4K Service Manual 4th Gen SM4014EN 200510

Service
Manual
2005 OCTOBER
SM4014EN
Allison Transmission
ALLISON 4TH GENERATION CONTROLS
VOCATIONAL MODELS
4000 EVS
4000 HS
4000 MH
4000 RDS
4000 SP
4000 TRV
4500 EVS
4500 HS
4500 RDS
4500 SP
4700 EVS
4700 RDS
4700 SP
4800 EVS
4800 SP
Allison Transmission, General Motors Corporation

P.O. Box 894 Indianapolis, Indiana 46206-0894
www.allisontransmission.com
Printed in USA
Copyright 2005 General Motors Corporation
B 500
T 425
T 450
T 525
INTRODUCTION
ELECTRONIC CONTROL UNIT AND DIAGNOSTIC DATA READER/TOOL
DISPLAYS AND BUTTON NAMES
(Up), (Down),
Shift Selector, Allison DOC button, and display names are printed in bold capital letters
MODE, MONITOR, SELECT, etc.
Transmission range shifts are indicated by the letter or number on the shift selector, in bold text, followed by the
name of the range in parenthesesD (Drive), N (Neutral), etc.
References to diagnostic messages displayed are printed within double quotation marks (OL, OK, etc.).
TRADEMARK USAGE
The following trademarks are the property of the companies indicated:
Allison DOC (Allison Diagnostic Optimized Connection Tool) is a trademark
of General Motors Corp.

DEXRON is a registered trademark of General Motors Corp.
Biobor JF is the registered trademark for a biological inhibitor manufactured by U.S. Borax
and Chemical Corporation.
Loctite is a registered trademark of the Loctite Corporation.
Teflon is a registered trademark of the DuPont Corporation.
TranSyndTM is a trademark of Castrol, Ltd.
Vespel is a registered trademark of DuPont Corporation.
NOTE:
This publication is revised periodically to include improvements,
new models, special tools, and procedures. A revision is indicated
by the date on the title page. Check with your Allison
Transmission service outlet for the currently applicable
publication. Additional copies of this publication may be
purchased from authorized Allison Transmission service outlets.
Look in your telephone directory under the heading of
TransmissionsTruck, Tractor, etc.
ii
Copyright 2005 General Motors Corp.
IMPORTANT SAFETY NOTICE

IT IS YOUR RESPONSIBILITY to be completely familiar with the Warnings and Cautions described in this Service Manual. These Warnings and Cautions advise against the
use of specific service methods that can result in personal injury, damage to the equipment, or cause the equipment to become unsafe. It is, however, important to understand
that these Warnings and Cautions are not exhaustive. Allison Transmission could not
possibly know, evaluate, and advise the service trade of all conceivable ways in which
service might be done or of the possible hazardous consequences of each way. Consequently, Allison Transmission has not undertaken any such broad evaluation. Accordingly, ANYONE WHO USES A SERVICE PROCEDURE OR TOOL WHICH IS NOT
RECOMMENDED BY ALLISON TRANSMISSION MUST first be thoroughly satisfied
that neither personal safety nor equipment safety will be jeopardized by the service
methods selected.
Proper service and repair are important to the safe, reliable operation of the equipment.
The service procedures recommended by Allison Transmission and described in this Service Manual are effective methods for performing service operations. Some of these service operations require the use of tools specifically designed for the purpose. The special
tools should be used when and as recommended.
WARNINGS, CAUTIONS, AND NOTES

Three types of headings are used in this manual to attract your attention:
WARNING!
is used when an operating procedure, practice,
etc., which, if not correctly followed, could result
in personal injury or loss of life.
CAUTION:
is used when an operating procedure, practice,
etc., which, if not strictly observed, could result
in damage to or destruction of equipment.
NOTE:
is used when an operating procedure, practice, etc.,
is essential to highlight.
iii
LIST OF WARNINGS
This manual contains the following Warnings
IT IS YOUR RESPONSIBILITY TO BE FAMILIAR WITH ALL OF THEM.
If you leave the vehicle and the engine is running, the vehicle can move suddenly and you
or others could be injured. If you must leave the engine running, do not leave the vehicle
until you:
Put the transmission in N (Neutral)and
Apply the parking brake and emergency brakes and make sure they are properly
engagedand
Chock the wheels and take any other steps necessary to keep the vehicle from moving.
Avoid contact with the hot fluid or the hot sump when draining transmission fluid. Direct
contact with the hot fluid or the hot sump may result in bodily injury.
DO NOT conduct a converter stall test until the following actions are taken. The parking
brake and/or emergency brakes must be set and properly engaged and the wheels must be
chocked. Warn personnel to keep clear of the vehicle and its travel path. Failure to do so
can cause serious injury.
Use appropriate safety equipment such as safety glasses, safety shoes, and gloves.
Do not burn discarded Teflon seals; toxic gases are produced by burning Teflon.
Never dry bearings by spinning them with compressed air. A spinning bearing can
disintegrate, allowing balls or rollers to become lethal flying projectiles. Also, spinning a
bearing without lubrication can damage the bearing.
DO NOT disconnect the hydraulic fluid line between the accumulator and the retarder
until air and hydraulic pressure have been bled from the retarder.
PREVENT PERSONAL INJURY: Use proper tools and lifting equipment when installing
or removing a transmission from the repair stand. Transmission dry weights are as
follows:
4000 and 4500 Models
Base transmission
377 kg (831 lbs)
With PTO provision
405 kg (893 lbs)
With retarder
411 kg (906 lbs)
With retarder and PTO provision
439 kg (968 lbs)
4700 and 4800 Models
Base transmission
With PTO provision
With retarder
With retarder and PTO provision
With retarder, PTO, and integral
retarder sump cooler
iv
493 kg (1087 lbs)

521 kg (1149 lbs)
529 kg (1162 lbs)
555 kg (1224 lbs)
496 kg (1032 lbs)
LIST OF WARNINGS
This manual contains the following Warnings
IT IS YOUR RESPONSIBILITY TO BE FAMILIAR WITH ALL OF THEM.
Get help when lifting the control module. Assistance from a hoist or another person may
be required. The control module weighs approximately 25 kg (55 lb).
Get help when lifting the retarder module. Assistance from a hoist or another person may
be required. The retarder module weighs approximately 34 kg (75 lb).
Get help when lifting the C6 adapter housing module. Assistance from a hoist or another
person may be required. The C6 adapter housing module weighs approximately 68 kg
(150 lb).
Carefully release spring force. Piston springs are highly compressed. Personal injury can
occur if the spring force is not controlled.
Piston springs are highly compressed. Be extremely careful during removal and
installation. Personal injury can occur if the spring force is not controlled.
Place the P3 planetary assembly on its side to avoid possible injury while disassembling
the planetary.
INTRODUCTION
NOTES
vi
TABLE OF CONTENTS
Paragraph
Page
Section 1. GENERAL INFORMATION

11. SCOPE OF MANUAL
a. Content And Organization. . . . . . . . . . . . 11
b. Illustrations. . . . . . . . . . . . . . . . . . . . . . . . 11
c. Maintenance Information . . . . . . . . . . . . 11
12. SUPPLEMENTARY INFORMATION . . . . 15
13. ORDERING PARTS
a. Transmission Nameplate . . . . . . . . . . . . . 15
b. Parts Catalog . . . . . . . . . . . . . . . . . . . . . . 15
14. GENERAL DESCRIPTION
a. Major Modules. . . . . . . . . . . . . . . . . . . . . 15
b. Unique Features. . . . . . . . . . . . . . . . . . . . 15
15. MAJOR COMPONENTS
a. Input Module . . . . . . . . . . . . . . . . . . . . . . 16
b. Torque Converter . . . . . . . . . . . . . . . . . . . 16
c. Power Takeoff . . . . . . . . . . . . . . . . . . . . . 16
d. Main Housing And Gear Module . . . . . . 16
e. Range Clutches . . . . . . . . . . . . . . . . . . . . 16
f. Control System . . . . . . . . . . . . . . . . . . . . 16
g. Transmission Fluid Filters . . . . . . . . . . . . 16
h. Transmission Fluid Coolers . . . . . . . . . . . 16
i. C6 Adapter Housing Module. . . . . . . . . . 16
j. Rear Cover . . . . . . . . . . . . . . . . . . . . . . . . 16
k. Output Retarder And Output Flange . . . . 16
16. 4000 PRODUCT FAMILY MODEL
DESIGNATION CODE . . . . . . . . . . . . . . . . 16
17. EXPLODED (DISASSEMBLED)
VIEWS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
18. DIAGNOSIS
a. Before Starting . . . . . . . . . . . . . . . . . . . . . 17
b. CHECK TRANS Light . . . . . . . . . . . . . . 17
c. Entering Diagnostic Mode . . . . . . . . . . . 18
d. Diagnostic Codes . . . . . . . . . . . . . . . . . . . 18
e. Displaying Diagnostic Codes . . . . . . . . . 18
f. Diagnostic Code Displays . . . . . . . . . . . . 18
g. Exiting Diagnostic Mode . . . . . . . . . . . . 18
19. PRESERVATION AND STORAGE
a. Storage (New Transmissions,
Before Installation) . . . . . . . . . . . . . . . . . 18
b. Preservation Methods . . . . . . . . . . . . . . . 18
c. One Year Storage (Without Fluid). . . . . . 18
d. One Year Storage (With Fluid) . . . . . . . . 19
Paragraph
Page
110. RESTORING TRANSMISSION

TO SERVICE
a. Transmission Exterior . . . . . . . . . . . . . . . 19
b. Sealed Breather And Openings . . . . . . . . 19
c. New Transmissions . . . . . . . . . . . . . . . . . 19
d. Stored Without Fluid . . . . . . . . . . . . . . . . 19
e. Stored With Fluid. . . . . . . . . . . . . . . . . . . 19
111. ELECTROMAGNETIC/RADIO
FREQUENCY INTERFERENCE . . . . . . . 110
112. OPERATING INSTRUCTIONS . . . . . . . . 110
113. SPECIFICATIONS AND DATA . . . . . . . . 110
Section 2. PREVENTIVE MAINTENANCE

21. SCOPE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
22. PERIODIC INSPECTION AND CARE
a. Exterior Cleaning And Inspection. . . . . . 21
23. IMPORTANCE OF PROPER
FLUID LEVEL
a. Transmission Fluid . . . . . . . . . . . . . . . . . 21
b. Oil Level Sensor . . . . . . . . . . . . . . . . . . . 21
c. Electronic Controls And
Protection Circuits . . . . . . . . . . . . . . . . . . 21
24. ELECTRONIC FLUID LEVEL CHECK
(WHEN AN OPTIONAL OLS IS
PRESENTFULL-FUNCTION
PUSHBUTTON OR LEVER SHIFT
SELECTORS)
a. Fluid Level Check Procedure . . . . . . . . . 22
25. MANUAL FLUID LEVEL CHECK
PROCEDURE
a. Preparation . . . . . . . . . . . . . . . . . . . . . . . 23
b. Consistency Of Readings . . . . . . . . . . . . 23
26. COLD CHECK
a. Purpose. . . . . . . . . . . . . . . . . . . . . . . . . . . 23
b. Cold Check Procedure . . . . . . . . . . . . . . . 23
27. HOT CHECK
a. Purpose. . . . . . . . . . . . . . . . . . . . . . . . . . . 24
b. Cold Check Procedure . . . . . . . . . . . . . . . 24
28. KEEPING FLUID CLEAN. . . . . . . . . . . . . . 24
29. FLUID RECOMMENDATIONS
a. Fluid Type . . . . . . . . . . . . . . . . . . . . . . . . 25
vii
4000 PRODUCT FAMILIES SERVICE MANUALALLISON 4 th GENERATION

Paragraph
Page
Paragraph
Page
210. FLUID AND FILTER

CHANGE INTERVALS
a. Fluid And Filter Changes . . . . . . . . . . . . 25
b. Fluid Analysis . . . . . . . . . . . . . . . . . . . . . 27
217. OUTPUT FLANGE/YOKE AND OIL

SEAL MAINTENANCE
211. FLUID CONTAMINATION

a. Water . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
b. Engine Coolant . . . . . . . . . . . . . . . . . . . . 27
c. Metal . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
218. ON-VEHICLE MAINTENANCE . . . . . . . 218
212. FLUID AND FILTER CHANGE

PROCEDURE
a. Drain Fluid . . . . . . . . . . . . . . . . . . . . . . . 27
b. Replace Filters. . . . . . . . . . . . . . . . . . . . . 28
c. Refill Transmission . . . . . . . . . . . . . . . . . 28
31. SCOPE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
213. BREATHER
a. Location And Purpose. . . . . . . . . . . . . . . 28
b. Maintenance . . . . . . . . . . . . . . . . . . . . . . 29
214. TRANSMISSION STALL TEST AND
NEUTRAL COOL-DOWN CHECK
a. Purpose . . . . . . . . . . . . . . . . . . . . . . . . . . 29
b. Stall Testing Preparation. . . . . . . . . . . . . 29
c. Performing a Transmission Stall Test . 210
d. Driving Transmission Stall Test . . . . . . 210
e. Driving Transmission Stall Test
Preparation . . . . . . . . . . . . . . . . . . . . . . 210
f. Performing a Driving Transmission
Stall Test . . . . . . . . . . . . . . . . . . . . . . . . . 211
g. Neutral Cool-Down Procedure. . . . . . . 211
h. Transmission Stall Test Results . . . . . . 211
215. READING CLUTCH PRESSURES
a. Purpose . . . . . . . . . . . . . . . . . . . . . . . . .
b. Transmission And Vehicle Preparation .
c. Recording Data . . . . . . . . . . . . . . . . . . .
d. Comparing Recorded Data
To Specifications. . . . . . . . . . . . . . . . . .
212
212
212
213
216. FLUID LEAK DIAGNOSIS

a. Finding Leak . . . . . . . . . . . . . . . . . . . . . 216
b. Powder Method . . . . . . . . . . . . . . . . . . . 216
c. Black Light and Dye Method . . . . . . . . 216
d. Possible Points Of Fluid Leaks And
Their Causes . . . . . . . . . . . . . . . . . . . . . 216
e. Repairing Leak . . . . . . . . . . . . . . . . . . . 217
viii
a. Disassembly . . . . . . . . . . . . . . . . . . . . . 217
b. Assembly. . . . . . . . . . . . . . . . . . . . . . . . 218
Section 3. GENERAL OVERHAUL

INFORMATION
32. TOOLS AND EQUIPMENT

a. Improvised Equipment . . . . . . . . . . . . . . 31
b. Special Tools . . . . . . . . . . . . . . . . . . . . . . 31
c. Mechanics Tools And
Shop Equipment . . . . . . . . . . . . . . . . . . . 31
33. REPLACEMENT PARTS
a. Ordering Information . . . . . . . . . . . . . . . 36
b. Parts Normally Replaced
at Overhaul . . . . . . . . . . . . . . . . . . . . . . . 36
34. CAREFUL HANDLING . . . . . . . . . . . . . . . 36
35. CLEANING AND INSPECTION
a. Dirt Causes Malfunction . . . . . . . . . . . . . 36
b. Cleaning Transmission, Parts . . . . . . . . . 36
c. Cleaning Bearings. . . . . . . . . . . . . . . . . . 36
d. Inspecting Bearings. . . . . . . . . . . . . . . . . 37
e. Keeping Bearings Clean . . . . . . . . . . . . . 37
f. Inspecting Cast Parts and
Machined Surfaces . . . . . . . . . . . . . . . . . 37
g. Inspecting Bushings and
Thrust Washers . . . . . . . . . . . . . . . . . . . . 37
h. Inspecting Sealrings and Gaskets . . . . . . 38
i. Inspecting Gears . . . . . . . . . . . . . . . . . . . 38
j. Inspecting Splined Parts . . . . . . . . . . . . . 38
k. Inspecting Threaded Parts. . . . . . . . . . . . 38
l. Inspecting Retaining Rings . . . . . . . . . . . 39
m. Inspecting Springs. . . . . . . . . . . . . . . . . . 39
n. Inspecting Clutch Plates . . . . . . . . . . . . . 39
o. Inspecting Swaged and
Interference-Fit Parts . . . . . . . . . . . . . . . 39
p. Inspecting Sealing Surfaces . . . . . . . . . . 39
TABLE OF CONTENTS
Paragraph
Page
36. ASSEMBLY PROCEDURES

a. Parts Lubrication . . . . . . . . . . . . . . . . . . . 39
b. Grease Used For Assembly . . . . . . . . . . . 39
c. Sealing Compounds And
Nonsoluble Greases . . . . . . . . . . . . . . . . . 39
d. Clutches And Pistons. . . . . . . . . . . . . . . . 39
e. Threaded Plugs And Hydraulic
Fittings . . . . . . . . . . . . . . . . . . . . . . . . . . 310
f. Coated Threaded Fasteners . . . . . . . . . . 310
g. Lip-Type Oil Seals. . . . . . . . . . . . . . . . . 310
h. Butt-Joint Sealrings . . . . . . . . . . . . . . . . 310
i. Bearings . . . . . . . . . . . . . . . . . . . . . . . . . 310
j. Bushings. . . . . . . . . . . . . . . . . . . . . . . . . 311
k. Electrical Components . . . . . . . . . . . . . 311
37. REMOVING TRANSMISSION
FROM VEHICLE
a. Drain Fluid. . . . . . . . . . . . . . . . . . . . . . . 311
b. Disconnecting Controls . . . . . . . . . . . . . 311
c. Uncoupling Transmission From
Vehicle And Engine Driveline. . . . . . . . 311
d. Removing The Transmission. . . . . . . . . 312
38. WEAR LIMITS . . . . . . . . . . . . . . . . . . . . . . 312
39. SPRING SPECIFICATIONS . . . . . . . . . . . 312
310. TORQUE SPECIFICATIONS . . . . . . . . . . 312
Section 4. TRANSMISSION DISASSEMBLY

41. SCOPE
a. Section . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
b. Procedures . . . . . . . . . . . . . . . . . . . . . . . . 41
c. Illustrations. . . . . . . . . . . . . . . . . . . . . . . . 41
d. General Information. . . . . . . . . . . . . . . . . 41
e. Foldouts . . . . . . . . . . . . . . . . . . . . . . . . . . 41
42. DISASSEMBLY OF TRANSMISSION
a. Mounting Transmission
On Repair Stand. . . . . . . . . . . . . . . . . . . . 41
b. Removal Of Power Takeoff. . . . . . . . . . . 41
c. Removal Of External Parts . . . . . . . . . . . 41
d. Removal Of Integral Oil Cooler . . . . . . . 43
e. Removing Integral Retarder Sump Oil
Cooler. . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
f. Removal Of Control Valve Module . . . . 44
g. Removal Of Torque Converter Module. . 44
h. Removal Of Converter
Housing Module . . . . . . . . . . . . . . . . . . . 46
i. Removal Of Retarder Module
(Except 4700 And 4800 Models). . . . . . . 46
Paragraph
Page
j. Removal Of Retarder And Output Shaft

Module (4700 And 4800 Models) . . . . . . 47
k. Removal Of Rear Cover Module (Except
4700 And 4800 Models) . . . . . . . . . . . . . 47
l. Removal Of Rear Cover And Output
Shaft Module (4700 And 4800 Models) . 48
m. Removal Of C6 Adapter Housing
Module (4700 And 4800 Models) . . . . . . 48
n. Removal Of P3 Planetary Module
(4700 And 4800 Models). . . . . . . . . . . . . 49
o. Removal Of Main Shaft Module . . . . . . . 49
p. Removal Of P2 Module,
C5 Clutch Plates, And P1 Module. . . . . . 49
q. Removal Of Front Support/
Charging Pump Module And
Rotating Clutch Module . . . . . . . . . . . . 410
r. Removal Of C3/C4 Clutch Assembly
From Main Housing Module. . . . . . . . . 410
Section 5. MODULE REBUILD

51. SCOPE
a. Section . . . . . . . . . . . . . . . . . . . . . . . . . . . 51
b. Procedures . . . . . . . . . . . . . . . . . . . . . . . . 51
52. GENERAL INFORMATION FOR
MODULE REBUILD . . . . . . . . . . . . . . . . . . 51
53. TORQUE CONVERTER MODULE
a. Disassembly . . . . . . . . . . . . . . . . . . . . . . . 51
b. Assembly . . . . . . . . . . . . . . . . . . . . . . . . . 52
54. TORQUE CONVERTER HOUSING
MODULE (Models Without PTO Provision)
a. Disassembly . . . . . . . . . . . . . . . . . . . . . . . 54
b. Assembly . . . . . . . . . . . . . . . . . . . . . . . . . 54
55. TORQUE CONVERTER HOUSING
MODULE (Models With PTO Provision)
a. Disassembly . . . . . . . . . . . . . . . . . . . . . . . 54
b. Disassembly Of Bearing Retainer. . . . . . 54
c. Disassembly Of PTO Gear Assembly. . . 54
d. Assembly Of PTO Gear Assembly . . . . . 54
e. Assembly Of Bearing
Retainer Assembly. . . . . . . . . . . . . . . . . . 55
f. Assembly . . . . . . . . . . . . . . . . . . . . . . . . . 55
ix

