilots for damage. The E. Inspect the P2 sun gear removed by light stoning.
front main shaft pilot fits inside the following the “General Inspection H. Inspect the P3 sun gear
turbine shaft. The rear main shaft Guidelines for Gears” and “General following the “General Inspection
pilot fits inside the output shaft. Inspection Guidelines for Splines” Guidelines for Gears” and “General
Replace the main shaft if pilot sections of this manual. Replace the
Inspection Guidelines for Splines”
outside diameter is less than 35.92 gear if it fails any of these inspection
sections of this manual. Replace the
mm (1.414 inch). procedures.
gear if it fails any of these
C. Inspect the P2 bushing journal F. Inspect the main shaft bearing inspection procedures.
area for damage. Replace the main spacer following the “General
I. Replace the spiral retaining
shaft if P2 planetary bushing Inspection Guidelines for Cast Parts
ring if it is removed.

WIDE RATIO MAIN SHAFT MODULE
B. Main Shaft Pilots
C. Journal
Wide Ratio Main B. Main Shaft
Shaft Module Pilots
A. Main
Shaft
E. Thrust
Bearing
G. Selective
Shim
F. Bearing
Spacer
D. P2 Sun
H. Spiral Gear
Retaining
Ring
A. Inspect the main shaft C. “Inspect the P2 bushing F. Inspect the main shaft bearing
following the “General Inspection journal for damage. Replace the spacer following the “General
Guidelines for Gears” and “General main shaft if P2 planetary bushing Inspection Guidelines for Cast
Inspection Guidelines for Splines” journal diameter is less than 52.98 Parts and Machined Surfaces”
sections of this manual. Replace the mm (2.085 inch). “General Inspection Guidelines for
main shaft if it fails any of these Splines” sections of this manual.
D. Inspect the P2 sun gear Replace the spacer if it fails any of
inspection procedures.
following the “General Inspection these inspection procedures.
B. Inspect the front and rear main Guidelines for Gears” and “General
Inspection Guidelines for Splines” G. Inspect the selective shim for
shaft pilots for damage. The front
sections of this manual. Replace the damage. Replace the shim if it is
main shaft pilot fits inside the
gear if it fails any of these distorted or if damage cannot be
turbine shaft. The rear main shaft removed by light stoning.
pilot fits inside the output shaft. inspection procedures.
Replace the main shaft if pilot H. Replace the spiral retaining
E. Inspect the thrust bearings
outside diameter is less than 35.92 ring if it is removed.
mm (1.414 inch). Guidelines for Bearings” section of
this manual. Replace any bearing that
fails any of these inspection
procedures.

P2 PLANETARY MODULE
C. Carrier D. P3 Ring
Hub Gear
A. P2 Planetary
Carrier
E. Index
Ring
I. Pinion
Gear
G. Pinion
J. Retaining Spindle
Rings H. Pinion
Roller F. Pinion Thrust
Bearings Washers
A. Inspect the P2 carrier D. Inspect the P3 ring gear excessive wear. Minimum allowable
following the “General Inspection following the “General Inspection thrust washer thickness is 1.40 mm
Guidelines for Cast Parts and Guidelines for Gears” and “General (0.055 inch). Maximum allowable
Machined Surfaces” and the Inspection Guidelines for Splines” thrust washer step wear is 0.12 mm
“General Inspection Guidelines for sections of this manual. Replace the (0.005 inch).
Splines” sections of this manual. ring gear if it fails any of these G. Replace planetary spindles if
Replace the carrier if any spindle inspection procedures. they are worn or damaged.
has more than 0.051 mm (0.002 E. Inspect the P2 indexing ring for Discoloration is only a concern if
inch) clearance in its bore. step wear in the area where it spindle surface damage exists.
B. Inspect the P2 carrier bushing contacts the spindle. Replace the (continued)
for damage. Replace the bushing if indexing ring if it is broken or if it
damaged. Replace the bushing if has excessive step wear or damage.
Indexing rings with acceptable
inside diameter exceeds 53.23 mm
wear can be flipped during
(2.096 inches).
reassembly so that a new contact
C. Inspect the carrier hub for surface is used.
damage. Replace the carrier if F. Replace the pinion gear thrust
damage cannot be repaired using a washers if they are damaged, B. Carrier
soft stone or crocus cloth. distorted, galled or showing signs of
Bushing

Planetary Spindle and Indexing Ring P1 P2 P3
Updates - Reference SIL 10-WT-00
Planetary spindles and indexing rings are

backward compatible. Current spindles are
stamped with the number “2.” Indexing rings
are stamped with the identifier “HD5.”
4000 Series
Wide Ratio 4000 Series
P2 Carrier Close Ratio
Assembly P2 Carrier
Assembly
H. Inspect the pinion roller NOTE: Current P3 ring gears are

bearings following the “General hardened. Former P3 ring gears
Inspection Guidelines for Bearings” were non-hardened. Each ring gear P3 Ring Gear Update -
section of this manual. Replace any requires a specific C5 clutch plate. SIL 12-WT-03
bearing failing these inspection There are two current versions of
procedures. C5 clutch plates. Plates which are
I. Inspect the P2 pinion gears missing two splined teeth must be
following the “General Inspection used with the hardened P3 ring gear
Use C5 friction
Guidelines for Gears” section of this (identified by the groove on the
plate missing
manual. Replace any gear that fails gear’s outside diameter). Plates
3 internal teeth.
these inspection procedures or if missing three splined teeth must be
damage cannot be removed using a used with the non-hardened P3 ring
soft stone. gear (no identification groove). FORMER (NON-HARDENED)
P3 RING GEAR
Reference the C5 clutch plate
J. Inspect the P2 carrier “Supersession Information” in this
retaining rings for damage or section and SILs 12-WT-03 and
distortion. Replace any retaining 4-WT-00, Revision B. The correct IDENTIFICATION
rings with damage that cannot be current C5 clutch plate must be

GROOVE
removed using a soft stone. used with each ring gear to avoid Use C5 friction
transmission damage. plate missing 2
internal teeth.
46 ALLISON TRANSMISSION TECHNICIANS’ GUIDE HARDENED
 2005 General Motors Corporation. P3 RING GEAR
P1 PLANETARY MODULE
A. P1
Planetary
Carrier
B. P2
Ring
Gear
H. Retaining
Ring
E. Pinion
Spindle
D. Pinion
Thrust
F. Pinion Washers
C. Index
Gear Ring
G. Pinion Roller
Bearings
A. Inspect the P1 carrier following B. Inspect the P2 ring gear

the “General Inspection Guidelines following the “General Inspection
Thrust for Cast Parts and Machined Guidelines for Gears” and the
bearing
Surfaces” and the “General “General Inspection Guidelines for
inspection.
Inspection Guidelines for Splines” Splines” sections of this manual.
sections of this manual. Replace the Replace the ring gear if it fails any
carrier if any spindle has more than of these inspection procedures.
0.051 mm (0.002 inch) clearance in
its bore. C. Inspect the P1 indexing ring
for step wear in the area where it
Thrust bearings fit on both sides of contacts the spindle. Replace the
the P1 carrier. Inspect the thrust indexing ring if it is broken or if it
bearings following the “General has excessive step wear or damage.
Inspection Guidelines for Bearings” Indexing rings with acceptable
section of this manual. Replace any wear can be flipped during
bearing that fails any of these reassembly so that a new contact
inspection procedures. surface is used.
(continued)

Planetary Spindle and Indexing Ring Updates -
SIL 10-WT-00
P1 P2 P3
Planetary spindles and indexing rings are backward

compatible. Current spindles are stamped with the number
“2.” Indexing rings are stamped with the identifier “HD5.”
D. Replace the pinion gear thrust G. Inspect the pinion roller

washers if they are damaged, bearings following the “General
distorted, galled or showing signs of Inspection Guidelines for Bearings”
excessive wear. Minimum allowable section of this manual. Replace any
thrust washer thickness is 1.39 mm bearing failing these inspection
(0.054 inch). procedures.
E. Replace planetary spindles if H. Inspect the P1 carrier retaining
they are worn or damaged. rings for damage or distortion.
Discoloration is only a concern if Replace any retaining rings with
spindle surface damage exists. damage that cannot be removed
using a soft stone.
F. Inspect the P1 pinion gears
Guidelines for Gears” section of this
manual. Replace any gear that fails
these inspection procedures or if
damage cannot be removed using a
soft stone.