Paragraph
Page
56. FRONT SUPPORT AND OIL PUMP MODULE

a. Disassembly . . . . . . . . . . . . . . . . . . . . . . 55
b. Assembly Of Front Support . . . . . . . . . . 57
c. Assembly Of Pump Housing . . . . . . . . . 57
57. ROTATING CLUTCH MODULE
a. Disassembly . . . . . . . . . . . . . . . . . . . . . . 58
b. Assembly . . . . . . . . . . . . . . . . . . . . . . . . 511
58. C3/C4 AND MAIN HOUSING MODULE
a. Disassembly . . . . . . . . . . . . . . . . . . . . . 512
b. Assembly . . . . . . . . . . . . . . . . . . . . . . . . 513
Paragraph
Page
e. Disassembly Of Retarder
Stator Assembly . . . . . . . . . . . . . . . . . . 522
f. Assembly Of Retarder Stator . . . . . . . . 523
g. Assembly Of P3 Planetary
Carrier Assembly . . . . . . . . . . . . . . . . . 523
h. Assembly Of Retarder Housing
Assembly. . . . . . . . . . . . . . . . . . . . . . . . 523
i. Assembly Of The Retarder Valve Body. 524
512. P3 PLANETARY MODULE

(4700 And 4800 Models)
a. Disassembly . . . . . . . . . . . . . . . . . . . . . 516
b. Assembly . . . . . . . . . . . . . . . . . . . . . . . 516
515. RETARDER AND OUTPUT SHAFT

MODULE (4700 And 4800 Models Equipped
With Retarder)
a. Disassembly Of Retarder Valve Body . 525
b. Disassembly Of Temperature Sensor . . 525
c. Disassembly Of Retarder Housing . . . . 525
d. Completion Of Retarder Housing
Disassembly . . . . . . . . . . . . . . . . . . . . . 526
e. Assembly Of Output Shaft Assembly . 526
f. Disassembly Of Retarder Stator
Assembly . . . . . . . . . . . . . . . . . . . . . . . . 526
g. Assembly Of Retarder Stator . . . . . . . . 526
h. Assembly Of Retarder Housing . . . . . . 527
i. Assembly Of Output Shaft Assembly. . 527
j. Completion Of Retarder Housing
Assembly . . . . . . . . . . . . . . . . . . . . . . . . 527
k. Assembly Of Retarder Valve Body . . . 528
513. C6 ADAPTER HOUSING MODULE

(4700 And 4800 Models)
a. Disassembly Of Ring Gear and Hub
Assembly . . . . . . . . . . . . . . . . . . . . . . .
b. Disassembly . . . . . . . . . . . . . . . . . . . . .
c. Disassembly Of P4 Planetary Carrier
Assembly . . . . . . . . . . . . . . . . . . . . . . .
d. Disassembly Of Remaining C6 Parts . .
e. Assembly . . . . . . . . . . . . . . . . . . . . . . .
f. Assembly Of P4 Planetary Carrier
Assembly . . . . . . . . . . . . . . . . . . . . . . .
g. Assembly Of C6 Clutch . . . . . . . . . . . .
519
520
516. REAR COVER MODULE (Models Equipped

With Rear Cover, Except 4700 And 4800
Models)
a. Disassembly. . . . . . . . . . . . . . . . . . . . . . 528
b. Disassembly Of P3 Planetary
c. Completion Of Rear Cover
Disassembly . . . . . . . . . . . . . . . . . . . . . 530
d. Beginning Rear Cover Assembly . . . . . 530
e. Assembly Of P3 Planetary
f. Completion Of Rear Cover Assembly . . 531
514. RETARDER AND P3 PLANETARY MODULE

a. Disassembly Of Retarder Valve Body . . 520
b. Disassembly Of Temperature Sensor . . 520
c. Disassembly Of Retarder Housing . . . . 521
d. Disassembly Of P3 Planetary
517. REAR COVER AND OUTPUT SHAFT

MODULE (4700 And 4800 Models Equipped
With Rear Cover)
a. Disassembly . . . . . . . . . . . . . . . . . . . . . 532
b. Disassembly Of Output Shaft
Assembly . . . . . . . . . . . . . . . . . . . . . . . 532
59. MAIN SHAFT MODULE

a. Disassembly . . . . . . . . . . . . . . . . . . . . . 513
b. Assembly (Except 4700 And
4800 Models). . . . . . . . . . . . . . . . . . . . . 514
c. Assembly (4700 And 4800 Models) . . . 514
a. Disassembly . . . . . . . . . . . . . . . . . . . . . 514
b. Assembly. . . . . . . . . . . . . . . . . . . . . . . . 514
a. Disassembly . . . . . . . . . . . . . . . . . . . . . 515
b. Assembly. . . . . . . . . . . . . . . . . . . . . . . . 515
517
517
517
517
518
TABLE OF CONTENTS
Paragraph
Page
c. Completion Of Rear Cover

Disassembly . . . . . . . . . . . . . . . . . . . . . 532
d. Beginning Rear Cover Assembly . . . . . 532
e. Assembly Of Output Shaft
Assembly . . . . . . . . . . . . . . . . . . . . . . . . 533
f. Completion Of Rear Cover Assembly. . 533
518. CONTROL VALVE MODULE
a. Removal Of Filters. . . . . . . . . . . . . . . . . 534
b. Removal Of Electrical Components
And Sensors . . . . . . . . . . . . . . . . . . . . . . 535
c. Disassembly Of Solenoid Valve Body . 535
d. Disassembly Of C6 Control Valve
Body . . . . . . . . . . . . . . . . . . . . . . . . . . . . 536
e. Disassembly Of Main
Valve Body. . . . . . . . . . . . . . . . . . . . . . . 536
f. Disassembly Of Channel Plate . . . . . . . 537
g. Assembly Of Channel Plate . . . . . . . . . 537
h. Assembly Of Main Valve Body. . . . . . . 537
i. Assembly Of C6 Control Valve Body. . 538
j. Assembly Of Solenoid Valve Body. . . . 538
k. Installation Of Electrical Components
And Sensors . . . . . . . . . . . . . . . . . . . . . . 538
l. Install Filters . . . . . . . . . . . . . . . . . . . . . 538
Section 6. TRANSMISSION ASSEMBLY

61. SCOPE
a. Section . . . . . . . . . . . . . . . . . . . . . . . . . . . 61
b. Procedures . . . . . . . . . . . . . . . . . . . . . . . . 61
c. Illustrations . . . . . . . . . . . . . . . . . . . . . . . 61
d. General Information . . . . . . . . . . . . . . . . 61
e. Foldouts . . . . . . . . . . . . . . . . . . . . . . . . . . 61
62. ASSEMBLY OF TRANSMISSION
a. Assembly Of Main Housing Module . . . 61
b. Installation Of Rotating Clutch Module. . 61
c. Installation Of Front Support/
Charging Pump Module. . . . . . . . . . . . . . 62
d. Installation Of P1 Planetary Module . . . . 62
e. Installation Of P2 Planetary Module . . . . 62
f. Installation Of C5 Clutch Pack . . . . . . . . 62
g. Installation Of Main Shaft Module
(Except 4700 And 4800 Models) . . . . . . 62
h. Installation Of Main Shaft Module
(4700 And 4800 Models) . . . . . . . . . . . . 63
Paragraph
Page
i. Main Shaft Selective Shim

Measurement (Close Ratio Models) . . . . 63
j. Main Shaft Selective Shim
Measurement (Wide Ratio Models) . . . 64
k. Installation Of P3 Planetary Module
(4700 And 4800 Models With Retarder). . 65
l. Installation Of C6 Adapter Housing
Module (4700 And 4800 Models With
Retarder). . . . . . . . . . . . . . . . . . . . . . . . . . 65
m. P3 Planetary Selective Shim
Measurement (4700 And 4800 Models
With Retarder) . . . . . . . . . . . . . . . . . . . . 66
n. P3 Planetary Selective Shim
Measurement (4700 And 4800 Models
With Rear Cover) . . . . . . . . . . . . . . . . . . 67
o. Installation Of Remainder Of P3 Planetary
Module and C6 Adapter Housing Module
(4700 And 4800 Models) . . . . . . . . . . . . 68
p. Installation Of Tolerance Rings
Module (4700 And 4800 Models With
Retarder) . . . . . . . . . . . . . . . . . . . . . . . . . 69
q. Installation Of Retarder Module (Except
4700 And 4800 Models) . . . . . . . . . . . . . 69
r. Installation Of Retarder and Output
Shaft Module (4700 And 4800 Models
With Retarders) . . . . . . . . . . . . . . . . . . . 610
s. Installation Of Rear Cover Module
(Except 4700 And 4800 Models) . . . . . 611
t. Installation Of Rear Cover Module
(4700 And 4800 Models). . . . . . . . . . . . 611
u. Installation Of Converter Housing
Module . . . . . . . . . . . . . . . . . . . . . . . . . . 613
v. Installation Of Torque Converter
Module . . . . . . . . . . . . . . . . . . . . . . . . . . 613
w. Installation Of Control Module . . . . . . . 616
x. Installing Integral Oil Cooler. . . . . . . . . 616
y. Installing Integral Retarder Sump Oil
Cooler. . . . . . . . . . . . . . . . . . . . . . . . . . . 617
z. Installation Of Externally
Mounted Parts . . . . . . . . . . . . . . . . . . . . 618
aa. Installation Of Power Takeoff . . . . . . . . 619
ab. Removal Of Transmission
From Repair Stand . . . . . . . . . . . . . . . . . 619
xi

Paragraph
Page
Section 7. WEAR LIMITS AND

SPRING DATA
Paragraph
Section 8. CUSTOMER SERVICE

81. OWNER ASSISTANCE. . . . . . . . . . . . . . . . 81
71. WEAR LIMITS DATA

a. Maximum Variations . . . . . . . . . . . . . . . 71
b. Cleaning and Inspection . . . . . . . . . . . . . 71
82. SERVICE LITERATURE . . . . . . . . . . . . . . 82
72. SPRING DATA

a. Spring Replacement . . . . . . . . . . . . . . . . 71
b. Inspection . . . . . . . . . . . . . . . . . . . . . . . . 71
xii
Page
LIST OF FOLDOUT ILLUSTRATIONS

(Back Of Service Manual)
CROSS-SECTION VIEWS
Foldout
1
2
3
3,A
3,B
3,C
4000 Product Family Transmission (Close Ratio)Cross Section

4500 Model (Wide Ratio) Transmission With PTO ProvisionCross Section
4000 Product Family (Close Ratio) Transmission With RetarderCross Section
4700 and 4800 Model TransmissionCross Section
4700 and 4800 Model Transmission With RetarderCross Section
4700 and 4800 Model Transmission With Retarder and PTO ProvisionCross Section
EXPLODED VIEWS
Foldout
4,A
4,B
5,A
5,B
6,A
6,B
7
8
9,A
9,B
9,C
10,A
10,B
10,C
10,D
11,A
11,B
12,A
12,B
12,C
13
Flexplate and Adapter

Torque Converter Module
Converter Housing Module
Converter Housing Module With PTO Provision
Front Support and Charging Oil Pump Module
Rotating Clutch Module
Main Housing Module
Main Shaft Module
P1 Planetary Module
P2 Planetary Module
P3 Planetary Module and C6 Adapter Housing Module (4700 and 4800 Models)
Rear Cover and P3 Planetary Module
Rear Cover and Output Shaft Module (4700 and 4800 Models)
Retarder and P3 Module
Retarder and Output Shaft Module (4700 and 4800 Models)
Control Module
Control Module
Output Flange and Yoke
Support Equipment
Integral Retarder Sump Cooler
4000 Product Family Hydraulic SchematicNeutral
xiii

NOTES
xiv
SECTION 1GENERAL INFORMATION

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

Manual describes overhaul procedures for 4000
Product Family transmissions with Allison 4th
Generation Controls. Power takeoff (PTO) and output
retarder options may be added to a base transmission
model.
Detailed instructions are provided for
disassembly in Section 4, rebuild in Section 5,

and reassembly in Section 6.
Part inspection instructions are in Section 3.
Wear limits and spring data are in Section 7.
Major transmission components and their
functions are explained in 3000 and 4000

Product Families Principles of Operation
PO4016EN.
The 4000 Product Family consists of the following
transmission series and models (Figures 11 through
16):
Highway Series:
4000 HS
4500 HS
Rugged Duty Series:
4000 RDS
4700 RDS
Emergency Vehicle Series:
4000 EVS
4500 EVS
4700 EVS
4800 EVS
Motorhome Series:
4000 MH
Truck Recreational Vehicle Series:
4000 TRV
4500 TRV
Specialty Series:
4000 SP
4500 SP
4700 SP
4800 SP
Bus Series:
B 500
T 400 Series:
T 425
T 450
T 525
b. Illustrations
1. The text is supported with line drawings and
cross-sectional views. Overhaul procedures are
illustrated by line drawings. Cross-sections
show the relationship of assembled parts.
Cross-sections, exploded views, and a
hydraulic schematic (transmission in Neutral)
are on foldout pages in the back of the manual.
2. Illustrations show correct procedures for all
modelsincluding models not illustrated.
c. Maintenance Information. Each task described
in this manual has been successfully completed by
service organizations and individuals. Not every
service organization or individual possesses the
required special tooling, training or experience to
perform all described tasks. However, any task may be
performed if the following conditions are met:
1. The organization or individual has the
required knowledge of the task through:
Formal instruction at Allison Transmission
or a Distributor training facility.

On-the-job instruction by an Allison
Transmission or Distributor representative.

Experience in performing the task.
2. The work environment is suitable to prevent

contamination or damage to transmission parts
or assemblies.
3. Required tools and fixtures are available as
shown in Section 3 of this manual. Refer to
Figures 32 and 33 and Tables 31 and 32.
4. Reasonable and prudent maintenance practices
are used.
NOTE:
Service organizations and individuals are
encouraged to contact their local Allison
Transmission Distributor for information and
guidance on any task outlined in this manual.
11
PTO PROVISION
(TOP RIGHT POSITION)
SHIPPING
BRACKET (3)
MOUNTING
PAD
FEEDTHROUGH
HARNESS
CONNECTOR
ENGINE SPEED
SENSOR
TURBINE SPEED
SENSOR
OUTPUT SPEED
SENSOR
COOLER PORTS
FILL TUBE
NAMEPLATE
V07319.01.00
Figure 11. 4000 Product Family Transmission With PTO Provision (Except 4700 and 4800 Models)Right-Rear View
FEEDTHROUGH
HARNESS
CONNECTOR
MOUNTING PAD
(BOTH SIDES)
PTO PROVISION
(BOTTOM LEFT POSITION)
MAIN-PRESSURE TAP
COOLER PORTS
V06830.01.00
Figure 12. 4000 Product Family Transmission With PTO Provision (Except 4700 and 4800 Models)Left-Rear View
12
GENERAL INFORMATION
FILL TUBE
PTO PROVISION
RETARDER
FEEDTHROUGH HARNESS
CONNECTOR
TORQUE CONVERTER
MODULE
NAMEPLATE
TURBINE-SPEED SENSOR
ENGINE-SPEED SENSOR
MOUNTING PAD
V07320.01.00
Figure 13. 4000 Product Family With PTO Provision and Retarder (Except 4700 and 4800 Models)Right-Front View
MOUNTING PAD
OUTPUT-SPEED
SENSOR
PTO PROVISION
(BOTTOM LEFT POSITION)
RETARDER
MAIN-PRESSURE TAP
COOLER PORTS
ACCUMULATOR PORT
V07334.01.00
Figure 14. 4000 Product Family With PTO Provision and Retarder (Except 4700 and 4800 Models)Left-Rear View
13

BREATHER
PTO PROVISION
C6 ADAPTER
HOUSING
RETARDER
OUTPUT
FLANGE
MOUNTING PAD
PTO PROVISION
MOUNTING PAD
V07333.01.00
Figure 15. 4000 Product Family With PTO Provision and Retarder (4700 and 4800 Models)Left-Rear View
PTO PROVISION
C6 ADAPTER
HOUSING
MOUNTING PAD
INPUT SPEED SENSOR
TURBINE
SPEED SENSOR
FILL T UBE
OUTPUT
SPEED SENSOR
NAMEPLATE
V07332.01.00
Figure 16. 4000 Product Family With PTO Provision (4700 and 4800 Models)Right-Rear View
14
GENERAL INFORMATION
12.
SUPPLEMENTARY
INFORMATION
Yellow Pages for your nearest authorized service

outlet. Listings are under TransmissionTruck or
EnginesDiesel.
Supplementary information will be issued, as required,

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

(Figure 17) is located on the right side of the
transmission. The nameplate is imprinted with the
following:
14.
GENERAL DESCRIPTION
Allison 4000 Product Family transmissions are a

complete transmission system that includes all
hardware needed for vehicle application.
a. Major Modules. 4000 Product Family
transmissions contain the following major modules:
Input Module
Main Housing and Gear Module
Model number
Control Module
Serial number
Output Module
Data code
C6 Adapter Module (4700 and 4800 models)
TransID number
b. Unique Features. Features unique to 4000

Product Family transmissions are:
configurations
Lockup clutch with torsional damper
Integral retarder (optional)
Integral oil filters, serviceable without
complete loss of transmission fluid

Adaptive electronic closed-loop controls with
LTURAL
IMP
MO
BIL
E , A E ROSPACE
AN
RICU
T WORKERS O
F
UT
TRANSMISSION
IDENTIFICATION
NUMBER
AG
EN
DATA CODE
EM
General Motors Corp.

Indianapolis, Indiana, USA
self-diagnostic capabilities
UNITED A
b. Parts Catalog. Replacement parts are listed in

the current 4000 Product Family Parts Catalog
PC2456EN. Do not order by the item numbers used on
exploded views in this manual. Use the Parts Catalog
to determine the correct part number. Order all
replacement parts from your distributor. Check the
Three, four, five, six, or seven forward speed
ICA
Use all of these numbers when ordering replacement

parts or requesting service information.
ER
(for Specialty Series vocation models)
AM
Engineering Feature Configuration Number
00A00
ENGINEERING FEATURE
CONFIGURATION
NUMBER FIELD
TIDA
S/N
XXXXXXXXXX
MODEL NUMBER FIELD
SERIAL NUMBER
V09468.01.01
Figure 17. Transmission Nameplate
15

15.
MAJOR COMPONENTS
a. Input Module. The Input Module includes:

Torque converter
Power takeoff gearing (optional)
b. Torque Converter
1. The torque converter includes a lockup clutch
and torsional damper for direct and smooth
transfer of engine power.
2. Torque converter models available are:
Torque Converter Model
TC 521
TC 531
TC 541
TC 551
TC 561
c. Power Takeoff. Direct, engine-driven PTO
gearing is available at two positions, except in the
4000 HS.
d. Main Housing and Gear Module. The Main
Housing and Gear Module include:
Main Housing
Oil pump charging system
Three planetary gear sets
(four for 4700 and 4800 models)

Two rotating clutches
Three stationary clutches
(four for 4700 and 4800 models)
e. Range Clutches. Range clutches are multipledisc, wet-type clutches. Exhaust backfill pressure is
used to reduce fill time for quick response and smooth
shifts.
f. Control System. The control system is capable of
recognizing hydraulic and electronic conditions that
are not within the operating limits of the programmed
calibration. Some out-of-limit conditions can be
corrected by the control system. All out-of-limit
condition diagnostic codes are stored for later retrieval
by a technician.
The Electronic Control System includes:
Transmission Control Module (TCM)
16
Sensors
Wiring harness (customer-furnished)
Engine adaptation
Control module
Shift selector
The TCM is a high-speed digital computer that

receives information from the sensors and shift
selector. This information is processed and shift
commands are sent to the control module for range
selection.
g. Transmission Fluid Filters. Two disposable
external-access filters are part of the control module.
Each filter is in a separate cavity which permits
removal and replacement without complete loss of
transmission fluid.
h. Transmission Fluid Coolers. The 4000 Product
Family has provision for remote or integral
transmission fluid coolers.
i. C6 Adapter Housing Module. The C6 adapter
housing module is unique to the 4700 and 4800
models. It provides a seventh range and is located
between the main housing and rear cover/retarder.
j. Rear Cover. A rear cover is standard equipment
on the 4000 Product Family. The output shaft can be
provided with a variety of companion flanges or yokes.
k. Output Retarder and Output Flange. The
optional output retarder module replaces the standard
rear cover. An output flange or yoke is available for
use with the retarder.
16.
BUS
EVS
HS
MH
RDS
SP
TRV
7 or 8
5
0
4000 PRODUCT FAMILY MODEL

DESIGNATION CODE
Bus Series
Emergency Vehicle Service
Highway Series
Motorhome Series
Rugged Duty Series
Specialty Series
Truck Recreational Vehicle Series
Widest Ratio Coverage (WRC)
Wide Ratio (WR)
Close Ratio (CR)
The following table lists the standard (STD) and

optional (OPT) features of each 4000 Product Family
model code designations:
GENERAL INFORMATION
CR/WR
Maximum
Forward
Ranges
PTO
Retarder
Deep
Sump
Shallow
Sump
OLS
4000 EVS
CR
STD
OPT
STD
OPT
STD
4000 HS
CR
N/A
OPT
STD
N/A
STD
4000 MH
CR
OPT
OPT
STD
OPT
STD
4000 RDS
CR
STD
OPT
STD
N/A
STD
4000 SP
CR
STD
OPT
STD
OPT
STD
4000 TRV
CR
OPT
OPT
STD
N/A
STD
4500 EVS
WR
STD
OPT
STD
OPT
STD
4500 HS
WR
N/A
OPT
STD
N/A
STD
4500 RDS
WR
STD
OPT
STD
N/A
STD
4500 SP
WR
STD
OPT
STD
OPT
STD
4700 EVS
WR
STD
OPT
STD
OPT
STD 1
4700 RDS
WRC
STD
OPT
STD
N/A
STD 1
4700 SP
WRC
STD
OPT
STD
N/A
STD
4800 EVS
WRC
STD
OPT
STD
OPT
STD 1
4800 SP
WRC
STD
OPT
STD
N/A
STD
B 500
CR
OPT
OPT
STD
OPT
STD
T 425
CR
OPT
OPT
STD
OPT
STD
T 450
CR
OPT
OPT
STD
OPT
STD
T 525
CR
OPT
OPT
STD
OPT
STD
Vocational
Model
1OLS not available on 7-speed models with retarders.
17.
EXPLODED
(DISASSEMBLED) VIEWS
Exploded views illustrate 4000 Product Family

transmission parts in relation to each other. The parts
numbering system in the exploded views is used in all
procedures described in the text.
18.
DIAGNOSIS
NOTE:
Refer to Allison 4th Generation Controls
Troubleshooting Manual (TS3989EN) for in-depth
troubleshooting procedures.
a. Before Starting. Before attempting to repair the

transmission, the faulty condition and its probable
cause should be identified.
b. CHECK TRANS Light. Continued illumination
of the CHECK TRANS light during vehicle operation
indicates the TCM has signaled a diagnostic code. At
start-up, the CHECK TRANS light will briefly
illuminate to indicate that the light is functioning
properly.
NOTE:
The Strip Pushbutton Shift Selector has no display
or diagnostic capabilities. Use the Allison DOC
For PCService Tool to display diagnostic trouble
codes.
17

c. Entering Diagnostic Mode
1. Pushbutton Shift Selector
When Oil Level Sensor (OLS) is present:
Press the (Up) and (Down) arrow keys
twice simultaneously. Diagnostics will be
displayed immediately. The display will list
the diagnostic codes logged by position
(d1, d2, d3, etc.).
When OLS is not present: Press the (Up)
and (Down) arrow keys simultaneously.
The display will list the diagnostic codes
logged by position (d1, d2, d3, etc.).
2. Lever Shift Selector
When OLS is not presentPress the
DISPLAY MODE button. Diagnostics will
be displayed immediately.
When OLS is presentPress the
DISPLAY MODE button twice to enter
Diagnostic Mode. The display will list the
diagnostic codes logged by position (d1,
d2, d3, etc.).
d. Diagnostic Codes. Diagnostic codes can be
displayed on the display portion of the shift selector or
by using the Allison DOC For PCService Tool. A
diagnostic code is either active or historical. An active
code is any code that is current in the TCM decisionmaking process. Historical codes are codes that are
retained in the TCM memory and will not necessarily
affect the TCM decision-making process. Active
codes are indicated on the shift selector by the MODE
ON indicator.
e. Displaying Diagnostic Codes. Press and release
the MODE button to sequentially display the logged
diagnostic codes.
f. Diagnostic Code Displays. The code list position
(d1, d2, d3, d4, and d5) is the first item displayed,
followed by the diagnostic trouble code (DTC). The
following example shows how DTC P0722 is
displayed on pushbutton and lever shift selectors:
SELECT
MONITOR
1
P
18
The display cycles continuously until the next code list

position is accessed by pressing the MODE button.
When all codes have been displayed by pressing the
MODE button, the first code will be redisplayed. Any
log position not containing a diagnostic code will
display at the DTC position. No codes are
logged after a display.
g. Exiting Diagnostic Mode
1. Press the same buttons used to enter the
diagnostic mode.
2. Select any range. The transmission will enter
the selected range if the range is not inhibited.
3. Turn off the ignition switch.
4. The TCM diagnostic mode is exited
automatically after approximately two minutes
have elapsed without an operator input.
19.
PRESERVATION AND STORAGE
a. Storage (New Transmissions, Before Installation).

New transmissions are filled with transmission fluid
and drained before shipment. The residual fluid in the
transmission provides adequate protection to safely
store the transmission without further treatment for
one full year if stored indoors, in conditions of normal
climate, and with all shipping plugs installed.
b. Preservation Methods. When the transmission is
stored or inactive for an extended period (one or more
years), specific preservation methods are required to
prevent damage from rust, corrosion, and organic
growth in the transmission fluid. Preservation methods
described are for storage with or without transmission
fluid and in or out of a vehicle.
c. One Year Storage (Without Fluid)
1. Drain the transmission fluid.
2. Remove the breather and spray 30 ml (one
ounce) of VCI #10 (or equivalent) into the
transmission through the breather hole.
Re-install the breather. Also, spray 30 ml (one
ounce) through the fill tube hole.
3. Seal all openings and the breather with
moisture-proof tape.
GENERAL INFORMATION
4. Coat all exposed, unpainted surfaces with
preservative grease such as petrolatum
(MIL-C-11796, Class 2).
8. Coat all exposed, unpainted surfaces with

preservative grease such as petrolatum
(MIL-C-11796), Class 2.
5. If additional storage time is required, repeat

Steps (2) through (4) at yearly intervals.
9. If additional storage time is required, repeat

Steps (2) through (8) at yearly intervals,
except, it is not necessary to drain the
transmission each year. Just add VCI #10 and
Biobor JF (or equivalents).
d. One Year Storage (With Fluid)

1. Drain the fluid and replace the oil filter
elements.
2. Fill the transmission to operating level with a
mixture of one part VCI #10 (or equivalent) to
30 parts transmission fluid. Add 3 ml of
Biobor JF (or equivalent) for each 10 liters
(1 4 teaspoon per gallon) of fluid in the system.
NOTE:
When calculating the amount of Biobor JF
required, use the total volume of the system, not just
the quantity required to fill the transmission.
Include external lines, filters, and the cooler.
3. Operate the transmission in N (Neutral) for
approximately five minutes at 1500 rpm.
4. Make sure the transmission shifts through all
ranges and the lockup clutch activates.
5. Continue operating the transmission in neutral
at 1500 rpm until normal operating
temperature is reached.
CAUTION:
If the unit does not have a converter-out temperature gauge, do not stall the converter.
6. If normal operating temperature is less than

107C (225F), shift the transmission to
forward range and stall the converter. Do not
exceed 107C (225F).
7. As soon as the transmission is cool enough to
touch, seal all openings and the breather with
moisture-proof tape.
110. RESTORING TRANSMISSION

TO SERVICE
CAUTION:
Whenever a transmission is overhauled or
exchanged, the Transmission Control Module
(TCM) must be RESET TO UNADAPTED
SHIFTS. This causes the TCM to erase previous
adaptive information and begin to adapt in Fast
Adaptive Mode from the base calibration. Use
the Allison DOC For PCService Tool and
select RESET UNADAPTED SHIFTS. Follow
the instructions in the Allison DOC For PC
Service Tool User Guide GN3433EN to
accomplish the reset.
a. Transmission Exterior. Wash all external grease
from the transmission with mineral spirits.
b. Sealed Breather and Openings. Remove all tape
from openings and the breather.
c. New Transmissions. If the transmission is new,
drain the residual preservative oil. Refill the
transmission to the proper level with an Allisonapproved transmission fluid. Refer to Paragraph 210.
d. Stored Without Fluid. If the transmission was
prepared for storage without fluid, drain the residual
fluid and replace the oil filter elements. Refill the
transmission to the proper level with an Allisonapproved transmission fluid. Refer to Paragraph 210.
e. Stored With Fluid. If the transmission was
prepared for storage with fluid, it is not necessary to
drain and refill the transmission with new transmission
fluid. Check for proper fluid level. Add or drain
transmission fluid, as required, to obtain the proper
level.
19

111. ELECTROMAGNETIC/RADIO
FREQUENCY INTERFERENCE
All electrical and electronic systems generate
electromagnetic fields that can interfere with other
electronic systems. Allison Transmissions electronic
transmission controls comply with Federal
Communications Commission (FCC) regulations and
other guidelines concerning emitted radio frequency
interference for transportation electronics. Some
radio-telephone or two-way communications radios
(land-mobile radio), or the manner in which they are
installed, can be affected by other vehicle components
or adversely affect vehicle operation. Manufacturers
and installers of EMI/RFI emitting equipment are
responsible for adhering to FCC regulations and other
guidelines concerning emitted radio frequency
interference for transportation electronics. Radio or
other two-way communication antenna, power, or
ground leads near the transmission wiring harness,
control devices, or power leads may create or be

subject to electromagnetic interference (EMI) from the
transmission control system. Refer to the Allison 4th
Generation Controls Troubleshooting Manual
(TS3989EN) for detailed instructions regarding EMI
problems.
112. OPERATING INSTRUCTIONS

Detailed transmission operation information is in the
3000 and 4000 Product Families Principles of
Operation PO4016EN manual or in vocational model
Operators Manual. Refer to the latest revision.
113. SPECIFICATIONS AND DATA

The following specifications and data provide a
quick reference to the major characteristics of the
transmission.
Table 11. Specifications and Data Chart*

GEAR DATA:
Type
Planetary helical, constant mesh
Range
Close-Ratio
Wide-Ratio
Widest-Ratio Coverage
First . . . . . . . . . . . . . . . . . . . . . . . . .
3.51:1
4.70:1
7.63
Second . . . . . . . . . . . . . . . . . . . . . . .
1.91:1
2.21:1
3.51
Third . . . . . . . . . . . . . . . . . . . . . . . .
1.43:1
1.53:1
1.91
Fourth . . . . . . . . . . . . . . . . . . . . . . .
1.00:1
1.00:1
1.43
Fifth . . . . . . . . . . . . . . . . . . . . . . . . .
0.74:1
0.76:1
1.00
Sixth. . . . . . . . . . . . . . . . . . . . . . . . .
0.64:1
0.67:1
0.74
Seventh . . . . . . . . . . . . . . . . . . . . . .
0.64
Reverse . . . . . . . . . . . . . . . . . . . . . .
4.80:1
5.55:1
4.80:1
ENGINE-DRIVEN POWER TAKEOFF PROVISION:

Positions . . . . . . . . . . . . . . . . . . . . . 8 oclock and 1 oclock (viewed from rear)
PTO Unit Ratings at the Transmission:
PTO Drive Gear . . . . . . . . . . . . . Maximum torque through one pad: 930 Nm (685 lb ft)
Maximum torque through both pads simultaneously: 1595 Nm (1175 lb ft)
NOTE: No more than 930 Nm (685 lb ft) allowed through any single pad.
* All data and specifications are subject to change without notice.

Gear ratios do not include torque converter multiplication.
110
GENERAL INFORMATION
Table 11. Specifications and Data Chart* (contd)
HYDRAULIC SYSTEM:
Fluid type . . . . . . . . . . . . . . . . . . . . TranSyndTM, MIL-PRF-2104, MIL-PRF-46167, MIL-PRF-21260,
DEXRON-III, C-4 (refer to Paragraph 210.)
Filters, main and lube . . . . . . . . . . . Dual integral, replaceable cartridge type
4000 PRODUCT FAMILY SIZES:
With PTO drive
Without PTO drive
Length (transmission mounting face to rear of output shaft)

without retarder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 854.0 mm (33.62 inch)
781.1 mm (30.75 inch)
with retarder. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 845.6 mm (33.29 inch)
772.6 mm (30.42 inch)
Length (transmission mounting flange to output flange

798.7 mm (31.45 inch)
mounting face on P3 carrier) . . . . . . . . . . . . . . . . . . . . . . . . . .
725.7 mm (28.57 inch)
Depth (standard sump, centerline to lowest point) . . . . . . . . . 374.7 mm (14.75 inch)
374.7 mm (14.75 inch)
Dry weightadd 16.0 kg (35.0 lb) if integral cooler is used

with retarder. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 439 kg (968 lb)
411 kg (906 lb)
without retarder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 405 kg (893 lb)
377 kg (831 lb)
with retarder and integral retarder sump cooler. . . . . . . . . . 469 kg (1032 lb)
441 kg (970 lb)
4700/4800 Models
With PTO drive
4700/4800 Models
Without PTO drive
Length (transmission mounting face to rear of output shaft)

with retarder or rear cover . . . . . . . . . . . . . . . . . . . . . . . . . . 1104.1 mm (43.47 inch) 966.3 mm (38.04 inch)
Depth (standard sump, centerline to lowest point) . . . . . . . . . 378.2 mm (14.89 inch)
378.2 mm (14.89 inch)
Dry weightadd 16.0 kg (35.0 lb) if integral cooler is used

with retarder. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 554 kg (1324 lb)
527 kg (1162 lb)
without retarder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 521 kg (1149 lb)
493 kg (1087 lb)
* All data and specifications are subject to change without notice.
111

NOTES
112
SECTION
PREVENTIVE
2PREVENTIVE
MAINTENANCE
MAINTENANCE
21.
SCOPE
Proper care and regular maintenance is necessary for

the transmission to meet its duty requirements.
Perform the maintenance procedures described in this
section on a regular basis to prevent premature
transmission or support equipment failure. Allison
transmissions are manufactured to provide long-term,
efficient service in their designed applications.
22.
PERIODIC INSPECTION
AND CARE
a. Exterior Cleaning and Inspection
level is too high, the fluid aerates causing the

transmission to shift erratically and overheat.
b. Oil Level Sensor. The optional oil level sensor
(OLS) allows the operator to determine the fluid level
from either a full-function pushbutton or a lever shift
selector. There is no fluid level reading capability for
an Allison 4th Generation Controls strip-type
pushbutton selector; use the Allison DOC For PC
Service Tool to obtain fluid level data from the OLS.
NOTE:
The oil level sensor compensates for transmission
fluid temperatures from 60104C (140220F).

Any temperature below 60C (140F) or above
104C (220F) will result in an Invalid for
Display condition.
CAUTION:
DO NOT pressure-wash the transmission
electrical connectors. Water and detergent cause
the electrical contacts to corrode and become
faulty.
1. Clean and inspect the exterior of the
transmission at regular intervals. Severity of
service and operating conditions determine the
frequency of inspections.
2. Inspect the transmission for:
Loose boltstransmission and mounting
components.
Fluid leaksrepair immediately.
Loose, dirty, or improperly adjusted throttle
To accurately determine the transmission
fluid level with the dipstick, the transmission

fluid must be at normal operating temperature (7193C; 160200F).
c. Electronic Controls and Protection Circuits.
4000 Product Family transmission electronic controls
and protection circuits alert the operator to a
transmission malfunction or the need for service. The
electronic controls and protection circuits do not
replace regular, manual, fluid level checks. Confirm
the fluid level at the intervals specified in vehicle
service instructions.
sensor linkage.
Damaged or loose fluid hoses.
24.
Worn, frayed, or improperly routed
electrical harnesses.
Bent, worn or out-of-phase driveline
U-joints and slip fittings.
23.
IMPORTANCE OF PROPER
FLUID LEVEL
a. Transmission Fluid. Transmission fluid cools,

lubricates, and transmits hydraulic power. Always
maintain the correct fluid level. If the level is too low,
the torque converter and clutches do not receive
enough fluid and the transmission overheats. If the
ELECTRONIC FLUID LEVEL

CHECK (WHEN AN OPTIONAL
OLS IS PRESENTFULLFUNCTION PUSHBUTTON OR
LEVER SHIFT SELECTORS)
NOTE:
The Allison 4th Generation Controls full-function
pushbutton and lever shift selectors can display two
characters at one time. One character is displayed
under the SELECT label and one under the
MONITOR label.
21

a. Fluid Level Check Procedure
1. Park the vehicle on a level surface and shift to
N (Neutral). Apply the parking brake.
2. To enter oil level display mode:
Pushbutton shift selectorsimultaneously
press the (Up) and (Down) arrow

buttons once.
additional quarts of fluid will bring the fluid

level within the middle of the O K zone.
5. High fluid level (o L H I 0 #) is reported
when o L is displayed, followed by H I
and a number. H I indicates high fluid level
and the number indicates the number of
quarts the transmission is overfilled.
Example: O L H I 0 1 indicates one quart
of fluid above the full level.
Lever shift selectorpress the DISPLAY
MODE pushbutton once.
CAUTION:
NOTE:
The TCM may delay the fluid level check until the
following conditions are met:
The fluid temperature is above 60C (140F)
or below 104C (220F).

The transmission is in neutral.
The vehicle has been stationary for approxi-
mately two minutes to allow the fluid to settle.

The engine is at idle.
Indication of a delayed fluid level check for Allison

4th Generation Controls is a flashing display under
SELECT label and a digit countdown from 8 to 1
under MONITOR label.
3. Correct fluid level is reported when o L is
displayed (o L indicates the Oil Level Check
Mode), followed by o K o K. The o K
display indicates the fluid level is within the
correct fluid level zone. The sensor display and
the transmission dipstick may not agree
exactly because the oil level sensor
compensates for fluid temperature. Example:
o L o K o K indicates correct fluid level.
4. Low fluid level is reported when o L is
displayed followed by L o and a number.
L o indicates a low fluid level and the
number indicates the number of quarts of fluid
the transmission requires. Confirm a low fluid
level condition by making a manual fluid level
check. Example: o L L o 0 2 indicates two
22
A low or high fluid level causes overheating and

irregular shift patterns and if not corrected, can
damage the transmission.
6. Invalid for Display condition is reported when
o L is displayed, followed by and a
number. The displayed number is a fault code,
and indicates improper conditions or a system
malfunction. Example: o L 70 indicates
an Invalid for Display condition and fault
code 70.
7. Invalid for Display is activated when
conditions do not allow the fluid level to be
determined. Review the following codes and
conditions, and correct as necessary. If these
conditions cannot be corrected, contact the
nearest distributor or dealer in your area (look
in the telephone directory for the Allison
Transmission service outlet nearest you.)
Code
Cause of Code
OL 0X Settling time too short

OL 50 Engine speed (rpm) too low
OL 59 Engine speed (rpm) too high
OL 65 N (Neutral) must be selected
OL 70 Sump oil temperature too low
OL 79 Sump oil temperature too high
OL 89 Output shaft rotation
OL 95 Sensor failure
PREVENTIVE MAINTENANCE
NOTE:
is not clogged. If readings are still inconsistent,

contact your nearest Allison distributor or dealer.
Report sensor failure to a distributor or dealer

in your area. Refer to the Allison Transmission
website www.allisontransmission.com or a telephone directory for the Allison Transmission distributor or dealer nearest you.
26.
8. To exit the oil level display mode:

Pushbutton shift selectorpress any
pushbutton on the shift selector.