ALLISON 4000 / B 500 PRODUCT FAMILIES C. Sealring Grooves
FRONT SUPPORT &

OIL PUMP MODULE
A. Front Support
D. Non-PTO Model Assembly
Ground Sleeve
B. Front
E. Bushing Support
Journal Sleeve
D. PTO-Model
Ground
Sleeve
H. Roller
Bearing
F. Charging
Pump G. Main
Housing Pressure
(PTO Model) Relief Ball
I. Charging Pump & Spring J. Wear
Gear Set Plate
A. Inspect the front support B. Replace the front support if

assembly following the “General the sleeve has damage that cannot
Redesigned Charging Pump Inspection Guidelines for Cast be repaired using a soft stone or
Gear Set - SIL 13-WT-04 Parts and Machined Parts” section crocus cloth. Minimum allowable
of this manual. Replace the front support sleeve diameter is
assembly if it fails any of these 119.81 mm (4.717 inches).
inspection procedures. If the
ground sleeve has rotated in the C. Inspect the three sealring
front support, replace both grooves on the front support
components (the ground sleeve and assembly hub for nicks, burrs,
Former the front support assembly). If the cracks and other damage.
ground sleeve is replaced, check the (continued)
front support for flatness after
ground sleeve installation. Replace
the front support if it is more than
0.051 mm (0.002 inch) from flat.
Current
Orange bushing identifies

current gear set. ALLISON TRANSMISSION TECHNICIANS’ GUIDE 49
FRONT SUPPORT & OIL PUMP MODULE (continued)
Oil Passage
Detail
Lube
Pressure Main
Pressure
Pump
Suction Lockup Pressure
Converter In Converter
C1
Pressure Out
C2
Pressure
D. Inspect the ground sleeve intervals is key to optimum

following the “General Inspection transmission life. Front support oil passage
Guidelines for Splines” section of detail - outside hub.
Inspect the area in the ground
this manual. Replace the shaft if it
sleeve where the turbine shaft
fails any of these inspection
sealrings ride for grooves, scoring
procedures.
and other wear or damage. Install
E. Inspect the journal area where new sealrings in the ground sleeve
the charging pump driven gear and measure the end gap. If the
bushing rides. Replace the shaft if ground sleeve is grooved or worn,
the journal is damaged or galled. place the sealrings directly in the
Minimum allowable journal grooved or worn area. Maximum
diameter is 66.67 mm (2.265 allowable sealring end gap is 1.01 C1 Pressure
inches). mm (0.039 inches). Replace the C2 Pressure
ground sleeve if any of the seal ring
NOTE: Ground sleeve galling is
end gaps exceeds this specification.
typically an indicator of poor
transmission fluid condition due to NOTE: When replacing the ground
improper maintenance intervals. sleeve, total shaft runout cannot
Observation of proper fluid change exceed 0.30 mm (0.012 inch) once it
is pressed into the front support.
(continued)
(continued) FRONT SUPPORT & OIL PUMP MODULE
Oil passage detail - Flat on

inside hub. Ground
Sleeve
Indexing
Alignment
Lube Lockup Converter Arrow
Out
C2 Pressure C1
Pressure
F. Inspect the charging pump G. Replace the main pressure H. The roller bearing fits inside
housing following the “General relief ball if it is damaged. Inspect the back of the front support hub.
Inspection Guidelines for Cast the main pressure relief spring Inspect this bearing following the
Parts and Machined Parts” section following the “General Inspection “General Guidelines for Bearings”
of this manual. Replace the housing Guidelines for Springs” section of section of this manual. Replace the
if it fails any of these inspection this manual. Replace the spring if it bearing if it fails any of these
procedures. Replace the charging is bent, broken, distorted or shows inspection procedures.
pump housing if gear cavity depth signs of wear from rubbing adjacent (continued)
exceeds 19.04 mm (0.750 inches). parts. Reference the Spring Data
Replace the charging pump housing Charts in the Service Manual for
if gear cavity diameter exceeds spring identification and
150.25 mm (5.915 inches). specifications.

FRONT SUPPORT & OIL PUMP MODULE (continued)
Lockup
Lube
Ground sleeve oil Converter Out

passage detail.
C2 Pressure
C1
Pressure
I. Replace the charging pump Maximum allowable clearance J. Replace the wear plate if it is
gear set if the sides, faces or gear between the installed gear set and galled or moderately scored. Pay
teeth are damaged. Replace the gear mounting face of the pump housing particular attention to the area
set if the inside gear shows damage is 0.10 mm (0.004 inch). This is where the charging pump gear set
or battering at the point where the often referred to as pump gear side rides. Minimum allowable wear
torque converter drive tangs (or the clearance. Maximum allowable gear plate thickness is 4.70 mm (0.0185
PTO drive hub tangs) index into tooth tip clearance (the gap inch). Replace the wear plate if it is
the gear. Replace the gear set if the between a tooth on the outer gear worn past service limits or if it has
bushing inside diameter exceeds and a tooth on the inner gear) is damage that cannot be repaired
57.30 mm (2.256 inch). Minimum 0.15 mm (0.006 inch). The using a soft stone or crocus cloth.
allowable outside diameter of the maximum allowable clearance
outer gear is 149.94 mm (5.903 between the outer gear and the
inch). pump housing is 0.30 mm (0.012
inch).
NOTE: Install the pump gear set in
the oil pump housing to perform
the following inspections and
measurements.

ROTATING CLUTCH MODULE
E. Rotating
J. Sealring Drum
Bore
A. Turbine Shaft
(Non-PTO Model)
K. Bushing
I. Retaining Ring
A. Turbine Shaft
(PTO Model)
H. Thrust
Bearing
F. Rotating
G. P1 Sun Clutch Hub
Gear
Assembly
H. Thrust
Bearing
A. Inspect the turbine shaft C. Inspect the bearing

following the “General Inspection journal area for damage. D. Sealring
Grooves
Guidelines for Cast Parts and Replace the turbine shaft if
B. Bushing C. Journal
Machined Surfaces” section of this damage cannot be repaired
manual. Replace the turbine shaft if with a light stone or crocus
it fails any of these inspection cloth.
procedures. Maximum allowable Machined Surfaces” and “General
D. Inspect the three sealring Inspection Guidelines for Splines”
spline wear is 0.38 mm (0.015 inch).
grooves for damage. Replace the sections of this manual. Replace the
B. Inspect the turbine shaft turbine shaft if damage cannot be drum if it fails any of these
bushing following the “General repaired with a light stone or inspection procedures. Maximum
Inspection Guidelines for Bushings” crocus cloth. Install three new allowable spline wear is 0.38 mm
section of this manual. Replace the sealrings and check end gap. 0.015 inch).
bushing if it fails any of these Minimum end gap allowed is 0.65
inspection procedures. Maximum mm (0.026 inch). Replace turbine F. Inspect the rotating clutch
allowable bushing inside diameter shaft if end gap is below minimum. hub following the “General
is 36.14 mm (1.423 inch). Inspection Guidelines for Cast
E. Inspect the rotating drum
Parts and Machined Surfaces” and
(continued)
Guidelines for Cast Parts and

ROTATING CLUTCH Rotating
MODULE (continued) clutch hub
oil passage
detail.
C2 Pressure
C1 Pressure
Supersession Information Supersession Information Supersession Information