Lever shift selectorpress the DISPLAY
MODE button twice.
25.
MANUAL FLUID LEVEL

CHECK PROCEDURE
COLD CHECK (Figure 21)
CAUTION:
DO NOT start the engine until the presence of
sufficient transmission fluid has been confirmed.
Remove the transmission fluid dipstick and be
sure the static fluid level is near the HOT FULL
mark.
a. Purpose. The purpose of the Cold Check is to
determine if the transmission has enough fluid to be
operated safely until a Hot Check can be made.
b. Cold Check Procedure
WARNING!
If you leave the vehicle and the engine is running,
the vehicle can move suddenly and you or others
could be injured. If you must leave the engine
running, do not leave the vehicle until you have
completed all of the following procedures:
1. Park the vehicle on a level surface, chock the

wheels, and apply the parking brake.
Be sure the engine is at low idle (500800 rpm).
2. Run the engine at idle (500800 rpm) for at

least one minute with the transmission in
N (Neutral). Shift to D (Drive), then shift to
R (Reverse) to clear the hydraulic system of
air. Then, shift to N (Neutral) and allow the
engine to idle.
Apply the parking brake and emergency

brakes and make sure they are properly engaged.
3. With the engine running, remove the dipstick

from the tube and wipe clean.
Put the transmission in N (Neutral).
Chock the wheels and take any other steps

necessary to keep the vehicle from moving.
a. Preparation. Clean all dirt from around the end
of the fluid fill tube before removing the dipstick. Do
not allow dirt or foreign matter to enter the
transmission. Dirt or foreign matter in the hydraulic
system may clog passages and cause undue
transmission part wear or sticking valves.
b. Consistency of Readings. Always test the fluid
level reading at least twice using the Hot Check and
Cold Check procedures in Paragraphs 26 and 27.
Consistency (repeatable readings) is important to
maintaining proper fluid level. If inconsistent readings
persist, inspect the transmission breather to be sure it
4. Insert the dipstick into the tube and remove.

Read the fluid level. Repeat the procedure to
verify the reading.
5. If the fluid level is within the COLD
CHECK band, the transmission can be
operated until the fluid is hot enough to
perform a Hot Check. If the fluid level is not
within the COLD CHECK band, add or
drain as necessary to bring the fluid level to the
middle of the COLD CHECK band.
6. Perform a Hot Check at the first opportunity
after normal operating temperature is
reached7193C (160200F).
23

27.
HOT CHECK (Figure 21)
WARNING!
If you leave the vehicle and the engine is running,
the vehicle can move suddenly and you or others
could be injured. If you must leave the engine
running, do not leave the vehicle until you have
completed all of the following procedures:
4. Insert the dipstick into the tube and remove.

Read the fluid level. Repeat the procedure to
verify the reading.
5. If the fluid level is not within the HOT
CHECK band, add or drain as necessary to
bring the fluid level within the band. Safe
operating level is within the HOT CHECK
band on the dipstick (refer to Figure 21).
Put the transmission in N (Neutral).

Be sure the engine is at low idle (500800 rpm).
Apply the parking brake and emergency
brakes and make sure they are properly engaged.
Chock the wheels and take any other steps
necessary to keep the vehicle from moving.
CAUTION:
An accurate fluid level check cannot be made
unless the engine is idling (500800 rpm) in
N (Neutral), the transmission fluid is at the
proper temperature, and the vehicle is on a level
surface.
a. Purpose. The purpose of the Hot Check is to
determine if the transmission has enough fluid to be
operated safely.
KEEPING FLUID CLEAN
CAUTION:
Containers or fillers that have been used for
antifreeze or engine coolant solution must
NEVER be used for transmission fluid.
Antifreeze and coolant solutions contain ethylene
glycol which, if put into the transmission, can
cause clutch plate failure.
Prevent foreign material from entering the
transmission by using clean containers, fillers, etc. Lay
the dipstick in a clean place while filling the
transmission.
Calibration level marking
locations with respect to
transmission control module
splitline and fill tube
SCALE NONE
1. Operate the transmission in D (Drive) range

until normal operating temperature is reached:
7193C (160200F)
HOT
ADD
DIMENSION A
SEE CHART
BELOW
Sump temperature
DIMENSION C
If a transmission temperature gauge is not

present, determine fluid level when the engine
water temperature gauge has stabilized and the
transmission has been operated under load for
at least one hour.
2. Park the vehicle on a level surface and shift to
N (Neutral). Apply the parking brake and
chock the wheels. Allow the engine to idle
(500800 rpm).
3. With the engine running, remove the dipstick
from the tube and wipe clean.
24
COLD
ADD
82104C (180220F)
132.6 mm
(5.22 in.)
COLD
FULL
DIMENSION B
Converter-out temperature
FILL
TUBE
HOT
FULL
b. Procedure
28.
13.8 mm (0.54 in.) REFERENCE DIMENSION D

DETERMINED BY
TRANSMISSION
INSTALLATION
CONTROL MODULE
SPLITLINE
DIMENSION DIMENSION DIMENSION
106.7 mm
(4.20 in.)
76.2 mm
(3.00 in.)
66.0 mm
(2.60 in.)
V02511.00.01
Figure 21. Fluid Dipstick Markings
29.
FLUID RECOMMENDATIONS
Table 21. Transmission Fluid Preheating

Requirements
a. Fluid Type
1. The hydraulic fluids (oils) used in Allison
transmissions directly affect transmission
performance, reliability, and durability.
Recommended fluids for 4000 Product Family
applications are TranSyndTM, or other TES-295
fluid, and DEXRON-III. Type C-4 fluids are
also approved.
2. Some DEXRON-III fluids are also qualified
as Type C-4 fluids. To be sure the fluid is
qualified for use in Allison transmissions, look
for a DEXRON-III or Type C-4 fluid license,
or approval numbers on the fluid container, or
consult the lubricant manufacturer. Fluid types
such as Type F, and universal farm fluids may
or may not be properly qualified to use in your
Allison transmission. Consult your Allison
Transmission dealer or distributor before using
any fluid types except those fluids qualified for
use in Allison transmissions.
CAUTION:
Disregarding minimum fluid temperature limits
can result in transmission malfunction or
reduced transmission life.
3. When choosing the optimum viscosity grade of
fluid to use, duty cycle, preheat capabilities,
and/or geographical location must be taken
into consideration. Table 21 lists the
minimum fluid temperatures at which the
transmission may be safely operated. Preheat
with auxiliary heating equipment or by running
the equipment or vehicle with the transmission
in N (Neutral) for a minimum of 20 minutes
before attempting range operation.
Viscosity Grade
SAE 0W-20* or
TranSyndTM
DEXRON-III
SAE 10W
SAE 15W-40W
SAE 30W
SAE 40W
(Ambient Temperature Below

Which Preheat Is Required)
C
F
30
22
25
20
15
0
10
13
4
5
32
50
* Arctic as defined by MIL-PRF-46167B (was MIL-L-46167)
210. FLUID AND FILTER CHANGE

INTERVALS
CAUTION:
Transmission fluid and filter change frequency is
determined by the severity of transmission
service. More frequent changes may be necessary
than recommended in the general guidelines
when operating conditions create high levels of
contamination or overheating.
a. Fluid and Filter Changes. Change the main
filter after the first 8000 km (5000 miles) then follow
the recommended fluid and filter change intervals.
Table 22 is given only as a general guide for fluid and
filter change interval.
Local conditions, severity of operation or duty cycle
may require more or less frequent fluid change
intervals that differ from the published
recommended fluid change intervals of Allison
Transmission. Transmission protection and fluid
change intervals can be optimized by the use of
fluid analysis. Filters must be changed at or before
recommended intervals.
25
26
Main
12,000 Miles
(20 000 km)
6 Months
500 Hours
Internal
Overhaul
Lube/
Auxiliary
12,000 Miles
(20 000 km)
6 Months
500 Hours
Fluid
25,000 Miles
(40 000 km)
12 Months
1000 Hours
Main
25,000 Miles
(40 000 km)
12 Months
1000 Hours
Internal
Overhaul
GENERAL VOCATION
Filters
Lube/
Auxiliary
25,000 Miles
(40 000 km)
12 Months
1000 Hours
Overhaul
75,000 Miles
(120 000 km)
36 Months
3000 Hours
150,000 Miles
(240 000 km)
48 Months
4000 Hours
75,000 Miles
(120 000 km)
36 Months
3000 Hours
Overhaul
50,000 Miles
(80 000 km)
24 Months
2000 Hours
Overhaul
50,000 Miles
(80 000 km)
24 Months
2000 Hours
150,000 Miles
(240 000 km)
48 Months
4000 Hours
50,000 Miles
(80 000 km)
24 Months
2000 Hours
50,000 Miles
(80 000 km)
24 Months
2000 Hours
75,000 Miles
(120 000 km)
36 Months
3000 Hours
Local conditions, severity of operation or duty cycle may require more or less frequent fluid change intervals that differ from the
published recommended fluid change intervals of Allison Transmission. Transmission protection and fluid change intervals can be optimized
by the use of fluid analysis. Filters must be changed at or before recommended intervals.
Severe Vocation: All Retarders, On/Off Highway, Refuse, Transit, and Intercity Coach with duty cycle greater than one (1) stop per mile.
General Vocation: Intercity Coach with duty cycle less than or equal to one (1) stop per mile and all other vocations.
Overhaul
Schedule 3. Recommended Fluid and Filter Change Intervals (TranSynd/TES 295 Fluid)
2 inch Control Module (1.75 inch approximately)Requires Filter Kit P/N 29540493
75,000 Miles
(120 000 km)
36 Months
3000 Hours
NOTE: Change fluid/filters after recommended mileage, months, or hours have elapsed, whichever occurs first.
50,000 Miles
(80 000 km)
24 Months
2000 Hours
75,000 Miles
(120 000 km)
36 Months
3000 Hours
Schedule 2. Recommended Fluid and Filter Change Intervals (TranSynd/TES 295 Fluid)
4 inch Control Module (3.5 inch approximately)Requires Filter Kit P/N 29540494
Flushing Machines are not recommended due to inconsistencies in removing 100 percent of the used fluid.
NOTE: The following recommendations in Schedule 2 are based upon the transmission containing 100 percent of TranSynd fluid.
4000 Product Family Filter change intervals in Schedule 2 and 3 are only valid with the use of Allison Transmission Gold series filters.
Fluid
12,000 Miles
(20 000 km)
6 Months
500 Hours
SEVERE VOCATION
Filters
Schedule 1. Recommended Fluid and Filter Change Intervals (Non-TranSynd/Non-TES 295 Fluid)
4000 Product Family
Table 22. Transmission Fluid and Filter Change
4000 PRODUCT FAMILIES SERVICE MANUALALLISON 4th GENERATION
b. Fluid Analysis. Transmission protection and

fluid change intervals can be optimized by monitoring
fluid oxidation according to the tests and limits shown
in Table 23. Consult your local telephone directory
for fluid analysis firms. For consistent and accurate
fluid analysis, use only one fluid analysis firm. Refer
to the Technicians Guide for Automatic Transmission
Fluid, GN2055EN, for additional information.
Table 23. Fluid Oxidation Measurement Limits
Test
Limit
Viscosity
25% change from new fluid
Total Acid Number
+3.0* change from new fluid
* mg of KOH to neutralize a gram of fluid.
211. FLUID CONTAMINATION

CAUTION:
immediate action to prevent malfunction and possible

serious damage. The transmission must be completely
disassembled, inspected, and cleaned. Remove all
traces of the coolant and varnish deposits resulting
from engine coolant contamination. Replace friction
clutch plates contaminated with engine coolant.
c. Metal
CAUTION:
If excessive metal contamination has occurred,
replace the oil cooler and visually inspect all
bearings in the transmission.
Metal particles in the fluid (except for the minute
particles normally trapped in the oil filter) may
indicate internal transmission damage. When these
particles are found in the sump, the transmission must
be disassembled and closely inspected to find the
source. Metal contamination requires complete
transmission disassembly. Clean all internal and
external hydraulic circuits, cooler, and all other areas
where the particles could lodge.
Contaminated fluid can leave the oil cooler

contaminated. The cleanliness of the oil cooler
affects the cleanliness of the transmission fluid. If
there is any doubt about the cleanliness of the
cooler, replace the cooler.
212. FLUID AND FILTER

CHANGE PROCEDURE
a. Water
NOTE:
If only filters are being replaced, do not drain the
fluid.
1. At each fluid change, examine the drained

fluid for evidence of dirt or water. A normal
amount of condensation will appear in the fluid
during operation.
2. Obvious water contamination of the
transmission fluid requires inspecting and
pressure testing the cooler (heat exchanger) for
leaks between the water and fluid areas.
Transmission fluid in the water side of the
cooler (heat exchanger) is another sign of a leak.
NOTE:
Cooler water can also be contaminated by engine
oil; be sure to locate the correct source of cooler
water contamination.
b. Engine Coolant. Engine coolant (ethylene
glycol) in the transmission hydraulic system requires
a. Drain Fluid
WARNING!
Avoid contact with the hot fluid or the hot sump
when draining transmission fluid. Direct contact
with the hot fluid or the hot sump may result in
bodily injury.
1. Drain the transmission when the fluid is at
operating temperature7193C (160200F).
Hot fluid flows quicker and drains more
completely.
2. Remove the drain plug from the control
module and allow the fluid to drain into a
suitable container.
3. Examine the fluid
Paragraph 211.
as
described
in
27

b. Replace Filters (Figure 22)
4. Install six bolts 6 into each cover 5 and tighten

them to 5161 Nm (3845 lb ft).
CAUTION:
c. Refill Transmission
Do not interchange filters for the deep and

shallow sump. Installation of the wrong filter can
cause damage to the transmission.
1. To replace the oil filters remove twelve bolts 6,
two filter covers 5, two gaskets 4, two
O-rings 3, two O-rings 2, and two filters 1
from the bottom of the control module.
1. If removed, inspect the drain plug. Replace the

O-ring. Install the drain plug and tighten it to
2532 Nm (1825 lb ft).
2. After refill, determine if fluid level is correct
(refer to Paragraphs 25 through 27). Table
24 shows typical transmission fluid capacity.
NOTE:
2. When reinstalling parts lubricate and install

new O-rings 2 and 3 on each cover 5. Lubricate
O-ring inside filter 1 and push filter onto each
cover 5. Install new gasket 4 on each cover 5
and align holes in gasket with holes in cover.
CAUTION:
Do not use the bolts to draw filter covers to the
sump. This can damage the covers, seals, or sump.
3. Install filter 1 and cover 5 assemblies into the
filter compartment. Index each filter/cover
assembly to the holes in the channel plate/
sump. Push the filter/cover assemblies in by
hand to seat the seals.
LUBE
MAIN
The quantity of refill fluid will be less than the

transmission fluid capacity due to fluid remaining
in the external circuits and transmission cavities.
Use Table 24 as a guideline for determining fluid
quantity during refill.
Table 24. Transmission Fluid Capacity
4000 Product Family
Item Being Filled
Capacity*
4.00 inch Sump
PTO Provision
48.0 liters
51.0 quarts
4.00 inch Sump
No PTO Provision
45.0 liters
48.0 quarts
2.00 inch Sump
PTO Provision
41.0 liters
43.0 quarts
2.00 inch Sump
No PTO Provision
38.0 liters
40.0 quarts
Additional Fill For Cooler*

Direct-mount
Non-retarder
1.0 liter
1.1 quart
Additional Fill For Retarder Accumulator*

7
8
1
2
3
4
5
6
Remote
Accumulator
0.5 liter
0.5 quart
* Does not include hoses or fittings.

LUBE
213.
MAIN
BREATHER
V07321.02.00
Figure 22. Filter Change

28
a. Location and Purpose. The breather is located

on top of the transmission converter housing. It serves
to prevent air pressure buildup within the transmission
and must be kept clean and open.
preparations have been made before conducting the

transmission stall test.
1. The manufacturer concurs with performing a
full-throttle transmission stall test.
b. Maintenance
1. The amount of dust and dirt encountered will
determine the frequency of breather cleaning.
Use care when cleaning the transmission
exterior. Spraying steam, water, or cleaning
solution directly at the breather can force the
water or cleaning solution into the
transmission.
2. The engine programmable parameter for 0 rpm

transmission output speed is set higher than the
value expected at transmission stall speed.
2. Always use a properly sized wrench to remove

or replace the breather. Pliers or a pipe wrench
can crush or damage the breathers stem and
produce metal chips which could enter the
transmission.
5. Make sure the engine air induction system and

exhaust system have no restrictions.
214. TRANSMISSION STALL TEST

AND NEUTRAL COOL-DOWN
CHECK
a. Purpose. Stall testing is performed to determine
if a vehicle performance complaint is due to an engine
or transmission malfunction. Stall testing is a troubleshooting procedure onlynever perform a stall test as
a general examination or during routine maintenance.
Transmission stall speed is the maximum engine rpm
attainable when the engine is at full throttle and the
torque converter turbine is not moving, or stalled.
After a transmission stall test, compare the actual full
throttle engine speed at torque converter turbine stall
with specifications established by the vehicle manufacturer.
NOTE:
Engine speed data can be obtained from the vehicle
manufacturer, or from the equipment dealer or distributor. Some engine manufacturers provide a
programmable parameter to limit engine speed
when the transmission output speed is 0 rpm, such
as at a stop. This parameter should be set to a higher
value than the expected transmission stall speed before performing a stall test.
b. Stall Testing Preparation. If a transmission stall

test is to be performed, make sure the following
3. The vehicle is in an area in which a transmission stall test can be safely performed.
4. Make sure the fuel control linkage goes to full
throttle and does not stick when released.
6. Install a temperature gauge with the probe in

the transmission converter out (to cooler) line.
Allison DOC displays sump temperature
only.
7. Perform a Cold Check of the transmission fluid
level and adjust as necessary.
8. Connect Allison DOC to the vehicle
diagnostic data connector or install an accurate
tachometer (do not rely on the vehicle
tachometer).
9. Install wheel chocks.
10. A driver is in the drivers position.
11. The vehicles service/park brakes are fully applied.
WARNING!
To help avoid personal injury, such as burns,
from hot transmission fluid and/or to help avoid
equipment damage, do not stall the torque converter for more than ten seconds maximum and
monitor transmission fluid temperature. Immediately return the engine to idle if converter out
(to cooler) temperature exceeds 150C (300F).
Operating the transmission at high engine power
at transmission stall or near stall conditions
causes a rapid rise in the transmission fluid temperature. The fluid in the transmission torque
converter is absorbing all of the engine power
and the vehicle cooling system cannot dissipate
the excessive heat load. Extended operation under high heat load conditions causes transmission and cooling system damage, and can
possibly fail hydraulic lines causing leaking high
temperature fluid.
29

8. Record converter out (to cooler) temperature.
WARNING!
To help avoid personal injury and equipment
damage while conducting a transmission stall
test, the vehicle must be positively prevented
from moving. Apply the parking brake, the service brake, and chock the wheels securely. Warn
personnel to keep clear of the vehicle and its
travel path.
9. Reduce engine speed to idle and shift the transmission to N (Neutral).

10. Raise engine speed to 12001500 rpm for
two minutes to cool the transmission fluid.
11. At the end of two minutes, record converter out
(to cooler) temperature.
d. Driving Transmission Stall Test
c. Performing a Transmission Stall Test

1. Start the engine. While in neutral let the transmission warm to normal operating temperature:
Sump temperature: 7193C (160200F)
Converter out temperature: 82104C
(180220F)
2. Perform a Hot Check of the transmission fluid
3. Turn OFF all engine accessories.
4. Use Allison DOC For PCService Tool to
select fourth range. Using fourth range reduces
the torque imposed on the transmission and
driveline. Do not perform a transmission stall
test in Reverse.
CAUTION:
To help avoid transmission or driveline damage,
full throttle transmission stall tests must never be
performed in reverse range (all models) or low
ranges (7-speed models).
5. Notify personnel in the area to keep clear of
the vehicle.
6. Slowly increase engine rpm until engine speed
stabilizes.
7. Record engine speed.
CAUTION:
The transmission stall test procedure causes a
rapid rise in transmission fluid temperature that
can damage the transmission. Never maintain a
stall condition once engine speed stabilizes or
converter out (to cooler) temperature exceeds
150C (300F). During a stall condition, converter out temperature rises much faster than internal (sump) temperature. Never use sump fluid
temperature to determine the length of the stall
condition. If the stall test is repeated, do not let
the engine overheat.
210
NOTE:
If the vehicle is equipped with a smoke controlled or
an emission controlled engine or engine control
programming inhibits engine acceleration, the
following transmission stall test procedure can be
used.
CAUTION:
To help avoid personal injury and/or equipment
damage, a driving transmission stall test must be
performed by a trained driver and a qualified
technician.
e. Driving Transmission Stall Testing Preparation. If a transmission stall test is to be performed, make sure the following preparations
have been made before conducting the transmission stall test.
1. The manufacturer concurs with performing a
full-throttle stall test.
2. Engine programmable parameter for 0 rpm
output speeds are set higher than value expected for stall speed.
3. The vehicle is in an area in which a transmission stall test can be safely performed.
4. Make sure the fuel control linkage goes to full
throttle and does not stick when released.
5. Inspect the engine air induction system and exhaust system for restrictions.
6. Perform a Cold Check of the transmission fluid
7. Install a temperature gauge with the probe in
the transmission converter out (to cooler) line.
Allison DOC displays sump temperature
only.
8. Install an accurate tachometer (do not rely on
the vehicle tachometer).
9. Connect Allison DOC to the vehicle diagnostic data connector.
f. Performing a Driving Transmission Stall Test
1. Start the engine while in Neutral and let the
transmission warm to normal operating temperature
Sump temperature:
7193C (160200F)
Converter out temperature:
82104C (180220F)
2. Perform a Hot Check of the transmission fluid
11. Raise engine speed to 12001500 rpm for two

minutes to cool the transmission fluid. At the
end of two minutes, record converter out (to
cooler) temperature
g. Neutral Cool-Down Check Procedure
1. At the end of two minutes, converter out (to
cooler) fluid temperature should return to
within normal operating temperature range.
2. If the transmission fluid does not cool within
two minutes, the cause could be a stuck torque
converter stator or an issue with the transmission cooler, lines, or fittings.
h. Transmission Stall Test Results
3. Turn OFF all engine accessories.