Turbine Shaft Update - Turbine Shaft Update - Rotating Clutch Hub Update -
Reference SIL 19-WT-94 Reference SIL 19-WT-94 Reference SIL 8-WT-99, Rev. A
& 22-WT-94
Turbine Shaft
Current
Turbine
Shaft
Ground Sleeve
Former Current
Former
(No Weld) (Weld)
Turbine
Shaft
Note: The rotating clutch hub was
updated beginning with serial number
6610037353. The former rotating clutch
Former turbine shaft and Former turbine shafts include a
hub is not welded in the area shown.
current ground sleeve are raised area toward the torque The current rotating hub is welded and
NOT compatible. converter end of the shaft. machined in the area shown.
“General Inspection Guidelines for this manual. Replace any bearings crocus cloth. Install three new
Splines” sections of this manual. which fail any of these inspection sealrings in the wear area of the
Replace the hub if it fails any of procedures. bore and check each seal’s end gap.
these inspection procedures. Replace the rotating clutch hub if
I. Inspect the turbine shaft end gap exceeeds 1.44 mm (0.056
G. Inspect the P1 sun gear retaining ring following the inch).
assembly following the “General “General Inspection Guidelines for
Inspection Guidelines for Gears and Retaining Rings” section of this K. Inspect the rotating hub
“General Inspection Guidelines for manual. Replace the retaining ring bushing following the “General
Splines” sections of this manual. if it fails any of these inspection Inspection Guidelines for Bushings”
Replace the assembly if it fails any procedures or if the ring is bent, section of this manual. Replace the
of these inspection procedures or if distorted or shows other signs of bushing if it fails any of these
it has damage which cannot be damage. inspection procedures or if it has
repaired using a soft stone or crocus damage which cannot be repaired
cloth. J. Inspect the area inside the hub using a soft stone or crocus cloth.
where the front support sealrings Maximum allowable bushing inside
H. Inspect the thrust bearings ride for grooves and damage. diameter is 120.27 mm (4.735 inch).
following the “General Inspection Replace the hub if damage cannot
Guidelines for Bearings” section of be repaired using a soft stone or (continued)

(continued) ROTATING CLUTCH MODULE
Housing in good condition - reuse.
C1 Clutch
Components
H. Thrust
Bearings
Etched housing - do NOT use. G. C1 Clutch

Pack
C. C1 Balance
Piston A. C1
Drive
B. C1 Piston
Hub
F. C1 Apply
Plate
E. C1 Backing
D. C1 Plate
Return
Spring
A. Inspect the C1 drive hub NOTE: Aluminum castings (like Spring Data Charts in the Service
following the “General Inspection clutch housings) can be etched by Manual for spring specifications
Guidelines for Cast Parts and caustic parts cleaners and solvents. and identification.
Machined Surfaces” and the Etched components are identified
E & F. Inspect the C1 pressure
“General Inspection Guidelines for by a dull to dark gray color - not the
plate and C1 backplate for flatness,
Splines” sections of this manual. bright finish of a normal machined galling and other damage. Replace
Replace the hub if it fails any of aluminum part. Etched components any plate with damage which
these inspection procedures. are also identified by roughness in cannot be removed using a soft
Maximum allowable spline wear is the piston seal surface which can stone or crocus cloth. Former C1
0.38 mm (0.015 inch). cause piston seals to abrade and pressure plate minimum allowable
result in low clutch apply pressure thickness is 7.90 mm (0.311 inch).
B & C. Inspect the C1 clutch and transmission damage. Replace Current C1 apply plate minimum
piston and C1 balance piston etched or damaged components. allowable thickness is 5.90 mm
following the “General Inspection (0.232 inch). Current C1 backplate
Guidelines for Cast Parts and D. Replace the C1 return spring minimum allowable thickness is
Machined Surfaces” section of this assembly if it has permanent spring 9.90 mm (0.390 inch). Maximum
manual. Replace any component if set, wear due to rubbing adjacent allowable distortion of all plates is
it fails any of these inspection parts or if springs are cracked or 0.15 mm (0.006 inch).
procedures. broken in any way. Reference the
(continued)

ROTATING CLUTCH MODULE (continued)

C1 Drive Hub Update - Reference SIL 26-WT-04 C1 Clutch Piston and Balance
Piston Re-design - Reference
SIL 30-WT-04
Current: C1 Former: C1
Drive Hub Drive Hub
Drill Point
Identifier
Drill point identifies the current hub which is Former and current components
backward compatible. can NOT be mixed.
NOTE: Transmissions built prior to Plates” section of this manual. have two or more missing splines.
S/N 6610032320 used two identical Replace any plates failing these Former friction plates will either
C1 pressure plates. Transmissions inspection procedures. Minimum have one spline missing or none
built after that used different plates. allowable friction plate thickness is missing. Any 4000/B 500 model
The current C1 apply pressure plate 2.92 mm (0.115 inch). Minimum transmission may be updated from
(next to the C1 piston) is allowable oil groove depth is 0.20 former C5 friction plates to current
approximately 2 mm thinner and mm (0.008 inch). Maximum C5 frictions without recalibrating
has a different shape than the allowable plate coning is 0.25 mm the transmission ECU. The rest of
current C1 backplate (opposite end the clutches in the main housing
(0.010 inch).
of the C1 clutch pack). When (C1 through C4) must be updated
replacing the former pressure plates NOTE: Battered and worn spline with current friction plates if any
in a transmission with the current teeth may be an indicator of other individual clutch besides C5
plate, both current plates must be driveline issues. Replace the clutch is updated from former to current
used. Mixing former and current plates and check the driveline. friction plates. Any update from
plates will result in C1 clutch former frictions to current frictions
failure. NOTE: The current clutch friction in C1 through C4 for a 4000 Series
plates were implemented April of or B500 with a WTEC II ECU will
G. Inspect the C1 clutch friction
2000 starting with s/n 6610062126. require a new ECU calibration from
plates following the “General Current clutch friction plates will Allison Transmission. Any update
Inspection Guidelines for Friction
(continued)

C1 Backing and Apply Plate Updates -
Reference SIL 22-WT-98, Rev. A
5.90 mm 9.90 mm
Former and current

components can NOT be mixed
from former frictions to current former C5 frictions. If any Inspect the C1 clutch reaction
frictions in C1 through C4 for a 4000/B500 series model without plates following the “General
4000 Series or B500 with a WTEC the harder ring gear (no groove on Inspection Guidelines for Reaction
III ECU with a calibration prior to O.D.) is being updated with current Plates” section of this manual.
October 25, 1999 will require an C5 frictions, then it will require the Replace any plates failing these
updated ECU calibration from C5 friction that has three missing inspection procedures. Minimum
Allison Transmission. Do not internal splines. The C5 friction allowable reaction plate thickness
intermix both former and current plate missing three splines will is 2.41 mm (0.095 inch). Maximum
friction plates in a clutch pack. exhibit spline wear if used with the
allowable reaction plate coning is
current P3 ring gear with a groove
The P3 ring gear changed to a 0.25 mm (0.010 inch).
identifier on the O.D. The former P3
harder ring gear on s/n 6610027070. ring gear (no groove on O.D.) will H. Inspect the thrust bearings
The current P3 ring gear identifier exhibit premature wear if used with
is a groove machined around the following the “General Inspection
the current C5 friction with two Guidelines for Bearings” section of
outer diameter of the gear. The P3 missing internal splines. No ECU
ring gear with a groove identifier this manual. Replace any bearings
calibration is necessary for
requires the C5 friction with two which fail any of these inspection
updating C5 clutch plates.
missing splines if updating from procedures.
(continued)

ROTATING CLUTCH MODULE (continued)
C2 Clutch
Components A. C2
Drive
Hub
D. C2 Spring
Plate
Etched housing - do NOT use.
G. Thrust
Bearing
F. C2
Clutch
Pack
B. C2 Piston
E. C2 Backplate
C. C2 Return
Spring
A. Inspect the C2 drive hub NOTE: Aluminum castings (like Spring Data Charts in the Service
following the “General Inspection clutch housings) can be etched by Manual for spring specifications
Guidelines for Cast Parts and caustic parts cleaners and solvents. and identification.
Machined Surfaces” and the Etched components are identified
“General Inspection Guidelines for by a dull to dark gray color - not the D. Replace the C2 spring plate if
Splines” sections of this manual. bright finish of a normal machined it is cracked, broken or showing
Replace the hub if it fails any of aluminum part. Etched components any signs of distortion or wear.
these inspection procedures. are also identified by roughness in E. Inspect the C2 backplate for
Maximum allowable spline wear is the piston seal surface which can damage. Replace the plate if damage
0.38 mm (0.015 inch). cause piston seals to abrade and cannot be removed using a soft
result in low clutch apply pressure stone or crocus cloth. C2 backplate
B. Inspect the C2 clutch piston and transmission damage. Replace minimum allowable thickness is
following the “General Inspection etched or damaged components. 7.90 mm (0.311 inch) when
Guidelines for Cast Parts and measured at the backing plate wear
Machined Surfaces” section of this C. Replace the C2 return spring area. Maximum allowable
manual. Replace the piston if it fails assembly if it has permanent spring distortion from flat is 0.015 mm
any of these inspection procedures. set, wear due to rubbing adjacent (0.006 inch).
parts or if springs are cracked or (continued)
broken in any way. Reference the

C2 Return Spring
Assembly Update -
Reference SIL 4-WT-00,
Rev. B
Former Current
Currently assembly is
backward compatible
with all transmissions.
F. Inspect the C2 clutch friction through C4) must be updated with with current C5 frictions, then it will
plates following the “General current friction plates if any other require the C5 friction that has three
Inspection Guidelines for Friction individual clutch besides C5 is missing internal splines. The C5
Plates” section of this manual. updated from former to current friction plate missing three splines
Replace any plates failing these friction plates. Any update from will exhibit spline wear if used with
inspection procedures. Minimum former frictions to current frictions in the current P3 ring gear with a groove
allowable friction plate thickness is C1 through C4 for a 4000 Series or identifier on the O.D. The former P3
2.92 mm (0.115 inch). Minimum B500 with a WTEC II ECU will ring gear (no groove on O.D.) will
allowable oil groove depth is 0.20 require a new ECU calibration from exhibit premature wear if used with
mm (0.008 inch). Maximum Allison Transmission. Any update the current C5 friction with two
allowable plate coning is 0.25 mm from former frictions to current missing internal splines. No ECU
(0.010 inch). frictions in C1 through C4 for a 4000 calibration is necessary for updating
Series or B500 with a WTEC III ECU C5 clutch plates.
NOTE: Battered and worn spline
with a calibration prior to October
teeth may be an indicator of Inspect the C2 clutch reaction
25, 1999 will require an updated ECU
driveline issues. Replace the clutch plates following the “General
calibration from Allison
plates and check the driveline. Inspection Guidelines for Reaction
Transmission. Do not intermix both
Plates” section of this manual.
NOTE: The current clutch friction former and current friction plates in a
Replace any plates failing these
plates were implemented April of clutch pack.
inspection procedures. Minimum
2000 starting with s/n 6610062126. The P3 ring gear changed to a harder allowable reaction plate thickness
Current clutch friction plates will ring gear on s/n 6610027070. The is 2.41 mm (0.095 inch). Maximum
have two or more missing splines. current P3 ring gear identifier is a allowable reaction plate coning is
Former friction plates will either groove machined around the outer 0.25 mm (0.010 inch).
have one spline missing or none diameter of the gear. The P3 ring gear
missing. Any 4000/B 500 model G. Inspect thrust bearings
with a groove identifier requires the
transmission may be updated from following the “General Inspection
C5 friction with two missing splines
former C5 friction plates to current Guidelines for Bearings” section of
if updating from former C5 frictions.
C5 frictions without recalibrating the this manual. Replace any bearings
If any 4000/B500 series model
transmission ECU. The rest of the which fail any of these inspection
without the harder ring gear (no
clutches in the main housing (C1 procedures.
groove on O.D.) is being updated

C3 / C4 CLUTCH MODULE
C3 Clutch Components
D. Piston Return
Plate and Spring Etched housing - do NOT use.
E. P1 Ring Gear Assembly
F. Clutch
Backplate
Assembly
Wear
Plates
C. C3 Clutch B. Spring Retainer
Pack Assembly A. C3 Clutch
Housing
A. Inspect the C3 clutch housing NOTE: Aluminum castings (like permanently set springs. Reference
following the “General Inspection clutch housings) can be etched by the Spring Data Charts in the
Guidelines for Cast Parts and caustic parts cleaners and solvents. Service Manual for spring
Machined Surfaces” section of this Etched components are identified by specifications and identification.
manual. Replace the housing if it a dull to dark gray color - not the
fails any of these inspection bright finish of a normal machined NOTE: The C3/C4 spring retainer
procedures. Check for C3 housing aluminum part. Etched components assemblies (sometimes referred to as
spline wear. Maximum allowable are also identified by roughness in clutch apply spring assemblies) and
spline wear is 1.15 mm (0.045 inch). the piston seals to abrade and result the C3/C4 piston return plate were
Replace the C3 housing if excessive in low clutch apply pressure and updated starting with S/N
spline wear exists. Check the C3 transmission damage. Replace 6610137389. Do not mix former and
housing wear plates for flatness. etched or damaged components. current parts in the same clutch
Maximum allowable distortion is pack. The identifier for the current
0.15 mm (0.006 inch). Minimum B. Inspect the C3 spring retainer return plate is a letter “V” stamped
allowable wear plate thickness is assembly following the “General in the face with an additional
2.82 mm (0.111 inch). Inspection Guidelines for Cast Parts external spline on the outside
and Machined Surfaces” section of diameter. The identifier for the
this manual. Inspect the assembly current apply spring assembly is the
for wear due to rubbing adjacent letter “B” stamped in the spring
parts and cracked, broken or retainer. Reference SIL 9-WT-04.
(continued)

(continued) C3 / C4 CLUTCH MODULE
C3/C4 Return Plate and C3/C4
Apply Spring Assembly
Update - SIL 9-WT-04
Former and current

components can
NOT be mixed in
the same clutch
pack.
C. Inspect the C3 clutch friction ECU. The rest of the clutches in the updating from former C5 frictions. If
plates following the “General main housing (C1 through C4) must any 4000/B500 series model without
Inspection Guidelines for Friction be updated with current friction the harder ring gear (no groove on
Plates” section of this manual. plates if any other individual clutch O.D.) is being updated with current
besides C5 is updated from former to C5 frictions, then it will require the
Replace any plates failing these current friction plates. Any update C5 friction that has three missing
inspection procedures. Minimum from former frictions to current internal splines. The C5 friction plate
allowable friction plate thickness is frictions in C1 through C4 for a 4000 missing three splines will exhibit
3.485 mm (0.137 inch). Maximum Series or B500 with a WTEC II ECU spline wear if used with the current P3
allowable plate coning is 0.25 mm will require a new ECU calibration ring gear with a groove identifier on
(0.010 inch). from Allison Transmission. Any the O.D. The former P3 ring gear (no
update from former frictions to groove on O.D.) will exhibit
NOTE: Battered and worn spline current frictions in C1 through C4 for premature wear if used with the
teeth may be an indicator of driveline a 4000 Series or B500 with a WTEC current C5 friction with two missing
issues. Replace the clutch plates and III ECU with a calibration prior to internal splines. No ECU calibration is
check the driveline. October 25, 1999 will require an necessary for updating C5 clutch plates.
updated ECU calibration from Allison
NOTE: The current clutch friction Transmission. Do not intermix both Inspect the C3 clutch reaction
plates were implemented April of former and current friction plates in a plates following the “General
2000 starting with s/n 6610062126. clutch pack. Inspection Guidelines for Reaction
Current clutch friction plates will Plates” section of this manual.
have two or more missing splines. The P3 ring gear changed to a harder
ring gear on s/n 6610027070. The Replace any plates failing these
Former friction plates will either have inspection procedures. Minimum
one spline missing or none missing. current P3 ring gear identifier is a
Any 4000/B 500 model transmission groove machined around the outer allowable reaction plate thickness is
may be updated from former C5 diameter of the gear. The P3 ring gear 2.41 mm (0.010 inch). Maximum
friction plates to current C5 frictions with a groove identifier requires the allowable reaction plate coning is
without recalibrating the transmission C5 friction with two missing splines if 0.25 mm (0.010 inch). (continued)