4. While located in isolated area, begin the driving transmission stall test.
NOTE:
6. Operate the engine at 100 percent full throttle,

maximum governed speed.
Environmental conditions, such as ambient

temperature, altitude, engine accessory loss
variations, etc., affect engine performance/power.
Due to such conditions, stall speed can vary from
specification by +/-150 rpm and still be accepted as
within published stall speed.
7. With the engine at maximum governed speed,

begin gradually applying the vehicle service
brakes while maintaining 100 percent full
throttle.
If engine speed with the transmission stalled is more

than 150 rpm below the stall speed specified, an engine issue is indicated.
5. Select a hold range that will limit road speed

(usually 2nd or 3rd range). Never perform a
driving stall test in Reverse or Low range
(7-speed models).
8. When the vehicle comes to a complete stop,

record engine speed.
CAUTION:
If engine speed with the transmission stalled is more

than 150 rpm above specification, a transmission issue
is indicated.
The transmission stall test procedure causes a

rapid rise in transmission fluid temperature that
can damage the transmission. Never maintain a
stall condition once engine speed stabilizes or
converter out (to cooler) temperature exceeds
150C (300F). During a stall condition, converter out temperature rises much faster than internal (sump) temperature. Never use sump fluid
temperature to determine the length of the stall
condition. If the stall test is repeated, do not let
the engine overheat.
Conditions that can exist to cause stall speed to be

150 rpm above specification could be:
9. Record converter out (to cooler) temperature.
A low stall speed that is at least 33 percent lower than

the published stall speed could indicate an engine issue or a freewheeling stator in the torque converter.
10. Reduce engine speed to idle and shift the transmission to N (Neutral).
Transmission fluid cavitation or aeration.

Verify proper fluid level using the oil level
sensor, if equipped, or dipstick.
Slipping clutch.
Torque converter malfunction.
Sticking/damaged torque converter valve
211

215. READING CLUTCH
PRESSURES
C3
a. Purpose. Reading individual clutch pressures

helps to determine if a transmission malfunction is due
to a mechanical or an electrical problem. Properly
making these pressure readings requires transmission
and vehicle (or test stand) preparation, recording of
data, and comparing recorded data against
specifications provided.
C5
NOTE:
Determine if there are diagnostic codes set that are
related to the transmission difficulty you are
evaluating. Proceed to make mechanical
preparations for reading clutch pressures only after
codes have first been evaluated.
b. Transmission and Vehicle Preparation
CAUTION:
Be sure that the hydraulic fittings have the same
thread as the plugs removed (716-20 UNF-2A).
These fittings must be straight thread, O-ring
style. Failure to use properly threaded fittings
will damage the control module.
1. Remove the plug from the pressure tap and
install a hydraulic fitting and a pressure gauge
or transducer at each location where
measurement is desired (refer to Figure 23 or
Figure 24). Pressure gauge set J 26417-A is
available for this purpose. Refer to Table 25
for pressure levels expected.
2. Provide for engine speed to be monitored. (The
Allison DOC For PCService Tool may be
used.)
3. Be sure that transmission sump fluid
temperature can be measured. (The Allison
DOC For PCService Tool may be used.)
4. Be sure that the transmission has enough fluid
for cold operation until an operating
temperature fluid level can be set.
212
LU
MAIN
C2
C4
C1
V07322.00.02
Figure 23. Clutch Pressure Check Points

(Except 4700 and 4800 Models)
5. Bring the transmission to normal operating

temperature of 7193C (160200F). Inspect
for fluid leaks in the circuits being tested.
Repair leaks as needed. Be sure that fluid level
is correct.
c. Recording Data
1. The Allison DOC For PCService Tool
allows reading of individual range clutch
pressures with the vehicle stationary. Clutch
Test instructions are located in the Action
Request section of the Allison DOC For PC
Service Tool User Guide, GN3433EN. Follow
instructions to read clutch pressures in
individual ranges.
NOTE:
Read lockup clutch pressure by driving the vehicle in
a range where lockup can be obtained. Record the
pressure values at the engine speed and sump fluid
temperature values shown in Table 25. The lockup
clutch is functioning correctly when engine speed
and turbine speed values are equal as recorded
from the Allison DOC.
2. Operate the transmission at the conditions
shown in Table 25 and record engine speed,
transmission sump fluid temperature, main
pressure, and clutch pressures in the ranges
where a problem is suspected.
d. Comparing Recorded Data To Specifications
1. Be sure that engine speed and transmission
sump fluid temperatures were within the
values specified in Table 25.
6. Return the transmission to its original

configuration. (Remove instrumentation and
reinstall any components removed for the
pressure testing.)
LOCKUP
PRESSURE TAP
C6 PRESSURE TAP
(On left side of
adapter housing,
near the bottom)
MAIN
C4
2. Compare the main pressure and clutch pressure

data, recorded in Step B, with the
specifications in Table 25.
C1
C5
C3
C2
MAIN
LUBE
3. If clutch pressures are within specifications,

return the transmission and vehicle to their
original configuration and proceed with
electrical troubleshooting.
4. If clutch pressures are not within specification,
take corrective action to replace the internal
parts of the transmission necessary to correct
the problem.
5. Reread pressure values after the transmission
has been repaired.
DRAIN PLUG
OIL FILTER
COVERS
LUBE PRESSURE
TAP
CLUTCH PRESSURE
TAPS
V05596.01.00
Figure 24. 4700 and 4800 Models Clutch Pressure

Check Points (4700 and 4800 Models)
213
214
580620
4000 Product FamilyIdle
Neutral
Main Mod OFF
Neutral
Main Mod ON
Reverse
Main Mod OFF
Reverse
Main Mod ON
Low C (4000 7-Speed)
Main Mod OFF
Main Mod ON
1C
Main Mod OFF
1C
Main Mod ON
2C
Main Mod OFF
2C
Main Mod ON
Range
C1, C4
C1, C4
C1, C5
C1, C5
C1, C6
C1, C6
C3, C5
C3, C5
C5
C5
Clutches
Applied
15152055
(220300)
13101725
(190250)
14502055
(210300)
11701585
(170230)
12401725
(180250)
8701340
(125195)
12401725
(180250)
8701340
(125195)
12401725
(180250)
8701340
(125195)
Main
kPa (psi)
14402055
(210300)
12351725
(180250)
13752055
(200300)
10951585
(160230)
11651725
(170250)
7951340
(115195)
11651725
(170250)
7951340
(115195)
11651725
(170250)
7951340
(115195)
Range Clutch*
kPa (psi)
3.5 min
(0.5 min)
3.5 min
(0.5 min)
3.5 min
(0.5 min)
3.5 min
(0.5 min)
3.5 min
(0.5 min)
3.5 min
(0.5 min)
3.5 min
(0.5 min)
3.5 min
(0.5 min)
3.5 min
(0.5 min)
3.5 min
(0.5 min)
Lockup Clutch*
kPa (psi)
* To pass this specification, measured clutch pressures must be within 75 kPa (10 psi) of actual measured main pressure and still be within the minimum and maximum value of
this specification.
Engine
rpm
Transmission Model/Test
Type
Pressure Specifications
Table 25. Main Pressure and Clutch Pressure Specifications

(Sump Fluid Temperature 7193C; 160200F)
17801820
4000 Product FamilyHigh

Speed
C3, C5
C1, C6

C1, C5
C1, C4
C1, C4, LU
C1, C3
C1, C3, LU
C1, C2
C1, C4, LU
C2, C3
C2, C3, LU
C2, C4
C2, C4, LU
1C
2C
2L
3C
3L
4C
4L
5C
5L
6C
6L
C5
C5
Clutches
Applied
Neutral
Main Mod OFF
Neutral
Main Mod ON
Reverse
Range
18052055
(260300)
14151725
(205240)
18052055
(260300)
15501795
(225260)
15501795
(225260)
15501795
(225260)
10801365
(155200)
15501795
(225260)
10801365
(155200)
15501795
(225260)
10801365
(155200)
15501795
(225260)
10801365
(155200)
13451590
(195230)
10351235
(150180)
Main
kPa (psi)
17302055
(250300)
13401725
(195240)
17302055
(250300)
14751795
(215260)
14751795
(215260)
14751795
(215260)
10051365
(145200)
14751795
(215260)
10051365
(145200)
14751795
(215260)
10051365
(145200)
14751795
(215260)
10051365
(145200)
12701590
(185230)
9601235
(140180)
Range Clutch*
kPa (psi)
160240
(2335)
160240
(2335)
160240
(2335)
160240
(2335)
160240
(2335)
160240
(2335)
160240
(2335)
160240
(2335)
160240
(2335)
125200
(1830)
125200
(1830)
125200
(1830)
125200
(1830)
125200
(1830)
125200
(1830)
Lockup Clutch*
kPa (psi)
* To pass this specification, measured clutch pressures must be within 75 kPa (10 psi) of actual measured main pressure and still be within the minimum and maximum value of
this specification.
Engine
rpm
Transmission Model/Test
Type
Pressure Specifications
Table 25. Main Pressure and Clutch Pressure Specifications (contd)

(Sump Fluid Temperature 7193C; 160200F)
215

216. FLUID LEAK DIAGNOSIS
Most fluid leaks can be located and repaired by
visually finding the leak and replacing or repairing the
necessary parts. On some occasions, a fluid leak may
be difficult to locate or repair. The following
procedure may help in locating and repairing most
leaks.
1. Pour the specified amount of dye into the

transmission fill tube.
2. Operate the vehicle under normal operating
conditions as directed in the kit.
3. Direct the black light toward the suspected
area. The dyed fluid will appear as a brightly
colored path leading to the source.
a. Finding The Leak

1. Identify the fluid. Determine whether it is
engine oil, automatic transmission fluid, or
hydraulic fluid from a specific vehicle system.
2. Operate the vehicle to reach normal operating
temperature and park the vehicle. After a few
minutes, look for dripping fluid to identify the
approximate location of the leak.
3. Visually inspect around the suspected area.
Inspect all gasket mating surfaces for leaks. A
mirror is useful for finding leaks in areas that
are hard to reach.
4. If the leak still cannot be found, clean the
suspected area with a degreaser, steam, or
spray solvent. Completely clean and dry the
area. Operate the vehicle for several miles at
normal operating temperature and varying
speeds. After operating, visually inspect the
suspected leak area. If the leak is not located,
use the powder or black light and dye methods.
b. Powder Method
d. Possible Points of Fluid Leaks

and Their Causes
1. Transmission mating surfaces:
Bolts improperly tightened
Improperly installed or damaged gasket
Mounting face damaged
2. Housing:
Filler pipe seal damaged or missing
Filler pipe bracket dislocated
Oil cooler connector fittings loose or
damaged
Output shaft seals worn or damaged
Pressure port plugs loose
Porous casting
3. Converter end:
Converter seal damaged
1. Clean the suspected area.
Seal lip cut (inspect converter hub for
2. Apply an aerosol-type white powder, such as

foot powder, to the suspected area.
3. Operate the vehicle under normal operating
conditions.
4. Visually inspect the suspected area and trace
the leak path over the white powder surface to
the source.
c. Black Light and Dye Method
damage)
Garter spring missing from seal
Converter leak in weld area
Damaged or missing converter O-ring seal
Porous casting
4. Breather or fill tube:

Overfilledincorrect dipstick
NOTE:
A dye and black light kit is available for finding
leaks. Refer to the manufacturers directions when
using the kit. Refer to kit directions for the color of
the fluid and dye mix.
Plugged breather
Water or coolant in fluidfluid will appear
milky
Incorrect electronic fluid level indication
Drain-back holes plugged
216
5. Gaskets:
Output shaft surface scratched, nicked, or
Fluid level/pressure is too high

Plugged vent or drain-back holes
Improperly tightened fasteners or dirty/
damaged threads
Warped flanges or sealing surface
Scratches, burrs, or other damage to a
sealing surface
Damaged or worn gasket
damaged
Loose or worn bearing causing excess seal
wear
e. Repairing the Leak. Once the leak has been
located and traced to its source, repair the leaking
components. If a gasket is replaced, but the sealing
flange is bent, the new gasket will not repair the leak.
The bent flange must also be repaired.
217. OUTPUT FLANGE/YOKE AND

OIL SEAL MAINTENANCE
Cracked or porous casting

Improper sealant used (where applicable)
6. Seals:
Fluid level/pressure is too high
a. Disassembly (Figures 25 and 26)

1. Remove one bolt 8, retainer plug 7, O-ring 6,
and O-ring 5.
Damaged seal bore
2. Remove flange 3 or yoke 4. Inspect journal

sealing area. Minimum journal area diameter is
85 mm (3.346 inch).
Damaged or worn seal
3. Inspect slinger 2. Replace if damaged.
Improper installation
4. Remove oil seal 1 using tool J 24171-A or

equivalent.
Plugged vent or drain-back holes
Cracks in component
3
1
2
4
5
6
7
8
V06834.01.00
Figure 25. Output Flange and Oil Seal (Except 4700 and 4800 Models)
217

218. ON-VEHICLE MAINTENANCE
b. Assembly (Figure 25 and 26)

1. Install oil seal 1 using installer J 37031-A
(except 4700 and 4800 models) or J 43024 (4700
and 4800 models), and J 8092 or equivalent.
2. If removed, use special tool J 46150 to press a
new slinger 2 onto the flange or yoke.
The following may be serviced or removed with the

transmission mounted in the vehicle. Refer to the
indicated paragraph for removal instructions:
3. Install flange 3 or yoke 4.
Item
Paragraph
4. Install O-ring 5 on plug 7.
PTO(s)
42b
5. Insert bolt 8 through retainer plug 7.
Oil Fill Tube
42c(2)
6. Install an O-ring 6 over the threaded end of

bolt 8 so that the O-ring seats against the
retainer plug.
Remote Cooler Manifold
42c(3)
Input, Turbine, and

Output Speed Sensor
42c(7)
7. Install retainer plug 7 into the yoke or flange.

Tighten bolt 8 to 7080 Nm (5160 lb ft).
Control Module
42f
3
1
2
4
5
6
7
8
V05578.01.00
Figure 26. Output Flange and Oil Seal (4700 and 4800 Models)
218
SECTION 3GENERAL OVERHAUL INFORMATION

31.
SCOPE
This section provides general information for

transmission overhaul. The information provided
includes:
Tools and equipment required for overhaul
Replacement parts information
Cleanliness and careful handling
Cleaning and inspection
Assembly procedures
Transmission removal and installation
Locating wear data
Locating spring specifications
Locating torque specifications for plugs, bolts,
and nuts
32.
TOOLS AND EQUIPMENT
a. Improvised Equipment. A work table700 kg

(1500 pound) capacity (Figure 31) may be improvised.
b. Special Tools. Special tools are illustrated in
Figure 32 and Figure 33 and are identified in
Table 31 and Table 32.
c. Mechanics Tools and Shop Equipment. The
following tools, in addition to the common tools
ordinarily required, should be available.
Common hand tools, metric where required
Metric wrench set (sockets, box-end wrenches,
and Allen wrenches)
Snapring (retaining ring) pliers

Micrometer (metric preferred)
Depth micrometer (metric preferred)
Dial indicator set (metric preferred)
Metric headless guide bolts set
M16 eye bolt
M10 eye bolt
Suitable hoist900 kg (2000 lb) capacity
A 20 Nm (150 lb inch) torque wrench
A 500 Nm (350 lb ft) torque wrench
Clean, lint-free shop cloths (do not use waste
cloths)
A press for disassembly and assembly of
spring-loaded clutches and interference-fit parts
Containers for parts
Supply of wood blocks
Petrolatum
Container of mineral spirits for cleaning parts
WARNING!
Use appropriate safety equipment such as safety
glasses, safety shoes, and gloves.
CAUTION;
Caustic cleaning compounds will damage some
transmission parts. Use only mineral spirits to
clean transmission parts.
120 cm
(48 in.)
200 cm
(78 in.)
OIL DRAIN
60 cm
(24 in.)
OIL DRAIN
(BOTH SIDES)
10x10 cm
(4x4 in. LEGS)
STEEL TOP
TROUGH
16-GAUGE SHEET STEEL
35 mm (112 in.) DEEP
35 mm (112 in.) WIDE
5x15 cm
(2x6 in. BOARD)
FOR TOP FRAME
AND LEG BRACKETS
V00660.02
Figure 31. Work Table
31
6
11
7
10
14
12
15
13
17
18
19
16
22
21
20
23
26
24
27
25
28
31
29
NOTE: Objects are not shown to scale
V06922.02.00
Figure 32. 4000 Product Family Special Tools
32
30
GENERAL OVERHAUL INFORMATION

Table 31. 4000 Product Family Special Tools*
Kent-Moore Figure 32
Tool No.** Item No. Description
J 3940
1
Bearing Race Remover
J 8092
2
Drive Handle
J 24171-A
J 26417-A
J 29109
J 33163
3
29
4
5
J 33884
J 35923-2
J 35924
J 35926
J 37030-1
J 37030-2
J 37030-3
J 37031-A
J 37032
J 37033
J 37034
NA
19
7
24
17
18
20
22
9
10
15
Seal Remover
Pressure Gauge Set
Overhaul Stand
Valve Body Parts Tray Set (includes
J 33163-1 and J 33163-2)
Pressure Switch Test Block
C1 Spring Compressor (use with J 37030-3)
Main-Pressure Spring Remover/Installer
Transmission Holding Bracket
C1, C2, and C5 Spring Compressor Tool Base
Output Seal Installer
Input Seal Installer
Output Bearing Cup Installer (use with J 37034)
Output Bearing Installer/Drive Sleeve
J 37035
11
Spanner Nut Torque Tool Set
J 37036
12
J 37038
21
J 37040
J 37041
J 38548
J 38564
J 39534
J 39949
J 39954
J 41445
J 41462
J 42048
J 46150
J 47942
13
14
27
25
26
8
16
23
6
28
30
31
Turbine Shaft Bushing/Output Bushing/P2

Carrier Bushing Installer
P1 Carrier Bushing and Ground Sleeve Bearing,
Pump Body Bushing, and Bearing Retainer
Bushing Installer
Rotating Clutch Bushing Installer
Front Support Sleeve and PTO Bearing Installer
Torque Converter End Play Gauge
Torque Converter Bolt Tool
Wear Plate Rivet Installer
Torque Converter Cover Bushing Installer
Charging Pump Bushing Installer
Main-Pressure Relief Spring Compressor
Retarder Flow Valve Spring Compressor
Slinger Installer
Valve Body Spring Compressor
Reference
Paragraph
514c,e; 516a,c
217b; 53b; 55e; 56b,c; 57b;
510b; 511b; 514g; 516e
217a; 55b; 56a; 514c; 516a
215b
42a; 62a
518a
NA
57a,b
518e,h
42a; 62a
57a,b
514e,f; 516c,d; 517c
57a,b; 514e,f; 515f; 516c,d
62q,s
55e; 56c
514f,h; 515g,h
55e; 56b,c; 514f,g,h; 515g,h,i,j;
516d,e,f; 517d,e,f
514c,h; 515c,j; 516a,f; 517a,f;
62q,r,s,t
57b; 511b; 514g; 516e
55e; 56b, c; 510b
57b
55d; 56b
53b; 62v
42g
NA
53b
56c
42a; 62a
56a,b
514c,h; 515c,j
62z
518c,j
We believe this source and its tools to be reliable. These tools may be available from other manufacturers. General
Motors does not endorse, indicate any preference for, or assume any responsibility for the products or tools from
these firms, or for any such items that may be available from other sources.
**
Kent-Moore Tool Division, 29784 Little Mack, Roseville, Michigan 48066
33
10
9
23
11
14
24
17
16
15
25
12
19
18
20
13
21
NOTE: Objects are not shown to scale
V06923.02.00
Figure 33. 4700 and 4800 Model Special Tools
34
22

Table 32. 4700 and 4800 Model Special Tools*
Kent-Moore
Tool No.**
J 3940
J 8092
J 24171-A
J 35923-4
J 35926-A
Figure 33
Item
Number
1
2
3
11
13
J 35926-UPD
NA
J 37030-2
J 37030-3
J 37032
J 37033
J 37034
10
11
4
5
9
J 37035
J 37036
6
8
J 41445
J 42048
J 43020
J 43023
J 43024 -A
J 43025
J 43046
J 43047
J 43202
J 43278
12
23
15
16
17
18
19
20
21
7
J 43922
J 43975
22
14
J 46150
J 47942
24
25
Description
Bearing Race Remover
Drive Handle
Seal Remover
Spring Compressor Tool Base
Transmission Lifting Bracket (modified to lift
4700 and 4800 models)
Modification Template (used to modify J 35926 to
become J 35926-A)
C5 Spring Compressor
C1, C2, and C5 Spring Compressor Tool Base
Input Seal Installer
Output Bearing Cup Installer
Output Bearing Installer/Drive Sleeve
Spanner Nut Torque Tool Set
Turbine Shaft Bushing/Output Bushing/P2 Carrier
Bushing Installer
Retarder Flow Valve Spring Compressor
P3 Planetary Lifting Ring
P4 Planetary Bushing Installer
Output Shaft Seal Installer
C5 Return Spring
Torque Wrench Adapter
Bearing Installer/Remover
Output Shaft Bearing Installer
Output Shaft Holding Tool
Reference
Paragraph
515d,f; 517c
217b; 515i; 517e
217a; 515c; 517a
513d,e; 517d
42a; 62a
NA
515f,g; 517c
515f,g; 517c
NA
516d; 517d
513d,e,f; 515g,h,i,j;
517d,e,f; 62r,t
515c,j; 517a,f; 62r,s,t
515i; 517e
42a; 62a
515c,j
42n; 62k
513f
217b; 62r,t
513d,e; 517d
42m; 62l
513d,e
515i; 517e
514h; 515j; 516f;
517a,f; 62r,t
Measuring Blocks And Straight Edge
62m,n
4700 and 4800 Model Tool Kit (Includes the following NA
special tools: J 43020, J 43023, J 43024, J 43025,
J 43046, J 43047, J 43202, J 43278, and J 43922)
Slinger Installer
62z
Valve Body Spring Compressor
518c,j
We believe this source and its tools to be reliable. These tools may be available from other manufacturers. General
Motors does not endorse, indicate any preference for, or assume any responsibility for the products or tools from these
firms, or for any such items that may be available from other sources.
**
Kent-Moore Tool Division, 29784 Little Mack, Roseville, Michigan 48066
35

33.
REPLACEMENT PARTS
a. Ordering Information. Refer to the current issue

of 4000 Product Family Parts Catalog PC2456EN for
parts information. Do not order replacement parts
using the reference numbers in this service manual.
b. Parts Normally Replaced at Overhaul. The
following parts are normally replaced at each
transmission overhaul:
Gaskets
Lockstrips
Washers or retaining rings damaged by
removal or abnormal wear

Oil seals and piston sealrings
Spiral retaining ring 4 (Foldout 8)
Suction filter 5 (Foldout 11)
CAUTION:
Seal all openings and the breather before steam
cleaning the transmission. The material on
friction-faced clutch plates, the bonding agent,
and clutch housing machined surfaces can be
damaged by water, steam cleaning, or
unapproved solvents and detergents. Use only
mineral spirits to clean friction-faced clutch
plates and clutch housings.
1. Clean all metallic transmission parts, except
bearings and friction-faced clutch plates, by
steam cleaning or with mineral spirits. Do not
use caustic soda solution for steam cleaning. If
steam cleaning, do not allow steam or water to
enter the transmission. Clean friction-faced
clutch plates and bearings with mineral spirits
only.
2. Dry all parts, except bearing assemblies, with
compressed air. To prevent rust, lubricate
steam-cleaned parts as soon as they are dry.
WARNING!
Do not burn discarded Teflon seals; toxic gases
are produced by burning Teflon.
34.
b. Cleaning Transmission, Parts
3. Clean fluid passages by working a piece of soft

wire through the passages and flushing them
with mineral spirits. Dry the passages with
compressed air.
CAREFUL HANDLING
Handle parts and subassemblies carefully to prevent

nicking, scratching, and denting. Parts that fit together
closely and have a specific operating clearance can
bind if damaged. Parts that depend upon smooth
surfaces for sealing may leak if scratched. Control
valve body assembly parts are especially susceptible
to leaking if scratched (valves, when dry, must move
freely by their own weight). Handle these parts
carefully and protect them during removal, cleaning,
inspection, and installation. Keep control valve body
assembly parts in clean containers until installation.
4. Examine parts, especially fluid passages, after

cleaning to make certain they are entirely
clean. Re-clean parts if necessary.
5. Removal of minor defects with such items as
crocus cloth, honing stones, and scrapers
produces debris and residue. Cover adjacent
parts, ports, and cavities before removing
defects. Thoroughly reclean the affected areas
after rework.
c. Cleaning Bearings
WARNING!
35.
CLEANING AND INSPECTION
a. Dirt Causes Malfunction. All parts must be

clean to permit effective inspection. Do not allow dirt
or foreign material to enter the transmission during
assembly. Even minute particles can cause close-fit
parts, such as valves, to malfunction.
36
Never dry bearings by spinning them with

compressed air. A spinning bearing can
disintegrate, allowing balls or rollers to become
lethal flying projectiles. Also, spinning a bearing
without lubrication can damage the bearing.
1. Bearings that have been in service should be
thoroughly cleaned in mineral spirits.

2. Soak particularly dirty bearings or ones filled
with hardened grease in mineral spirits before
trying to clean them.
If a bearing is not installed immediately, wrap
3. Before inspection, lubricate bearings with

transmission fluid.
f. Inspecting Cast Parts and Machined Surfaces
d. Inspecting Bearings
CAUTION:
If excessive metal contamination has occurred,
replacement of all bearings is recommended.
1. Inspect bearings for rough rotation. Replace a
bearing if its rotation is still rough after
cleaning and lubrication.
2. Inspect bearings for scored, pitted, scratched,
cracked, or chipped races, and for excessive
roller or ball wear. Replace the bearing if any
of these defects are found.
3. Inspect a defective bearings bore and mating
shaft for grooved, burred, or galled conditions
that indicate the bearing has been turning in the
bore or on the shaft. If shaft or bore damage
cannot be repaired with crocus cloth, replace
the defective part.
4. When removing a bearing, do not apply
pressure across the balls. This can cause
brinelling and bearing failure.
or cover the lubricated bearing with clean

paper or lint-free cloth to keep out dust.
1. Inspect bores for wear, scratches, grooves, and

dirt. Remove scratches and burrs with crocus
cloth. Clean the part. Replace parts that are
deeply scratched or grooved.
2. Inspect all fluid passages for obstructions. If an
obstruction is found, remove it with
compressed air, or by working a soft wire back
and forth through the passage and flushing it
with mineral spirits.
3. Inspect mounting faces for nicks, burrs,
scratches, and foreign matter. Remove any
defects with crocus cloth or a soft stone. Clean
the part. If scratches are deep, replace the
defective part.
4. Inspect threaded openings for damaged
threads. Chase damaged threads with a
correctly sized tap. Clean the part.
5. Inspect the ribs inside the main housing for
reaction plate wear grooves in the side of the
ribs. Replace housings that have wear grooves
beyond wear limits. (Refer to Wear Limits,
Table 71 in Section 7.)
6. Replace housings or other cast parts that are
cracked.
5. If a bearing must be removed or installed

without the proper tool, press only on the
race which is adjacent to the mounting
surface.
7. Inspect all machined surfaces for damage that

could cause fluid leakage or other malfunction.
Rework or replace defective parts.
e. Keeping Bearings Clean. Ball or roller bearing

failures are usually caused by dirt or grit in the
bearing. Keep bearings clean during removal and
installation. Observe the following rules to be sure
maximum bearing life:
8. Inspect the oil tracks of the control module and

main housing for porosity, broken lands,
cracks, dirt, and land surface imperfections.
These imperfections will cause severe fluid
leakage leading to transmission failure.
Do not unwrap new bearings until they are to
be installed.
Do not remove the grease in which new
bearings are packed until they are to be

installed.
Do not lay bearings on a dirty bench. Place
bearings on clean paper, or lint-free cloth.
g. Inspecting Bushings and Thrust Washers

1. Inspect bushings for scores, burrs, sharp edges,
and evidence of overheating. Remove scores
with crocus cloth. Remove burrs and sharp
edges with a scraper or knife blade. Before
reinstalling, carefully check bushings for signs
of distress. Clean the part.
37

i. Inspecting Gears
CAUTION:
When removing a defective bushing, do not
damage the bushing bore.
2. Replace bushings that are out-of-round, deeply
scored, or excessively worn. Inspect parts
mated to bushings to be sure they are not
damaged or worn beyond use.
3. Inspect thrust washers for distortion, scores,
burrs, and wear. Replace a thrust washer if
defective or worn.
h. Inspecting Sealrings and Gaskets
1. Inspect piston sealrings and lip-type seals for
nicks, cuts, tears, splits, and pattern damage. A
damaged seal can indicate rough or sharp
edges in piston grooves or on a mating surface
that could damage a new seal.
2. Inspect piston sealring grooves for nicks, burrs,
dents, or displaced metal that could damage
the new seal. Remove raised metal, sharp
edges, burrs, or nicks with a soft stone and
crocus cloth. Thoroughly clean all residue
from the piston before assembly.
3. Replace all composition gaskets.
4. Inspect hook-type sealrings for wear, broken
hooks, and distortion. Install a new hook-type
sealring if the old ring shows any wear on its
outside diameter, or if there is excessive side
wear. Install a new sealring if there is wear on
the sealring outside diameter mating surface.
5. Inspect clutch housing sealing surfaces for
nicks, burrs, dents, or displaced metal that
could interfere with mating parts or damage
the piston seal. Remove raised metal, sharp
edges, burrs, or nicks with a soft stone and
crocus cloth. Thoroughly clean all residue
from the housing before assembly.
6. Measure butt-joint sealring end gap by
inserting the sealring into its respective sealing
bore. Use a feeler gauge to measure end gap.
Discard sealrings that do not meet
specifications. Refer to Table 71, Wear Limits
Data, in Section 7.
38
1. Inspect gears for scuffed, nicked, burred, or

broken teeth. If a defect cannot be removed
with a soft stone, replace the gear.
2. Inspect gear teeth for wear that has changed
the original tooth shape. If this condition is
found, replace the gear.
3. Inspect the thrust face of gears for scores,
scratches, and burrs. Remove such defects with
a soft stone. If scratches and scores cannot be
removed with a soft stone, replace the gear.
Thoroughly remove all residue from surface.
4. Inspect gears for load pattern and signs of
distress. Any sign of distress indicates that a
gear failure during operation is possible.
Reusing distressed gears is an individual
customer decision based upon experience.
Backlash cannot be used to establish critical
gear wear. Backlash tolerances are of such
nature that a gear usually pits, scuffs, scores, or
galls long before gear wear becomes critical.
j. Inspecting Splined Parts
1. Inspect splined parts for stripped, twisted,
chipped, or burred splines. Remove burrs with
a soft stone. Replace the part if other defects
are found. Spline wear is not considered
harmful except where it affects the fit of the
splined parts. Thoroughly remove all residue
from surface.
2. Spline wear is determined by measuring and
comparing the unworn and worn areas of the
spline. This can also be checked by comparing
feeler gauge thickness to the depth of the worn
area. Replace parts having excessive spline
wear. Refer to Table 71, Wear Limits Data, in
Section 7.
3. Backlash cannot be used to establish critical
spline wear. Accurate backlash measurement
requires the mating parts to be concentrically
located.
k. Inspecting Threaded Parts. Inspect threaded
parts for burred or damaged threads. Remove burrs
with a soft stone or fine file. Replace damaged parts.
Thoroughly remove all residue from surface.

l. Inspecting Retaining Rings. Inspect all retaining
rings for nicks, distortion, or excessive wear. Replace
the retaining ring if any of these defects are found. The
retaining ring must snap tightly into its groove to
function properly.
m. Inspecting Springs. Inspect springs for signs of
cracking, overheating, permanent set, or wear due to
rubbing adjacent parts. Replace the spring if any of
these defects are found. Refer to Table 72, Spring
Data, in Section 7.
n. Inspecting Clutch Plates (Figure 34)
1. Inspect friction-faced clutch plates for burrs,
embedded metal particles, severely pitted
faces, loose faces, excessive wear, cone,
cracks, distortion, shallow oil groove depth, or
damaged spline teeth. Remove burrs using a
soft stone. Replace plates which have any
defects. Remove all residue from part.
2. Inspect steel plates for burrs, scoring,
excessive wear, excessive cone, distortion,
embedded metal, galling, cracks, breaks, or
damaged tangs. Remove burrs and minor
surface irregularities using a soft stone.
Replace plates which have any non-repairable
defects. Remove all residue from part.
3. The amount of clutch plate cone is determined
by measuring the distance between the inside
diameter of the plate and a level surface
(Figure 34). Discard plates having excessive
cone. Refer to Table 71, Wear Limits Data, in
Section 7.
4. Determine oil groove depth with a depth
micrometer or by measuring the smooth
surface (total) thickness of the plate, measuring
the thickness of the steel part of the plate at the
oil groove, and subtracting this measurement
from the total thickness. Replace plates not
having the minimum oil groove depth. Refer to
Table 71, Wear Limits Data, in Section 7.
LEVEL SURFACE
o. Inspecting Swaged And Interference-Fit Parts.

If there is evidence of looseness, replace the assembly.
p. Inspecting Sealing Surfaces
1. Inspect surfaces in contact with hook-type and
butt-joint sealrings for step wear, nicks,
scratches, and scoring. Use a soft stone or
crocus cloth to remove only the raised metal
portion of these defects. Polishing the area to
remove a defect is neither necessary nor
desirable. If the defects are too severe to
correct, replace the defective part. Remove all
residue from part.
2. Inspect surfaces in contact with spring-loaded,
lip-type oil seals for nicks, scratches,
roughness, or other surface irregularities.
Inspect for embedded particles, step wear, and
dirt on flanges or other components exposed to
external contamination. Remove the defects
and restore the finish. Replace the part if scores
or scratches permit fluid leakage. Remove all
residue from part.
36.
ASSEMBLY PROCEDURES
a. Parts Lubrication. During final assembly,

lubricate all moving parts with transmission fluid. The
fluid will help protect friction surfaces and ferrous
metals until the unit is in service.
b. Grease Used for Assembly. During assembly use
oil-soluble grease with a low melting point
(petrolatum) to temporarily retain parts, butt-joint
sealrings, scarf-cut sealrings, and hook-type sealrings.
c. Sealing Compounds and Nonsoluble Greases.
Do not use gasket-type sealing compounds, fibrous
greases, or nonsoluble vegetable-base cooking
compounds inside the transmission or where they
could be flushed into the transmission hydraulic
system.
d. Clutches and Pistons
1. Soak each friction-faced clutch plate (twominute minimum) in transmission fluid before
final assembly.
CLUTCH PLATE
2. Apply a generous amount of transmission fluid

to the piston cavity before final assembly.
MEASURE HERE FOR CONE

V00493.01
Figure 34. Method Of Measuring Clutch Plate Cone
3. Assemble clutch plates so that the cone of each

plate faces the same direction.
39

e. Threaded Plugs and Hydraulic Fittings
h. Butt-Joint Sealrings
CAUTION:
CAUTION:
Teflon
Do not use
tape on threaded parts
where slivers can enter the transmission and
cause a malfunction.
Improperly installed plugs or fittings can
cause leakage and cracked housings.
Threaded plugs in 4000 Product Family transmissions
are the straight-thread, O-ring type. Be sure that the
O-ring is in like-new condition and tighten all plugs to
the torque value specified in the assembly procedure or
in the exploded views.
f. Coated Threaded Fasteners. Control module
bolts are manufactured with a band of sealant on the
threads. Coated bolts may be reused, however repeated
removal and installation may reduce the effectiveness
of the coating. If fluid leaks are detected around the
bolts, replace the coated bolts. Do not attempt to
re-apply a sealing compound. The coated bolts sizes
are M10 x 1.5 x 55 mm and M10 x 1.5 x 100 mm.
g. Lip-Type Oil Seals
1. When replacing lip-type seals, make sure the
spring-loaded lip is toward the fluid to be
sealed (toward the inside of the unit). Coat the
inside of the seal with high temperature grease
(MIL-G-3545A or equivalent) to protect the
seal during shaft installation and to provide
lubrication during initial operation.
2. The circumference of some seals is precoated
with a dry sealant. The sealant is usually
colored for easy identification. Precoated seals
do not require any additional sealant before
installation.
If humidity is allowed to penetrate and expand a

butt-joint sealring, the sealring can be damaged
during installation. A damaged sealring will
permit transmission fluid to leak from the clutch
piston cavity and cause clutch slippage. Do not
open the sealed package until you are ready to
install the sealring.
1. Butt-joint sealrings require special handling
during assembly. The sealrings contain
materials that absorb moisture from the
atmosphere causing the sealring to expand.
Check sealring end clearance before
installation to make sure the sealring has not
expanded.
2. Remove the sealring from its package and
place the sealring in its operational position
inside the bore that it will be sealing.
3. Use a feeler gauge to check the end clearance
of the sealring. The end clearance must not be
less than the specifications. Refer to the
respective rebuild Steps in Section 5.
4. If the end clearance is less than specifications,
bake the sealring in an oven at 93149C
(200300F) for 24 hours or get a new
sealring. Repeat Steps (2) and (3).
5. Pack the sealring and its groove with a liberal
amount of oil-soluble grease.
6. Roll the sealring to about half its free diameter
and hold it for about 10 seconds. Being careful
not to spread the sealring more than necessary,
slide it onto the hub. Place one end of the
sealring into the groove and gradually work the
seal into the groove.
i. Bearings
3. Before installation, apply a non-hardening

sealant to the circumference of seals not
precoated with a dry sealant.
310
1. When removing a bearing, do not apply

pressure across the balls. This can cause
brinelling and bearing failure.