C3 / C4 CLUTCH MODULE (continued)
Stampings identify current

components.
D. Inspect the C3 piston return letter “B” stamped in the spring wear plates will have to be updated
plate and spring assembly following retainer. Reference SIL 9-WT-04. to the current wear plates that are
the “General Inspection Guidelines black in color. The former P1 ring
for Reaction Plates” section of this E. Inspect the P1 ring gear gear (with the O.D. groove
manual. Minimum allowable plate following the “General Inspection identifier) is compatible with the
thickness is 4.91 mm (0.193 inch). Guidelines for Gears” and General black wear plates. Do not replace the
Replace springs which are cracked, Inspection Guidelines for Splines” former P1 ring gear just because a
broken or permanently set. sections of this manual. Replace the unit has the black wear plates
Reference the Spring Data Charts in ring gear if it fails any of these installed. Reference SIL 18-WT-04.
the Service Manual for spring inspection procedures.
specifications and identification. F. Inspect the clutch backplate
NOTE: The P1 ring gear end face assembly following the “General
NOTE: The C3/C4 spring retainer grind operation was eliminated Inspection Guidelines for Cast Parts
assemblies (sometimes referred to as starting with S/N 6610136125. The and Machined Surfaces” section of
clutch apply spring assemblies) and former P1 ring gear identifier is a this manual. Replace the assembly if
the C3/C4 piston return plate were groove machined on the outside it fails any of these inspection
updated starting with S/N diameter of the gear. The current P1 procedures. Check the backplate
6610137389. Do not mix former and ring gear does not have a groove on and wear plates for flatness.
current parts in the same clutch the O.D. The current P1 ring gear is Maximum allowable distortion is
pack. The identifier for the current not compatible with aluminum wear 0.15 mm (0.006 inch). Minimum
return plate is a letter “V” stamped plates riveted to the C3 housing and allowable wear plate thickness is
in the face with an additional the clutch backplate. If the former P1 2.82 mm (0.111 inch).
external spline on the outside ring gear is replaced with the (continued)
diameter. The identifier for the current P1 ring gear and the unit has
current apply spring assembly is the aluminum wear plates, then the

C3 / C4 CLUTCH MODULE
(continued)
C4 Clutch
Components
D. Piston
Return Plate
and Spring
A. C4 Clutch
Assembly
Housing
C. C4
Clutch B. Spring
Pack Retainer
Assembly
A. Inspect the C4 clutch housing B. Inspect the C4 spring retainer C. Inspect the C4 clutch friction
following the “General Inspection assembly following the “General plates following the “General
Guidelines for Cast Parts and Inspection Guidelines for Cast Inspection Guidelines for Friction
Machined Surfaces” section of this Parts and Machined Surfaces” Plates” section of this manual.
manual. Replace the housing if it section of this manual. Inspect the Replace any plates failing these
fails any of these inspection assembly for wear due to rubbing inspection procedures. Minimum
procedures. Check for C4 housing adjacent parts and cracked, broken allowable friction plate thickness is
spline wear. Maximum allowable or permanently set springs. 3.485 mm (0.137 inch). Maximum
spline wear is 1.15 mm (0.045 inch). Reference the Spring Data Charts in allowable plate coning is 0.25 mm
Replace the C4 housing if excessive the Service Manual for spring (0.010 inch).
spline wear exists. specifications and identification. NOTE: Battered and worn spline
NOTE: The C3/C4 spring retainer
teeth may be an indicator of
NOTE: Aluminum castings (like
assemblies (sometimes referred to as driveline issues. Replace the clutch
clutch housings) can be etched by
clutch apply spring assemblies) and plates and check the driveline.
caustic parts cleaners and solvents.
Etched components are identified the C3/C4 piston return plate were Inspect the C4 clutch reaction
by a dull to dark gray color - not the updated starting with S/N
plates following the “General
6610137389. Do not mix former and
bright finish of a normal machined Inspection Guidelines for Reaction
current parts in the same clutch pack.
aluminum part. Etched components The identifier for the current return Plates” section of this manual.
are also identified by roughness in plate is a letter “V” stamped in the Replace any plates failing these
the piston seals to abrade and result face with an additional external inspection procedures. Minimum
in low clutch apply pressure and spline on the outside diameter. The allowable reaction plate thickness
transmission damage. Replace identifier for the current apply spring is 2.41 mm (0.095 inch). Maximum
etched or damaged components. assembly is the letter “B” stamped in allowable reaction plate coning is
the spring retainer. Reference 0.25 mm (0.010 inch).
(continued)
SIL 9-WT-04.
C3 / C4 CLUTCH MODULE (continued)
C3/C4 Return
Plate and
C3/C4 Clutch
Apply Spring
Assembly
Update -
SIL 9-WT-04
Former and
current
components
can NOT be
mixed in the
same clutch
pack.
NOTE: The current clutch friction calibration from Allison Transmission. D. Inspect the C4 piston return
plates were implemented April of 2000 Do not intermix both former and plate and spring assembly
starting with s/n 6610062126. Current current friction plates in a clutch pack. following the “General Inspection
clutch friction plates will have two or Guidelines for Reaction Plates”
The P3 ring gear changed to a harder
more missing splines. Former friction section of this manual. Minimum
ring gear on s/n 6610027070. The
plates will either have one spline
current P3 ring gear identifier is a allowable plate thickness is 4.91
missing or none missing. Any 4000/B
groove machined around the outer mm (0.193 inch). Replace springs
500 model transmission may be
diameter of the gear. The P3 ring gear which are cracked, broken or
updated from former C5 friction plates
with a groove identifier requires the C5 permanently set. Reference the
to current C5 frictions without
friction with two missing splines if Spring Data Charts in the Service
recalibrating the transmission ECU.
updating from former C5 frictions. If Manual for spring specifications
The rest of the clutches in the main
any 4000/B500 series model without
housing (C1 through C4) must be and identification.
the harder ring gear (no groove on
updated with current friction plates if
O.D.) is being updated with current C5 NOTE: The C3/C4 spring retainer
any other individual clutch besides C5
frictions, then it will require the C5 assemblies (sometimes referred to as
is updated from former to current
friction that has three missing internal clutch apply spring assemblies) and the
friction plates. Any update from former
splines. The C5 friction plate missing C3/C4 piston return plate were updated
frictions to current frictions in C1
three splines will exhibit spline wear if starting with S/N 6610137389. Do not
through C4 for a 4000 Series or B500
used with the current P3 ring gear with mix former and current parts in the
with a WTEC II ECU will require a
a groove identifier on the O.D. The same clutch pack. The identifier for the
new ECU calibration from Allison
former P3 ring gear (no groove on O.D.) current return plate is a letter “V”
Transmission. Any update from former
will exhibit premature wear if used stamped in the face with an additional
frictions to current frictions in C1
with the current C5 friction with two external spline on the outside diameter.
through C4 for a 4000 Series or B500
missing internal splines. No ECU The identifier for the current apply
with a WTEC III ECU with a
calibration is necessary for updating C5 spring assembly is the letter “B” stamped
calibration prior to October 25, 1999
clutch plates. in the spring retainer. Reference
will require an updated ECU
SIL 9-WT-04.

MAIN HOUSING
B. Splines
C. Fluid
Passages
Check for spline wear.

A. Main Housing
(rear view)
A. Inspect the main housing C. Inspect all fluid passages for

assembly following the “General obstructions, porosity and cracks.
Inspection Guidelines for Cast Inspect bolt holes for stripped or
Parts and Machined Surfaces” and damaged thread. Replace the
“General Inspection Guidelines for housing if damage cannot be
Splines” sections of this manual. repaired.
(continued)
Replace the housing if it fails any of
the damage cannot be repaired
using a soft stone or crocus cloth.
B. Maximum C5 clutch spline
wear is 1.15mm (0.045 inch).