2. If a bearing must be removed or installed
without an installation sleeve, drive or press
only on the race which is adjacent to the
mounting surface. If a press is not available,
carefully seat the bearing with a drift and a
hammer, driving against the supported race.
j. Bushings. Whenever a new bushing is being
installed, NEVER allow the pressing tool to bottom
against a needle thrust bearing. ALWAYS make sure
that the pressing tool bottoms against the part that the
bushing is being pressed into.
k. Electrical Components. For inspection and
repair of electrical components, refer to the 3000 and
4000 Product Families Troubleshooting Manual
TS3989EN.
37.
REMOVING TRANSMISSION
FROM VEHICLE (Figure 35)
NOTE
A significant amount of fluid may drain from a
hydraulic hose when it is disconnected from the
transmission.
4. Disconnect all hydraulic hoses from the
transmission. If a retarder is installed,
disconnect the accumulator line from the
retarder housing. Remove the hoses from the
vehicle if they interfere with the transmission
removal. Plug all openings to keep dirt from
entering the hydraulic system.
5. If an integral cooler is used, drain coolant from
the cooler and disconnect coolant hoses.
Remove the hoses from the vehicle if they
interfere with transmission removal. Plug all
openings to keep dirt from entering the cooling
system.
b. Disconnecting Controls
a. Drain Fluid
WARNING!
Avoid contact with the hot fluid or the hot sump
when draining transmission fluid. Direct contact
with the hot fluid or the hot sump may result in
bodily injury.
1. Drain the transmission fluid before removing
the transmission from the vehicle. The
transmission fluid should be warm to promote
complete drainage.
2. Remove the drain plug from the control
module. Examine the drained fluid for evidence
of contamination (see Paragraph 211).
Reinstall the drain plug. If the drain plug
threads are damaged, see Paragraph 212 for
corrective action.
3. Remove transmission fill tube if it interferes
with transmission removal.
1. Disconnect or completely remove controls. If

controls are not removed from the
transmission, position them so that they do not
interfere with transmission removal.
2. Loosen bolt in 20-way
feedthrough harness connector.
transmission
3. Disconnect the transmission external harness

from the 20-way transmission feedthrough
harness connector. Also disconnect the external
harness from the engine, output, and turbine
speed sensors (Figure 35). Place a cover on
the transmission electrical connector to keep
out dirt. Also be sure to disconnect the
transmission feedthrough harness from the
harness bracket.
4. If PTO(s) are used, disconnect the PTO(s)
harness.
5. Disconnect the transmission external harness
from the retarder temperature sensor and the
retarder control valve body.
c. Uncoupling Transmission From Vehicle and
Engine Driveline
WARNING!
DO NOT disconnect the hydraulic fluid line
between the accumulator and the retarder until
air and hydraulic pressure have been bled from
the line.
1. Disconnect the vehicle drive shaft from the

transmission output flange or yoke. Position
the disconnected shaft to avoid interference
with removing the transmission.
311
OUTPUT
SPEED
SENSOR
REAR
COOLER
PORTS
FRONT COOLER
PORTS (OPTIONAL)
FRONT
REAR (WITHOUT RETARDER)

PTO CONTROLS
AND LINES
OUTPUT SPEED SENSOR

RETARDER
TEMPERATURE
SENSOR
ACCUMULATOR LINE
(RETARDER ONLY)
TURBINE
SPEED SENSOR
REAR COOLER PORTS

RETARDER K SOLENOID CONNECTOR
REAR (WITH RETARDER)
ENGINE SPEED SENSOR
RIGHT SIDE
V07323.01.00
Figure 35. Disconnection Locations
2. Transmissions with PTOs require uncoupling

one of the following:
PTO from transmission
PTO drive shaft from the PTO
3. If the transmission supports the rear of the

engine, place a jack or other support under the
engine.
4. Securely support the transmission with a hoist,
jack, or other suitable removal equipment.
38.
WEAR LIMITS
Refer to Table 71, Wear Limits Data, in Section 7, for

information covering part fits, clearances, and wear
limits.
39.
SPRING SPECIFICATIONS
Refer to Table 72, Spring Data, in Section 7, for

spring identification and specifications.
5. Remove all bolts, nuts, washers, spacers, and

supports that attach the transmission to the
vehicle and the engine.
310.
d. Removing the Transmission

1. Move the transmission away from the engine
approximately 106 mm (4.17 inch) until it is
completely clear of the engine. Remove the
adapter ring and/or gasket (if used).
2. Raise or lower the transmission as necessary to
remove it from the vehicle.
312
TORQUE SPECIFICATIONS
Assembly procedures in Sections 5 and 6 specify

the torque requirements for all plugs, bolts, and
nuts. Torque values are also presented with the
foldout illustrations in the back of this manual.
Torque values specified are for dry assembly, except
when otherwise noted. Wash and dry bolts and
washers before assembly.
SECTION 4TRANSMISSION DISASSEMBLY

41.
SCOPE
a. Mounting Transmission on Repair Stand
a. Section. This section covers disassembly of 4000

Product Family transmissions. The disassembly sequence is continuous and includes all models.
b. Procedures. When a procedure does not apply to
your specific model, go to the next applicable
procedure.
c. Illustrations. Illustrations will not always show
your model, but when an operation is identical for all
models, the correct procedure is shown.
d. General Information. Refer to Sections 3 and 7
for general information as follows:
Paragraph
32
33
34
35
37
71
72
Title
Tools and Equipment
Replacement Parts
Careful Handling
Cleaning and Inspection
Removing Transmission From Vehicle
Wear Limits Data
Spring Data
1. Mount holding bracket J 35926 or J 35926-A

(4700 and 4800 models), with holding bracket
J 41445 attached, onto the main housing
module.
2. Attach a hoist, making sure lifting attachments
are placed so that the transmission is balanced,
and raise the transmission to the mounting face
of the overhaul stand.
3. Secure the transmission holding fixture to
overhaul stand J 29109.
b. Removal of Power Takeoff (Figure 41)
NOTE:
Each PTO has eight mounting bolts, two studs, and
a gasket. Removal instructions are for a
transmission with a single left-side or top mounted
PTO. If your transmission has more than one PTO
or the PTO is mounted in a different location, use
the same procedure to remove the PTO(s).
e. Foldouts. Refer to Foldouts 4 through 12 for

exploded views.
1. Remove eight PTO mounting bolts 1.

Carefully remove PTO assembly 2, and
gasket 3.
42.
2. Inspect two PTO studs 4 for damage and

remove if necessary.
DISASSEMBLY OF
TRANSMISSION
c. Removal of External Parts

(Figures 42 and 43)
WARNING!
PREVENT PERSONAL INJURY
Use proper tools and lifting equipment when
installing or removing a transmission from the
repair stand.
Transmission dry weights are as follows:
4000 Product Family (except 4700 and 4800
models)
Base Transmission
377 kg (831 lb)
With PTO Provision
405 kg (893 lb)
With Retarder
411 kg (906 lb)
With PTO and Retarder 439 kg (968 lb)
4000 Product Family (4700 and 4800 models)
Base Transmission
493 kg (1087 lb)
With PTO Provision
521 kg (1149 lb)
With Retarder
527 kg (1162 lb)
With PTO and Retarder 555 kg (1224 lb)
1. Inspect transmission breather 20 for damage or

an obstruction. Remove if necessary for
replacement or cleaning.
NOTE:
If your transmission is PTO equipped and you have
not removed the PTO(s), return to Paragraph 42b.
2. Remove screw 5 retaining oil fill tube bracket 6
to the main housing module. Remove
bracket 6, fill tube 8, seal 9, and dipstick 7.
3. Remove six bolts 12 retaining remote cooler
manifold 11 to the main housing module.
Remove remote cooler manifold 11 and
gasket 10.
41
2
4
3
1
2
4
V06836
Figure 41. PTO Removal
20
ENGINE
SPEED
SENSOR
2
TURBINE 1
SPEED
SENSOR
7
5
9
OUTPUT
SPEED
SENSOR
15
13
16
10
11
17
18
19
12
14
V06837.03.00
Figure 42. Removal of Externally Mounted Parts
42
TRANSMISSION DISASSEMBLY
7. Remove bolt 4, retainer 3, speed sensor 2, and
O-ring 1 from the converter housing module
(engine speed sensor), main housing module
(turbine speed sensor), and rear cover or
retarder (output speed sensor). Refer to Figure
43 for sensor locations.
d. Removal of Integral Oil Cooler (Figure 44)
1. Remove two bolts 11 and seventeen bolts 12.
Remove cover 13, gasket 14, and two
O-rings 10.
2. Remove plate assembly 9 and four O-rings 8.
ENGINE
SPEED SENSOR
OUTPUT
SPEED SENSOR
TURBINE
SPEED SENSOR
3. Remove nine bolts 7 and nine washers 6.

Remove cooler housing 3 and gasket 1.
e. Removing Integral Retarder Sump Oil Cooler
(Foldout 12,C)
V09786.00.00
1. If used and not already removed, remove the

retarder accumulator hose from the fitting on
cooler manifold 16.
Figure 43. Speed Sensors
4. Remove bolt 19.
2. If not already removed, remove inlet and outlet

water hoses from hose adapter 2 on the cooler
manifold 16.
5. Remove flange 15 or yoke 14. Remove

O-ring 17, retainer plug 18, and O-ring 16.
6. Inspect journal sealing area for minimum
allowed diameter of 85.0 mm (3.346 inch).
3. Remove six bolts 5.
3
1
11
4
5
8
2
6 7
8
19
18 17
19
18 17
11
15
9
10
10
16
11
12
14
13
11
V06843
Figure 44. Integral Oil Cooler
43

WARNING!
To help avoid personal injury, securely support
the cooler before removing the bolts retaining the
cooler to the manifold. The cooler weighs 30 kg
(64 lbs); use care when handling the cooler.
4. Support cooler 7 to prevent it from falling from
manifold 16.
5. Remove sixteen M10 x 1.5 x 60 bolts 1.
6. Remove inlet and outlet water hose adapters 2
from cooler manifold 16. Remove two
gaskets 3.
7. Remove cooler assembly 7.

8. Remove two gaskets 6 from the cooler.
9. Rotate the transmission so that the retarder is
facing up.
10. Remove seven M10 x 1.5 x 187.5 bolts 9.
11. Remove M10 x 1.5 x 50 bolt 8.

12. Remove three M12 x 1.75 x 195 bolts 10.
13. Remove cooler manifold 16.
f. Removal of Control Valve Module

(Figure 45)
WARNING!
Get help when lifting the control module.
Assistance from a hoist or another person may be
required.
The
control
module
weighs
approximately 25 kg (55 lb).
1. Remove forty-three bolts 3 and 4 retaining
control module 1 to the main housing module,
including the bolts retaining the filter covers.
2. Loosen control module 1 by applying pressure
at the reinforced tabs or use jack bolts, inserted
into the control module bolt holes that bottom
against the main housing module.
3. Remove covers and filters if a handhold is
needed to remove the control module.
4. Remove control module assembly 1 and
gasket 2.
44
4
V09785.00.00
14. Remove gasket 4.
Figure 45. Control Module Removal
g. Removal of Torque Converter Module

(Figure 46)
1. Remove any brackets installed to prevent
torque converter movement.
2. Keep the torque converter cover from turning
by using a heel bar, two bolts, and a
screwdriver (Figure 46, View C).
3. Remove threaded plug 2 and O-ring 1 using a
34 inch Allen wrench (Figure 46, View A).
4. Attempting to loosen bolt 3 may cause the
turbine and turbine shaft to rotate. Hold the
turbine and turbine shaft stationary by using
one of the methods listed below:
If the control module is removed, insert a
screwdriver into the vanes on the rotating

clutch module (Figure 46, View B).
If the control module is in place, apply the
lockup clutch by applying restricted air

pressure through the lockup pressure tap
located on the main housing (Figure 46,
View D). Insert a heel bar into a torque
converter housing bolt hole. Insert two bolts
into the flexplate adapter bolt holes. Then
place a screwdriver at an angle to prevent
converter rotation (Figure 46, View C).
5. Using converter bolt tool J 38564, remove
bolt 3.
6. Remove selective shim 4 located under bolt 3
(Figure 46, View A).
CUPPED END DOWN
5
1
7. Attach a sling to the flexplate adapter by

positioning the adapter connections an equal
distance from each other. Using a chain
hoist, carefully lift torque converter
module 5 out of the converter housing
8. Place two wooden blocks on the workbench,
spaced to support the torque converter module
and high enough for the converter hub to clear
the workbench. Lower the converter module,
converter hub down, onto the blocks.
RESTRICT MOVEMENT
USE HOIST AND SLING
J 38564
VIEW A
VIEW B
LOCKUP
PRESSURE
TAP
VIEW C
VIEW D
VL06840.01.00
Figure 46. Torque Converter Module Removal
45

h. Removal of Converter Housing Module
(Figure 47)
NOTE:
Proceed to Paragraph 42 sub-paragraph shown
below by output module configuration and model.
NOTE:
Seven converter housing retaining bolts 3 are
removed from inside converter housing 1. Use
mechanical fingers or a similar tool to remove these
bolts.
iRetarder (except 4700 and 4800 models)

jRetarder (4700 and 4800 models)
kRear Cover (except 4700 and 4800 models)
1. Remove twenty-five bolts 3 that retain

converter housing 1 to main housing module 4.
lRear Cover (4700 and 4800 models)
2. Using the same sling used for removing the

converter module, lift straight up on converter
housing module 1 to remove it.
i. Removal of Retarder Module (Except 4700

and 4800 Models) (Figure 48)
3. Remove main housing gasket 2 from converter

housing 1 or from main housing module 4.
1. Remove twelve bolts 2, three bolts 3, two

bolts 4, four bolts 5, and four bolts 6 that
secure retarder module 1 to main housing
module 8. If used, remove the rear support
bracket.
WARNING!
Get help when lifting the retarder module.
required. The retarder module weighs
1
3
2. Thread an M14 eye bolt into the retarder

output shaft and lift retarder module 1 from
main housing module 8.
3. Remove retarder gasket 7 from main housing

module 8 or from retarder module 1.
V07335
Figure 47. Converter Housing Module Removal
2
2
1
2
8
7
4
6
3
6 5
2
5
5
3
OR
3
V06844
Figure 48. Removal of Retarder Module (Except 4700 and 4800 Models)
46
1
4
2
4
4
4
3
5
7
4
7
9
6
9
OR
7 8
V06845
Figure 49. Removal of Retarder Module (4700 and 4800 Models)
j. Removal of Retarder and Output Shaft Module

(4700 and 4800 Models) (Figure 49)
1. Remove twelve bolts 4, three bolts 6, two
bolts 7, four bolts 8, and four bolts 9 that
secure retarder module 5 to main housing
module 1. If used, remove the rear support
bracket.
2. If used, remove the rear support bracket.

3. Thread an M10 or M14 eye bolt into the output
shaft and lift upward to remove rear cover
module 3.
4. Remove rear cover gasket 2 from main housing
module 1 or from rear cover module 3.
WARNING!
2. Thread an M14 eye bolt into the retarder
output shaft and lift retarder module 5 from
main housing module 1.
3. Remove retarder gasket 3 from main housing
module 1 or from retarder module 5.
1
2
k. Removal of Rear Cover Module (Except 4700

and 4800 Models) (Figure 410)
1. Remove nineteen bolts 5 and washer 4, if
present.
V06846
Figure 410. Rear Cover Module Removal
47

l. Removal of Rear Cover and Output Shaft
Module (4700 and 4800 Models)
(Figure 411 and Figure 412)
1. Remove fourteen bolts 4 (Figure 412). Remove
five bolts 5.
2. If used, remove the rear support bracket.
3. Thread an M14 eye bolt into output shaft 7
(Figure 411) and lift upward to remove rear
cover module 6.
4. Remove rear cover gasket 3 from C6 adapter
housing module 2 or from rear cover module 6.
m. Removal of C6 Adapter Housing Module

1. Remove fourteen bolts 3 that secure the C6
adapter housing module 4 to main housing
module 1 using special tool J 43046.
WARNING!
Get help when lifting the C6 adapter housing
module. Assistance from a hoist or another
person may be required. The C6 adapter housing
module weighs approximately 68 kg (150 lb).
1
2
4
2. Attach a sling to the C6 adapter housing

module 4 with the legs of the sling equally
spaced on the module. Using a chain hoist,
carefully lift the C6 adapter housing module 4
from the transmission.
3. Remove and discard C6 adapter housing

gasket 2.
4. Remove and discard eleven tolerance rings 5.
V05580
Figure 411. Removal of Rear Cover and Output

Shaft Module
J 43046
BOLT, M12 x 1.75 x 45

(14) MARKED 4
4
4
4
BOLT,
METRIC HEAVY
(5) MARKED 5
4
4
5
5
5
V05374
V07494
Figure 412. Rear Cover and Output Shaft Module Bolts
48
Figure 413. Removal of C6 Adapter Housing Module

(4700 and 4800 Models)
n. Removal of P3 Planetary Module
p. Removal of P2 Module, C5 Clutch Plates,

and P1 Module (Figures 416 and 417)
1. Lift P2 planetary module 1 from the main
housing module (Figure 417).
1. Remove selective shim 5.

2. Remove shim locating ring 4.
3. Remove P4 shaft flange 3.
4. Attach special tool J 43020 to P3 planetary 2.
Attach chain hoist and lift from transmission.
o. Removal of Main Shaft Module (Figure 415).
Remove main shaft module assembly 1 from the
transmission.
2. Lift C5 clutch pack from the main housing

moduleeight friction plates 3 and nine steel
reaction plates 2 (Figure 416).
3. Measure the thickness and cone of each
friction plate 3. Minimum thickness is
3.48 mm (0.137 inch). Maximum allowable
cone is 0.25 mm (0.010 inch).
4. Measure thickness and cone of each steel
reaction plate 2. Minimum thickness is
5. Lift P1 planetary module 1 from the

transmission (Figure 417).
2
3
4
5
1
J 43020
C5
2
3
V05375
Figure 414. Removal of P3 Planetary Module

E02516.01
Figure 416. P2 Module and C5 Clutch Plates
WIDE RATIO MODELS
1
CLOSE RATIO MODELS
3
V01737.00.06
E01271.01
Figure 415. Removal of Main Shaft Module
Figure 417. P1 Module
49

q. Removal of Front Support/Charging Pump
Module and Rotating Clutch Module
(Figures 418 and 419)
1. Remove seven bolts 1 and seven bolts 2 that
retain front support and charging pump
module 3 to the main housing module
(Figure 418).
2. Lift front support and charging pump module 3
over the turbine shaft and away from the main
housing module.
CAUTION:
Always remove the turbine speed sensor before removing the rotating clutch module to
avoid possible damage to the turbine speed
sensor.
When you remove rotating clutch module 1,
carefully place it on the workbench and prevent it from rolling off the bench.
3. Using a hoist and an M16 eye bolt, lift turbine
shaft and rotating clutch module 1 (Figure 419)
from the main housing module and place it on
the workbench.
2
3
r. Removal of C3/C4 Clutch Assembly From

Main Housing Module (Figure 420)
CAUTION:
Make sure the main housing module is
horizontal when removing the C3/C4 clutch
assembly.
1
1. Remove fourteen bolts 3 retaining C3/C4

clutch assembly 1 in main housing module 2.
2. Remove the C3/C4 clutch assembly by sliding
it out of the input end of the main housing.
V01272
Figure 418. Removal of Front Support/Charging

Pump Module
3. Remove the main housing from the repair

stand for cleaning.
4. Inspect the main housing C5 clutch plate
splines. Maximum wear allowed is 1.15 mm
(0.045 inch).
1
3
E01273.01
Figure 419. Removal of Rotating Clutch Module
410
E01274.01
Figure 420. Removal of C3/C4 Clutch Module
SECTION 5MODULE REBUILD

51.
SCOPE
7. Remove turbine hub assembly 17 from torque

converter cover assembly 6.
a. Section. This section describes the disassembly

and assembly of the modules removed in Section 4.
b. Procedures. During rebuild procedures, refer to
the exploded views (Foldouts 4 through 12) in the
back of this manual.
52.
GENERAL INFORMATION
FOR MODULE REBUILD
Refer to Sections 3 and 7 for general overhaul

information as follows:
Paragraph
32
33
34
35
36
71
72
Description
Tools, Equipment
Replacement Parts
Careful Handling
Cleaning and Inspection
Assembly Procedures
Wear Limits Data
Spring Data
8. Remove stator assembly 20.