MAIN HOUSING (continued)
Oil Passage Detail: Main Housing (bottom view)
From Cooler Main Pressure

To Cooler Control Main
C3 Pressure Lube
Pressure
C6 Pressure
C5 Pressure
Wiring
C4 Pressure Harness
Feedthrough
Main Pressure
Suction
Lube
Pressure
Lock-up Converter C1 Pressure Converter In
Pressure Out C2 Pressure
Oil Passage Detail -

Main Housing C5
Back View Pressure
Main
C6 Control
Pressure Main
Exhaust To From
Cooler Cooler
Oil Passage Detail - Converter

Main Housing Out
Front View Lube
Pressure
Main
Pump Pressure
Suction
C2 Pressure Lock-up
Converter In Pressure
C1 Pressure
C6 ADAPTER HOUSING MODULE
J. C6 Piston A. Adapter H. C6 Clutch

Return I. C6 Housing Hub
Spring Clutch
Assembly Piston K. P4 Planetary
Assembly
G. P4 Ring
Gear
D. P4
Ring
Gear
Hub
L. Output
Shaft
E. P4 Shaft
F. P4 Sun
Flange
Gear B. C6
Clutch C. C6
Pack Backplate
A. Inspect the adapter housing B. Inspect the C6 clutch friction Inspection Guidelines for Reaction
following the “General Inspection plates following the “General Plates” section of this manual.
Guidelines for Cast Parts and Inspection Guidelines for Friction Replace any plates failing these
Machined Surfaces” and “General Plates” section of this manual. inspection procedures. Minimum
Inspection Guidelines for Splines” Replace any plates failing these allowable reaction plate thickness
section of this manual. Replace the inspection procedures. Minimum is 3.24 mm (0.128 inch). Maximum
housing if it fails any of these allowable friction plate thickness is allowable reaction plate coning is
inspection procedures or if the 3.68 mm (0.145 inch). Maximum 0.25 mm (0.010 inch).
damage cannot be repaired using a allowable plate coning is 0.25 mm
soft stone or crocus cloth. (0.010 inch). C. Inspect the clutch backplate
Maximum clutch spline wear is assembly following the “General
NOTE: Battered and worn spline Inspection Guidelines for Cast
1.15mm (0.045 inch). Inspect all
teeth may be an indicator of Parts and Machined Surfaces”
fluid passages for obstructions,
driveline issues. Replace the clutch section of this manual. Replace the
porosity and cracks. Inspect bolt
plates and check the driveline. assembly if it fails any of these
holes for stripped or damage
threads. Replace the housing if inspection procedures.
Inspect the C6 clutch reaction
damage cannot be repaired. plates following the “General (continued)

C6 ADAPTER HOUSING MODULE (continued)
4070 Output Shaft Update -
Reference SIL 25-WT-01
Current output shaft requires

current bearing retainer locknut
and Belleville washer.
D. E. F. G. & H. Inspect the P4 ring NOTE: Aluminum castings (like spring specifications and
gear hub, P4 shaft flange, P4 sun clutch housings) can be etched by identification.
gear, P4 ring gear and C6 clutch caustic parts cleaners and solvents.
Etched components are identified K. Inspect the P4 carrier
hub following the “General
by a dull to dark gray color - not the following the “General Inspection
Inspection Guidelines for Gears”
bright finish of a normal machined Guidelines for Cast Parts and
and General Inspection Guidelines
aluminum part. Etched components Machined Surfaces” and the
for Splines” sections of this manual. “General Inspection Guidelines for
Replace any components failing any are also identified by roughness in
the piston seal surface which can Splines” sections of this manual.
of these inspection procedures. Replace the carrier if it fails any of
cause piston seals to abrade and
Replace any components with these inspection procedures.
result in low clutch apply pressure
damage which cannot be repaired and transmission damage. Replace Replace the carrier if it fails any of
using a soft stone or crocus cloth. etched or damaged components. these inspection procedures.
Replace the carrier and spindles if
I. Inspect the C6 clutch piston J. Replace the C6 return spring the spindle bores are worn, out-of-
following the “General Inspection assembly if it has permanent spring round or otherwise damaged.
Guidelines for Cast Parts and set, wear due to rubbing adjacent Maximum allowable movement
Machined Surfaces” section of this parts or if springs are cracked or between the P4 carrier and P4 ring
manual. Replace the piston if it fails broken. Reference the Spring Data gear is 0.38mm (0.015 inch).
any of these inspection procedures. Charts in the Service Manual for (continued)

(continued) C6 ADAPTER HOUSING MODULE
J. C6 Piston A. Adapter H. C6 Clutch

Return I. C6 Housing Hub
Spring Clutch
Assembly Piston K. P4 Planetary
Assembly
G. P4 Ring
Gear
D. P4
Ring
Gear
Hub
L. Output
Shaft
E. P4 Shaft
F. P4 Sun
Flange
Gear B. C6
Clutch C. C6
Pack Backplate
Inspect the P4 carrier indexing Replace pinion spindles if they are L. Inspect the output shaft
ring for wear and damage, damage or showing signs of following the “General Inspection
especially where the spindles make overheating. Guidelines for Cast Parts and
contact with the ring. Replace the Machined Surfaces” and the
indexing ring if it shows signs of Inspect the P4 pinion gears “General Inspection Guidelines for
spindle battering or has damage following the “General Inspection Splines” sections of this manual.
which cannot be repaired using a Guidelines for Gears” section of this
Replace the output shaft if it fails
light stone. manual. Replace any gear that fails
any of these inspection procedures.
Inspect the output shaft bushing
Replace the pinion gear thrust damage cannot be repaired using a
washers if they are damaged, soft stone or crocus cloth.
Guidelines for Bushings” section of
distorted or showing signs of
Inspect the pinion roller bearings this manual. Replace the bushing if
overheating. Minimum allowable
following the “General Inspection it fails these inspection procedures.
thrust washer thickness is 1.40 mm
Guidelines for Bearings” section of Maximum allowable bushing inside
(0.055 inch).
this manual. Replace any bearing diameter is 36.14 mm (1.423 inch).
failing these inspection procedures.

WEAR LIMITS AND SPRING DATA
7–1. WEAR LIMITS DATA adjacent parts, or permanent set. Discard springs
which do not meet the load height speciÞcations
A. Maximum Variations. Wear limit information in
according to Table 7–2, Spring Data.
this Section shows the maximum wear at which
components are expected to function satisfactorily. B. Inspection. Inspection criteria (load vs. height)
Table 7–1 lists the Wear Limits Data and is referenced and identiÞcation characteristics of the springs are
to the exploded views (Foldouts 4 through 12) in the presented in Table 7–2. The Spring Data are keyed to
back of this manual. the exploded views (Foldouts 4 through 12) in the
B. Cleaning and Inspection. Parts must be clean to back of this manual.
permit effective inspection for wear or damage. Refer
to Section 3. NOTE:
When more than one spring part number is listed
7–2. SPRING DATA for the same location, refer to the HD/B 500/T 400
A. Spring Replacement. Springs should be replaced Series Parts Catalog PC2456EN to determine which
if there are signs of overheating, wear due to rubbing spring is used in your specific assembly number.
Table 7–1. Wear Limits Data Wear Limit

Illustration Description mm (inches)
Foldout 4,B TORQUE CONVERTER MODULE
10 Converter Cover Bushing, Maximum ID 66.91 2.634
12 Lockup Piston Assembly, Minimum Thickness 6.53 0.257
14 Damper Assembly Plate, Maximum Distortion 0.51 0.020
14 Damper Assembly Plate, Minimum Thickness 8.51 0.335
14, 18 Turbine-To-Damper, Maximum Spline Wear 0.38 0.015
15 Backplate, Maximum Distortion 0.15 0.006
15 Backplate, Minimum Wear Surface Thickness 11.79 0.464
18 Turbine Hub, Minimum OD 66.69 2.626
19 Turbine Hub Sealring, Maximum ID 61.77 2.432
24 Stator Thrust Plate, Minimum Thickness 9.45 0.372
36 Converter Pump Hub, Minimum OD 88.99 3.504
Foldout 5,B TORQUE CONVERTER HOUSING MODULE — PTO EQUIPPED

6 Bearing Retainer Bushing, Maximum ID 89.19 3.511
8, 14 Oil Pump Drive Hub Seal, Minimum End Gap 1.18 0.047
8, 14 Oil Pump Drive Hub Seal, Maximum End Gap 1.66 0.065
13 Oil Pump Drive Hub, Maximum Tang Wear 0.31 0.012

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

Foldout 6,A FRONT SUPPORT AND CHARGING PUMP MODULE
8 Pump Housing Bushing, Maximum ID 89.19 3.511
9, 10 Pump Housing Gear, Maximum Cavity Depth 19.04 0.750
9, 10 Pump Housing Gear, Maximum Cavity Diameter 150.25 5.915
9, 10, 11 Driven Gear-To-Pump Housing, Maximum Diametric Clearance 0.30 0.012
9, 10, 13 Gear-To-Plate, Maximum Side Clearance 0.10 0.004
11 Gear Set, Maximum Gear Tooth Tip Clearance 0.15 0.006
12 Pump Gear Bushing, Maximum ID 66.93 2.635
16, 17 Ground Sleeve, Minimum OD In Bushing Area 66.67 2.625
16, 17, 20 Spline OD, Maximum Total Runout 0.13 0.005
20 Front Support, Minimum OD 119.81 4.717
25 Front Support Seal, Minimum End Gap 1.00 0.040
25 Front Support Seal, Maximum End Gap 1.44 0.056
Foldout 6,B ROTATING CLUTCH MODULE

5 Turbine Shaft Bushing, Maximum ID 36.14 1.423
8 Turbine Seal, Minimum End Gap 0.65 0.026
8 Turbine Seal, Maximum End Gap 1.01 0.039
9 Drum Spline, Maximum Wear 0.38 0.015
12 Rotating Clutch Hub Bushing, Maximum ID 120.27 4.735
29 C1 Clutch Apply Plate, Minimum Thickness 5.90 0.232
29, 39 C1 Clutch Apply Plate or C2 Backplate, Maximum Distortion 0.15 0.006
30, 38 C1, C2 Friction Plate, Maximum Cone 0.25 0.010
30, 38 C1, C2 Friction Plate, Minimum Thickness 2.92 0.115
30, 38 C1, C2 Friction Plate, Minimum Oil Groove Depth 0.20 0.008
31, 37 C1, C2 Reaction Steel Plate, Maximum Cone 0.25 0.010
31, 37 C1, C2 Reaction Steel Plate, Minimum Thickness 2.41 0.095
32 C1 Clutch Backplate, Minimum Thickness @ ID 9.90 0.390
34, 36 C1, C2 Drive Hub, Maximum Spline Wear 0.38 0.015
39 C2 Backplate, Minimum Thickness 7.90 0.311
39 C2 Backplate, Maximum Distortion 0.15 0.006

WEAR LIMITS AND SPRING DATA (continued)

Foldout 7 MAIN HOUSING MODULE

4 Backplate, Maximum Step Wear 0.13 0.005
4 Backplate, Maximum Distortion 0.15 0.006
5, 18 P1 Ring Thrust Plate, Minimum Thickness At Wear Point 2.82 0.111
7 P1 Ring Gear Spline, Maximum Wear 0.38 0.015
8, 21, 29 C3, C4, C5 Friction Plate, Maximum Cone 0.25 0.010
8, 21, 29 C3, C4, C5 Friction Plate, Minimum Thickness 3.485 0.137
9, 20, 30 C3, C4, C5 Reaction (Steel) Plate, Maximum Cone 0.25 0.010
9, 20, 30 C3, C4, C5 Reaction (Steel) Plate, Minimum Thickness 2.41 0.095
11, 23 C3, C4 Piston Return Plate, Minimum Thickness 4.91 0.193
19, 28 C3, C4 Clutch Housings, Maximum Spline Wear 1.15 0.045
43 Main Housing, Maximum Spline Wear 1.15 0.045
Foldout 8 MAIN SHAFT MODULE — WIDE RATIO AND CLOSE RATIO

7, 8 Main Shaft Bearing Journal, Minimum OD 52.98 2.085
7, 8 Main Shaft Pilots (both ends), Minimum OD 35.92 1.414
Foldout 9,A P1 PLANETARY MODULE

3 P1 Planetary Carrier Assembly, Maximum Pinion End Play 0.94 0.037
9 P1 Carrier Bushing, Maximum ID 89.32 3.516
10, 13 P1 Pinion Thrust Washer, Minimum Thickness 1.40 0.055
10, 13 P1 Pinion Thrust Washer, Maximum Step Wear 0.12 0.005
Foldout 9,B P2 PLANETARY MODULE


(continued) WEAR LIMITS AND SPRING DATA

Foldout 9,C P3 PLANETARY AND C6 ADAPTER HOUSING MODULE

(HD 4070/4076 MODELS)
1 P3 Carrier Module, Maximum Pinion End Play 0.94 0.037
8 P3 Pinion Thrust Washer, Minimum Thickness 1.40 0.055
8 P3 Pinion Thrust Washer, Maximum Step Wear 0.12 0.005
27 C6 Reaction Plate, Minimum Thickness 3.24 0.128
27, 28 C6 Friction and Reaction Plate, Maximum cone 0.25 0.010
28 C6 Friction Plate, Minimum Thickness 3.68 0.145
32 P4 Carrier Assembly, Maximum Pinion End Play 0.94 0.037
40 P4 Planetary Thrust Washer, Minimum Thickness 1.40 0.055
40 P4 Planetary Thrust Washer, Maximum Step Wear 0.12 0.005
Foldout 10,A RETARDER AND P3 MODULE (HD PRODUCT LINE MODELS

PRIOR TO S/N 6610066447)
5 Output Shaft Bushing, Maximum ID 36.14 1.423
27, 30 Retarder Rotor Sealring, Maximum ID 139.72 5.501
29 Rotor Hub, Maximum Spline Wear 0.38 0.015
Foldout 10,B REAR COVER AND P3 MODULE

(EXCEPT HD 4070/4076 MODELS)
5 P3 Planetary Carrier Assembly, Maximum End Play 0.94 0.037
8 Output Shaft, Maximum Spline Wear 0.38 0.015

WEAR LIMITS AND SPRING DATA (continued)

Foldout 10,C RETARDER AND OUTPUT SHAFT MODULE

(HD 4070/4076 MODELS PRIOR TO S/N 6610066447)
18 Rotor Assembly 0.38 0.015
Foldout 10,D REAR COVER & OUTPUT SHAFT MODULE

(HD 4070/4076 MODELS)
Foldout 10,E RETARDER AND P3 MODULE (ALL MODELS

EXCEPT HD 4070/4076 STARTING WITH S/N 6610066447)
29 Rotor Hub, Maximum Spline Wear 0.38 0.015
Foldout 10,F RETARDER AND OUTPUT SHAFT MODULE

(HD 4070/4076 MODELS STARTING WITH S/N 6610066447)
18 Rotor Assembly 0.38 0.015
Foldout 12,A OUTPUT FLANGE AND YOKE

1, 2, 8 Output Seal Journal, Minimum OD 85.0 3.346

Table 7–1. Spring Data
Length under load
Approx.
Spring Free
No. of Wire Dia OD Length mm N
Foldout Ref. Spring Part No. Color Code Coils mm (in.) mm (in.) mm (in.) (in.) (lb)
4,B 27 Stator 29501300 No Code N/A N/A N/A 17.8 5.7 0.9
(0.70) (0.224) (0.2)
6,A 22 Main Relief 29507709 No Code 10 3.25 17.96 52.4 40.7 474
(0.128) (0.707) (2.06) (1.60) (106.5)
6,B 20 C2 Return 29505719 No Code 11.5* 2.04* 19.06* 70.76* 28.2 5185**
(continued) WEAR
(0.080) (0.750) (2.786) (1.110) (1165.6)

6,B 25 C1 Return 29509453 No Code 12* 2.10* 16.0* 57.53* 34.8 4649**
(0.083) (0.630) (2.265) (1.37) (1045.4)
ALLISON
6,B 25 C1 Return 29537301 No Code 11.8* 2.17* 16.8* 52.89* 34.5 4893**
(0.085) (0.661) (2.082) (1.358) (1100.0)
7 10 C3 Return 29506206 No Code 13* 2.10* 15.0* 52.3* 35.4 274.4**
(0.083) (0.590) (2.06) (1.39) (61.69)
7 12 C3 Retainer 29507882 No Code 4* 2.36* 12.62* 11.2* 9.3 16 408**
(0.093) (0.497) (0.44) (0.37) (3689)
(0.093) (0.497) (0.44) (0.41) (3463)
TRANSMISSION
7 22 C4 Return 29506206 No Code 13* 2.10* 15.0* 52.3* 35.4 274.4**
(0.083) (0.590) (2.06) (1.39) (61.69)
(0.093) (0.497) (0.44) (0.37) (3689)
(0.093) (0.497) (0.44) (0.41) (3463)
9,C 17 C5 Return 29530488 No Code 11.6* 2.03* 17.00* 53.80 37.7 3611**
TECHNICIANS’
(0.080) (0.669) (2.11) (1.48) (811.8)
10,A 20, 22, 9, 12, C5 Return 29503036 No Code 12* 2.10* 17.00* 57.3* 37.6 3086**
through F 20, 9 (0.083) (2.26) (1.48) (693.8)
GUIDE
10,A 35 Retarder Flow Valve 29512751 Silver (End) 10.5 2.16 19.05 61.5 25.9 186.9
(0.085) (0.750) (2.42) (1.020) (42.02)
LIMITS AND SPRING DATA
75
* Individual springs
** For the complete spring assembly
Table 7–1. Spring Data (cont’d)
76
Length under load
Approx.
Spring Free
ALLISON
10,A 35 Retarder Flow Valve 29515101 Green 16 3.78 36.58 106.68 73.66 133.4
(0.149) (1.440) (4.200) (2.900) (29.99)
10,A, C, E, 35, 25, 35, Retarder Flow Valve 29515692 No Code 11.4 4.12 36.17 114.3 91.1 213.3
and F 25 (0.162) (1.424) (4.500) (3.587) (47.95)

10,A, C, E, 76, 56, 75, Exhaust BackÞll 23049391 No Code 20.4 0.61 8.00 29.2 18.2 2.67
and F 63 (0.024) (0.315) (1.15) (0.716) (0.60)
10,A 81 Retarder Control 29510495 Silver 7.5 1.40 15.1 30.8 18.0 33
(0.055) (0.594) (1.212) (0.71) (7.42)
TRANSMISSION
10,A, C, E, 81, 65, 80, Retarder Control 29512792 Lt. Green 7.5 1.40 15.09 33.69 18.0 40
and F 68 (on end) (0.055) (0.594) (1.326) (0.71) (9.0)
10,A 81 Retarder Control 29510494 Orange 7 1.60 15.50 27.8 18.0 44
(0.063) (0.610) (1.09) (0.71) (9.9)
11,A and 101, 120, Solenoid Regulator 29502195 No Code 4 0.67 11.05† 6.5 3.45 3
Fig. 5–31 152, 167 (0.026) (0.440) (0.26) (0.14) (0.7)
11,A 112 Accumulator Relay 29507455 Silver 12.8 1.28 11.68 43.6 20.0 49.8
TECHNICIANS’
(0.050) (0.460) (1.72) (0.79) (11.2)
11,A 112 Accumulator Relay 28537452 Dark Blue 12.8 1.275 11.68 43.6 20.0 49.8
(0.050) (0.460) (1.72) (0.79) (11.2)
GUIDE
11,A 127 Overdrive 23049332 Orange 12 0.76 7.75 26.6 12.5 12.0
(0.030) (0.305) (1.05) (0.49) (2.7)
11,B 134 Lockup 23049326 Yellow 10 1.37 14.1 42.1 17.0 49

(0.054) (0.555) (1.66) (0.67) (11.0)
11,B 138 Lube Regulator 23049327 Red 13 1.22 11.1 46.3 3.5 47
WEAR LIMITS AND SPRING DATA
(0.048) (0.437) (1.82) (0.93) (10.6)

11,B 142 Main Regulator 29500963 Lt. Blue 15 2.87 22.00 98.5 54.6 305
(0.113) (0.866) (3.88) (2.15) (68.6)
(continued)
(continued) WEAR
ALLISON
Table 7–1. Spring Data (cont’d)
Length under load
Approx.
Spring Free
TRANSMISSION
11,B 146 Control Main 23049325 Orange 10 1.83 14.8 44.6 24.0 131
(0.072) (0.583) (1.76) (0.95) (29.5)
11,B 156 C2 Latch 29501071 Lt. Green 11 1.32 11.43 41.3 19.0 71.0
(0.052) (0.450) (1.63) (0.75) (16.0)
11,B 160 Exh. Back 23049391 No Code 17 0.61 7.80 29.2 18.2 2
TECHNICIANS’
(0.024) (0.307) (1.14) (0.72) (0.5)
11,B 164 C1 Latch 6885065 Blue 12 1.37 16.26 46.2 29.2 18
(0.054) (0.640) (1.82) (1.15) (4.0)
GUIDE
11,B 168 Converter Regulator 29507456 Pink 10.2 1.53 11.00 30.3 22.8 54
(0.060) (0.433) (1.19) (0.90) (12.1)
LIMITS AND SPRING DATA
77
NOTES

TORQUE CONVERTER MODULE
Allison Transmission
General Motors Corporation
Indianapolis, IN 46206-0894
1-800-252-5283
www.allisontransmission.com
 2005 General Motors Corporation. (5/05)

GN4065EN
GUIDE
TECH
GN4065EN
(5/05)
ALLISON 4000 & B 500 PRODUCT FAMILIES

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TECHNICIANS’ GUIDE

INSPECTION AND ANALYSIS OF THE

Glossary Of Terms . . . . . . . . . . . 2 Control Module . . . . . . . . . . 16-21

ALLISON TRANSMISSION TECHNICIANS’ GUIDE i

Abrade - Scrape off Metal Transfer - Metal from one

Burr - Sharp metal extending Score - Deep scratch

Cone - A shape whose base is a Spalled - Damage characterized by

Gall - Wear between parts such

Light Stoning - Using a

2 ALLISON TRANSMISSION TECHNICIANS’ GUIDE

The Technicians’ Guide is

General Rework Guidelines

ALLISON TRANSMISSION TECHNICIANS’ GUIDE 3

A. Replace housings or other cast D. Replace housings that have

Check gears for

A. Inspect gears for damaged or

Inspect splined parts

A. Inspect splined parts for 0.38 mm (0.015 inches) if not

6 ALLISON TRANSMISSION TECHNICIANS’ GUIDE

A. Replace the bearing if any bearing. Replace the bearing if races

ALLISON TRANSMISSION TECHNICIANS’ GUIDE 7

General Bearing Handling When immersing in solvent, place

8 ALLISON TRANSMISSION TECHNICIANS’ GUIDE

Bushing wear is strongly

ALLISON TRANSMISSION TECHNICIANS’ GUIDE 9

A. Inspect retaining rings for Examine retaining

10 ALLISON TRANSMISSION TECHNICIANS’ GUIDE

A. Replace thrust washers if they

ALLISON TRANSMISSION TECHNICIANS’ GUIDE 11

12 ALLISON TRANSMISSION TECHNICIANS’ GUIDE

ALLISON TRANSMISSION TECHNICIANS’ GUIDE 13

Reference the Service Manual

A. Inspect springs for permanent

Inspect springs for signs of

14 ALLISON TRANSMISSION TECHNICIANS’ GUIDE

Valves should move freely in

A. Valves must be free of nicks,

ALLISON TRANSMISSION TECHNICIANS’ GUIDE 15

A. Inspect the channel plate for B. Inspect both

16 ALLISON TRANSMISSION TECHNICIANS’ GUIDE

B Solenoid D Solenoid (C4)

ALLISON TRANSMISSION TECHNICIANS’ GUIDE 17

Supersession Information Supersession Information

18 ALLISON TRANSMISSION TECHNICIANS’ GUIDE

ALLISON TRANSMISSION TECHNICIANS’ GUIDE 19

Identification Detail: Rotating Clutch Valve Body Assembly

Identification Detail: Stationary Clutch Valve Body Assembly

Identification Detail: Main Valve Body Assembly

Exhaust Main Regulator Valve

C2 Latch C2 Latch Main Valve Control Main

ALLISON TRANSMISSION TECHNICIANS’ GUIDE 21

22 ALLISON TRANSMISSION TECHNICIANS’ GUIDE

Current Converter Turbine Shaft

Model Identifiers (see

ALLISON TRANSMISSION TECHNICIANS’ GUIDE 23

A. Inspect the converter pump

24 ALLISON TRANSMISSION TECHNICIANS’ GUIDE

ALLISON TRANSMISSION TECHNICIANS’ GUIDE 25

Current damper is backward

26 ALLISON TRANSMISSION TECHNICIANS’ GUIDE

E. Front Stator I. Roller

ALLISON TRANSMISSION TECHNICIANS’ GUIDE 27

F. PTO Drive J. Bearing