9. If replacement is necessary, remove thrust
bearing race 32 from torque converter pump
assembly 33.
10. Remove thrust bearing assembly 18 from the
turbine. Remove turbine hub sealring 16. Place
turbine hub sealring 16 into its mating bore.
Measure the ID of the sealring at the maximum
distance from the hook. Replace the sealring if
the maximum ID of 61.77 mm (2.432 inch) is
exceeded. Inspect and measure the OD of the
turbine hub 17. Minimum OD wear is
66.69 mm (2.626 inch).
11. Remove pump thrust bearing assembly 30,
race 29, and selective shim 28.
12. Remove retaining ring 21.
13. Remove star plate 19.
14. Remove stator thrust plate assembly 22 and
measure its thickness. Minimum thickness
allowed is 9.45 mm (0.372 inch).
15. Remove stator thrust washer 23.
53.
TORQUE CONVERTER MODULE
a. Disassembly (Foldout 4,B)

1. Before disassembling the torque converter,
note balance marks or mark a line across the
converter cover to the pump assembly with a
scribe. Aligning these marks will make sure
the torque converter is correctly assembled and
reduce balance problems.
2. Place torque converter module 4 on a flat
surfacepump drive tangs downward.
3. Remove thirty-six nuts 5 from the OD of
torque converter cover 7.
4. If replacement is necessary, remove damaged
T-head bolt(s) 34 from the OD of torque
converter pump assembly 33.
5. Carefully remove torque converter cover
assembly 6 from pump assembly 33. Avoid
damage to their sealing surfaces.
6. Remove O-ring 31 used between the cover
assembly and pump assembly.
16. Remove and inspect stator race 24, thirteen

springs 25, and rollers 26.
17. From torque converter cover assembly 6, remove forty-four bolts 14 retaining lockup
clutch backplate 13 to torque converter cover
assembly 7.
18. Remove lockup clutch backplate 13. Measure
the thickness of the backplate wear surface.
Minimum thickness allowed is 11.79 mm
(0.464 inch). Measure for distortion of the
lockup clutch backplate. Maximum distortion
19. Remove lockup clutch damper assembly 12
from torque converter cover assembly 6. Measure the thickness of the lockup clutch. Minimum thickness allowed is 8.51 mm
(0.335 inch). Measure for distortion of the
lockup clutch. Maximum allowable distortion is
0.51 mm (0.020 inch). Measure spline wear between the turbine hub and the lockup clutch
damper. Maximum allowable wear is 0.38 mm
(0.015 inch) on either spline.
51
4000 PRODUCT FAMILY SERVICE MANUAL

20. Remove lockup clutch piston assembly 10. Remove inner sealring 9 and outer sealring 11
from the lockup piston assembly. Measure the
thickness of the lockup piston assembly. Minimum thickness allowed is 6.53 mm
(0.257 inch).
SPRING (End of spring

may be up or down)
Roller to be installed in
small end of cam pocket
STATOR CAM
21. Inspect the ID of cover bushing 8. Maximum

ID of the bushing allowed is 66.91 mm
(2.634 inch). Remove the bushing if
replacement is necessary.
22. Inspect converter pump hub 33. Minimum OD
is 88.99 mm (3.504 inch).
23. Remove thrust bearing assembly 15.
b. Assembly (Foldout 4,B and Figure 51)
1. Install stator race 24 into stator and cam
assembly 27.
2. Install thirteen springs 25 and stator rollers 26
into stator and cam assembly 27. Be sure
springs and rollers are installed as shown in
Figure 51. Use oil-soluble grease to help hold
the springs and rollers in place.
3. Install thrust washer 23 and thrust plate
assembly 22 onto stator and cam assembly 27.
Install star plate 19.
4. Install retaining ring 21.
5. Do not install selective shim 28 at this time.
Install thrust bearing race 29 and bearing
assembly 30.
Figure 51. Stator Roller/Spring Installation
9. Install thrust bearing assembly 15 in converter

cover 7.
10. Install lockup piston sealring 9 on the hub of
converter cover 7 and lockup piston sealring 11
on the OD of lockup piston assembly 10. Install the lockup clutch piston.
11. Install lockup clutch damper assembly 12 into
cover 7.
12. Install lockup clutch backplate 13.
13. Install forty-four bolts 14. Tighten the bolts to
2429 Nm (1821 lb ft).
14. Install the turbine hub sealring 16 onto turbine
assembly 17. Install the turbine hub
assembly 17 into torque converter cover assembly 6 aligning balance mark on the turbine
with the balance mark on the lockup clutch
damper.
15. Install stator assembly 20.
CAUTION:
When installing thrust bearings, make sure that
the locating lip on either the inner or outer thrust
bearing race is not preventing the race from
contacting the thrust surface of the mating part.
Failure to do this leads to premature thrust
bearing failure and incorrect shim selection to
maintain proper internal part clearance.
6. Install thrust bearing assembly 18.
7. If removed, press a new bushing 8 into cover 7
bushing bore using J 39949 bushing installer
and J 8092 drive handle.
8. Install new sealring 16 onto turbine hub and
insert turbine assembly 17 into the new
bushing and inspect for freedom of rotation.
52
V01360.03.00
16. If removed, install thirty-six T-head bolts 34

into the flange of converter pump assembly 33.
If removed, install pump thrust bearing race 32
into torque converter pump assembly 33.
17. Install O-ring 31 onto converter cover assembly 6. With balance marks or scribe mark
aligned, place converter pump assembly 33
over the top of converter cover assembly 6.
18. Install four nuts 5, evenly spaced, onto four
T-head bolts 34. Tighten the nuts to 3035 Nm
(2226 lb ft).
19. Using a depth micrometer, measure from the
top of the drive tang surface to the thrust surface of the turbine hub. This is dimension A
(Figure 52).
MODULE REBUILD
DRIVE TANG SURFACE
THRUST
SURFACE
OF
TURBINE
HUB
DIM.
SHIM (30) LOCATION
DRIVE TANG SURFACE
DIM.
THRUST
SURFACE
OF
TURBINE
HUB
J 38548
E02517.01
Figure 52. Torque Converter Selective Shim
26. Perform the measurement again. Dimension C

must be 0.080.36 mm (0.0030.014 inch). If
dimension C is correct, proceed with Step (28).
20. Turn the converter on its side and insert tool

J 38548, with bolt removed, into the converter
plug bore. Turn the torque converter so that it
rests on tool J 38548. Repeat the same measurement as in Step (19). This is dimension B.
27. If dimension C is not correct, then a shim

change is needed. Disassemble the converter
and reassemble without shim 28, and go back
to Step (18).
21. Subtract dimension B from dimension A to get

dimension C (AB=C).
22. Dimension C must be 0.080.36 mm (0.003
0.014 inch). If dimension C is correct, proceed
with Step (28).
28. Install the remaining thirty-two nuts 5 onto T-head

bolts 34. Tighten all the nuts to 3035 Nm
(2226 lb ft).
23. If dimension C is not correct, then a shim is

needed. Select the proper shim from Table 51
and proceed with Step (24).
NOTE:
24. Disassemble the converter and reassemble using selected shim.
For models without PTO provision, proceed
with Paragraph 54.
25. Install four nuts 5, evenly spaced, onto four

T-head bolts 34. Tighten the nuts to 3035 Nm
(2226 lb ft).
For models with PTO provision, skip Para-
graph 54 and proceed with Paragraph 55.
Table 51. Torque Converter Selective Shims

Dimension C
Use P/N
Shim Thickness
0.080.36 mm (0.0030.014 inch)
0.360.58 mm (0.0140.023 inch)
29503879
0.230.27 mm (0.0090.011 inch)
0.580.81 mm (0.0230.032 inch)
29503880
0.460.48 mm (0.0180.019 inch)
0.810.99 mm (0.0320.039 inch)
29503881
0.690.711 mm (0.0270.028 inch)
53

54.
TORQUE CONVERTER
HOUSING MODULE
(Models Without PTO Provision)
a. Disassembly (Foldout 5,A)

1. If not previously removed, remove bolt 7,
speed sensor retainer 6, and engine speed
sensor assembly 4. Measure engine speed
sensor resistance (speed sensor resistance
varies by temperature).
Resistance (Ohms) Temperature (C) Temperature (F)
250
40
40
340
20
68
450
110
230
CAUTION:
Use the correct wrench size to avoid crushing the
vent assembly.
b. Assembly (Foldout 5,A)

1. Install engine speed sensor assembly 4, speed
sensor retainer 6, and bolt 7. Tighten the bolt to
2429 Nm (1821 lb ft).
CAUTION:
vent assembly.
2. Install breather assembly 2. Torque breather
assembly to 1216 Nm (912 lb ft).
4. Remove eleven bolts 2 holding bearing

retainer assembly 3 and PTO gear assembly 10
into converter housing 19.
5. Remove bearing retainer assembly 3 and PTO
gear assembly 10. If necessary, use jack bolts
to loosen the bearing retainer assembly.
b. Disassembly of Bearing Retainer
(Foldout 5,B)
1. Remove sealrings 8 and 9 from bearing
retainer 7. Remove oil seal assembly 4 using
tool J 24171-A.
2. Inspect bushing 6 for damage or wear.
Maximum allowable bushing ID is 89.19 mm
(3.511 inch). Remove the bushing if damaged or
worn.
1. Remove oil pump drive hub 13 from PTO

gear 12.
2. Inspect oil pump drive hub for excessive wear
on drive tangs. Maximum allowable tang wear
is 0.31 mm (0.012 inch).
3. Remove sealring 14 from PTO gear 12. If
damaged, press two bearings 11 from PTO
gear 12.
d. Assembly of PTO Gear Assembly
(Foldout 5,B)
1. Press two bearings 11 onto the PTO gear using
tool J 37041.
3. Skip to Paragraph 56.
TORQUE CONVERTER
HOUSING MODULE
(Models With PTO Provision)

1. If not previously removed, remove bolt 18,
speed sensor retainer 17, and engine speed
sensor assembly 15. The engine speed sensor
must have a resistance of 300 30 Ohms.
CAUTION:
vent assembly.
54
3. If present, remove ten bolts 24 or 27, PTO

cover 25 or 28, and gasket 26 or 29.
c. Disassembly of PTO Gear Assembly

(Foldout 5,B)
2. Remove breather assembly 2.
55.
2. Remove breather assembly 20.
CAUTION:
Oil pump drive hub 13 can be incorrectly
installed backwardsposition the oil pump
drive hub tangs toward the oil pump.
2. Install oil pump drive hub 13 into PTO gear 12,
aligned with hub tangs toward the oil pump.
3. Insert sealring 14 into the sealing bore of pump
housing 10 (Foldout 6,A) and measure end gap
with feeler gauges. Sealring end gap must be
1.181.66 mm (0.0470.065 inch). Refer to
Paragraph 36h.
MODULE REBUILD
4. Remove sealring 14 (Foldout 5,B) from the
seal bore and install the sealring onto PTO
gear 12.
e. Assembly of Bearing Retainer Assembly
(Foldout 5,B)
1. If removed, install bushing 6 using a press, and
tools J 37038 and J 8092.
2. Install sealring 9 onto bearing retainer 7. Install
oil seal 4 using a press, and tools J 37032 and
J 37034.
3. Insert sealring 8 into the sealing bore in PTO
gear 12 and measure the end gap using feeler
gauges. Sealring end gap must be 1.181.66 mm
(0.0470.065 inch). Refer to Paragraph 36h.
4. Remove sealring 8 from sealing bore and
install the sealring onto bearing retainer 7.
f. Assembly (Foldout 5,B)
1. Using a mallet, lightly tap PTO gear
assembly 10 into converter housing 19 until
the gear assembly is seated.
2. Use guide bolts to install bearing retainer
assembly 3, rocking the retainer while
installing it.
3. Install eleven bolts 2 to hold bearing retainer
assembly 3 and PTO gear assembly 10 to
housing 19. Tighten the bolts to 5161 Nm
(3845 lb ft).
4. If used, install PTO covers 25 or 28 and
gaskets 26 or 29 using ten bolts 24 or 27 in
the cover. Tighten the bolts to 5161 Nm
(3845 lb ft).
5. Install engine speed sensor assembly 15 and
engine speed sensor retaining bolt 18. Tighten
the bolt to 2429 Nm (1821 lb ft).
CAUTION:
breather.
6. Install breather 20. Tighten the breather to
1216 Nm (912 lb ft).
56.
FRONT SUPPORT AND OIL

PUMP MODULE

1. Remove three sealrings 25 from the hub of
front support 20.
2. Remove eight bolts 6 retaining pump housing
assembly 7 or 10 (PTO unit) to front support
assembly 15.
3. Remove pump housing assembly 7 or 10 and
gear set 11.
4. On models without PTO, remove O-ring 4 and
oil seal assembly 5 using tool J 24171-A.
5. Measure gear-cavity depth of pump housing 9
or 10. Maximum depth allowed is 19.04 mm
(0.750 inch) (Figure 53).
6. Measure gear-cavity diameter of pump
housing 9 or 10. Maximum ID allowed is
150.25 mm (5.915 inch) (Figure 54).
7. For models without PTO provision, inspect
bushing 8 inside pump housing 9 for wear or
damage. Measure the ID of the pump bushing.
Maximum ID allowed is 89.19 mm
(3.511 inch).
8. If worn or damaged, remove bushing 8 from
pump housing 9.
9. Install gear set 11 into pump housing 9.
Measure pump gear side clearance of both
gears. Maximum allowable clearance is
0.10 mm (0.004 inch) (Figure 55).
55
PUMP
HOUSING
MAX DEPTH OF
GEAR CAVITY
19.04 mm (0.75 in.)
PUMP
HOUSING
DRIVE
GEAR
MAX SIDE
CLEARANCE
0.10 mm (0.004 in.)
DRIVEN GEAR
V02518
V01899.01
Figure 53. Measuring Gear-Cavity Depth

of the Pump Housing
Figure 55. Measuring Gear Side Clearance

of the Pump Housing
PUMP
HOUSING
MAX GEAR TOOTH

TIP CLEARANCE
0.15 mm (0.006 in.)
MAX ID OF
GEAR CAVITY
150.25 mm (5.915 in.)
V02519
V01277.01
Figure 56. Measuring Gear Tooth Tip Clearance

Figure 54. Measuring Gear-Cavity Diameter
of the Pump Housing
10. Measure gear tooth tip clearance. Maximum

allowable clearance is 0.15 mm (0.006 inch)
(Figure 56).
11. Measure driven gear to pump housing clearance. Maximum clearance allowed is 0.30 mm
(0.012 inch) (Figure 57).
12. Inspect bushing 12 that is inside the inner
(drive) gear of gear set 11. Measure the ID of
bushing 12. The maximum allowable ID is
66.93 mm (2.635 inch).
13. If bushing 12 is damaged or worn, remove the
bushing.
56
PUMP HOUSING
DRIVEN GEAR
MAX CLEARANCE BETWEEN

DRIVEN GEAR OD AND PUMP
HOUSING 0.30 mm (0.012 in.)
V02520
Figure 57. Measuring Driven Gear Clearance

to the Pump Housing
MODULE REBUILD
14. Remove fourteen bolts 14 retaining the wear
plate 13 to front support 20. Remove wear
plate 13.
15. If damaged, remove roller bearing 26 from
front support 20 using a drift and hammer.
16. Measure the OD of front support sleeve 21.
Minimum diameter is 119.81 mm (4.717 inch).
Also inspect for wear. If worn or damaged, remove front support sleeve 21 from front support 20.
17. If damaged, remove dowel pins 19 from front
support 20.
18. If worn or damaged, remove ground sleeve 16
or 17 by pressing ground sleeve from front
support 20.
19. Compress spring 22, using tool J 41462, until
load is removed from dowel pin 24. Remove
dowel pin 24 and carefully release the load on
spring 22 by rotating the handle on tool
J 41462 in the counter-clockwise direction.
When spring 22 has reached its free length, remove tool J 41462. Remove spring 22 and ball
23 from the front support 20.
4. If removed, install ground sleeve 16 or 17.

Place front support 20 on press bed. The
machined flat at the base of the ground sleeve
must align with the arrow cast on the front
support (Figure 58, View C). Press ground
sleeve 16 or 17 into front support 20 to
shoulder. Total runout of spline OD may not
exceed 0.13 mm (0.005 inch).
5. If removed, install dowel pins 19. Press the
pins to a height of 14.5 mm (0.57 inch) from
the surface of front support 20.
6. If removed, align the lubrication hole in
sleeve 21 with the relief valve bore (bottom of
front support), and install front support sleeve
21 using a press and tools J 37041 and J 37034.
Refer to Figure 58, View B.
7. Install wear plate 13. Secure with fourteen
bolts 14. Tighten the bolts to 5161 Nm
(3845 lb ft).
8. Install bearing 26 using a press, and tools
J 37038 and J 8092. Press bearing 26 flush to
0.25 mm (0.010 inch) below the surface.
c. Assembly of Pump Housing (Foldout 6,A)
NOTE:
20. Inspect for damage in the ball seat area of front

support 20. Measure tension of spring 22 and
compare to value in Table 72, Spring Data, in
Section 7.
b. Assembly of Front Support
(Foldout 6,A and Figure 58)
1. Replace front support 20 if damage to the ball
seat or other area was found.
Steps (1), (2), and (3) below apply only to

transmissions without PTO provision.
1. If removed, install bushing 8 into pump
housing 9 using a press, and tools J 37038 and
J 8092.
2. Install oil seal 5 using a press, and tools
J 37032 and J 37034.
3. Install O-ring 4.
2. Replace spring 22 if spring load did not meet

load specifications.
3. Install ball 23 and spring 22 into front
support 20. Compress spring 22 using tool
J 41462 until dowel pin 24 can be inserted to
retain spring 22. Remove tool J 41462.
4. If removed, install bushing 12 into drive

(inner) gear of gear set 11. Align the staking in
the pre-staked bushing with the slots in the
inside gear of gear set 11. Use tool J 39954.
5. Lubricate pump gear set 11 and install the gear
set in pump housing 9 or 10.
57

FRONT
TOP
FRONT SUPPORT (20)

DOWEL PINS
(19 )
DOWEL PIN
14.5 mm
(0.57 in.)
GROUND SLEEVE
INSTALL
REMOVE
SPLINE OD T.I.R.
0.30 mm
(0.012 in.)
E
SECTION E-E
BOTTOM
VIEW A
RELIEF VALVE
BORE
VIEW B
To install, align flat on
ground sleeve with arrow
on front support.
GROUND SLEEVE (16 OR 17)
20
VIEW C
V01344.00.04
Figure 58. Ground Sleeve Removal and Installation
6. Retain the pump housing to the front support with

eight bolts 6. Tighten the bolts to 5161 Nm
(3845 lb ft).
7. Measure the end gap of three rotating
sealrings 25 before installation. Insert the
sealrings into the rotating clutch hub bore
and measure end gap with a feeler gauge.
Sealring end gap must be 1.001.44 mm
8. Install three rotating sealrings 25 on front
support 20 hub.
58
57.
ROTATING CLUTCH MODULE

1. Remove internal retaining ring 43.
2. Remove P1 sun gear assembly 41.
3. Inspect thrust bearing 42 for wear. Replace the
bearing if it is worn.
4. Remove C2 internal retaining ring 40.
5. Remove C2 clutch backplate 39.
MODULE REBUILD
6. Measure the wear surface thickness of C2
clutch backplate 39. Minimum thickness
allowed is 7.90 mm (0.311 inch). Measure
flatness of the backplate. Maximum allowable
distortion is 0.15 mm (0.006 inch).
7. Remove C2 clutch packseven friction plates
38 and seven steel reaction plates 37.
8. Measure the thickness of each friction plate 38.
(0.115 inch). Measure the oil groove depth and
cone of each friction plate. Minimum groove
depth allowed is 0.20 mm (0.008 inch).
Maximum cone allowed is 0.25 mm (0.010 inch).
depth allowable is 0.20 mm (0.008 inch). Maximum cone allowed is 0.25 mm (0.010 inch).
14. Measure the thickness of each steel reaction
plate 31. Minimum allowable thickness is
2.41 mm (0.095 inch). Maximum cone allowable is 0.25 mm (0.010 inch).
15. Measure the wear surface thickness and cone
of C1 clutch apply plate 29 and backplate 32.
(0.232 inch) and 9.90 mm (0.390 inch), respectively. Measure flatness of the C1 clutch apply
plate and backplate. Maximum allowable distortion is 0.15 mm (0.006 inch).
9. Measure the thickness and cone of each steel

reaction plate 37. Minimum thickness allowed
is 2.41 mm (0.095 inch). Maximum cone
allowable is 0.25 mm (0.010 inch).
16. Remove thrust bearing 14 from rotating clutch

hub assembly 11.
10. Remove C2 drive hub 36, including two thrust

bearings 35. Inspect the splines of the C2 drive
hub. Maximum spline wear allowed is
0.38 mm (0.015 inch).
18. Inspect bushing 5 inside the end of turbine

shaft 4 or 7. Measure the ID of the turbine shaft
bushing. Maximum ID allowed is 36.14 mm
(1.423 inch).
11. Remove C1 drive hub 34. Inspect the splines of

the C1 drive hub. Maximum allowable spline
wear is 0.38 mm (0.015 inch).
19. Remove three rotating sealrings 8.
12. Remove C1 external retaining ring 33 and

C1 clutch packone backplate 32, seven friction plates 30 and six steel reaction plates 31,
and one apply plate 29.
13. Measure the thickness of each friction plate 30.
Minimum allowable thickness is 2.92 mm
(0.115 inch). Measure the oil groove depth and
cone of each friction plate. Minimum groove
17. Remove retaining ring 15 and turbine shaft assembly 3 or 6.
20. Remove O-ring

assembly 3 or 6.
from
turbine
shaft
21. Place rotating clutch on tool base J 37030-3 so

rotating drum is supported by tool tangs (Figure 59, View C). Install J 35923-2 (Figure 5
9, View A), including the bearing, washer and
handle. Tighten tool, compressing C1 balance
piston 26 and C1 return spring assembly 25,
and remove the balance piston retaining
ring 28.
59

J 37030-3
J 37030-3
HANDLE
HANDLE
FLAT WASHER
FLAT WASHER
BEARING
J 35923-2
BEARING
J 35923-2
VIEW A
VIEW B
J 37030-3
VIEW C
VIEW D
ALIGNMENT SLOTS
V06847.02.00
Figure 59. Rotating Clutch Disassembly/Assembly
25. Remove C2 spring assembly 20.
WARNING!
Carefully release spring force. Piston springs are
highly compressed. Personal injury can occur if
the spring force is not controlled.
22. Release spring force by rotating handle in
counterclockwise direction. Remove handle,
flat washer, bearing, and J 35923-2 tool.
23. Remove balance piston 26, sealring 27, and
C1 spring assembly 25.
24. Install tools J 37030-3, J 37030-1, J 35923-2
(Figure 59, View B), bearing, washer, and
handle. Tighten tool and remove internal retaining ring 22. Remove tools after relieving
spring force.
510
26. Lift rotating clutch drum 9 free of rotating

clutch hub 13 and C1/C2 pistons 24 and 19. Inspect the clutch splines of the rotating drum.
Maximum spline wear allowed is 0.38 mm
(0.015 inch).
27. Remove C1/C2 pistons 24 and 19 and
sealrings 18 and 23 from hub assembly 11
rocking the piston from side to side.
28. Inspect the ID of rotating clutch hub
bushing 12. Maximum allowable ID of the
bushing is 120.27 mm (4.735 inch). Remove
the bushing from hub assembly 11 if replacement is necessary. Avoid damaging the bushing bore.
MODULE REBUILD
29. Remove piston sealrings 16 and 17 from
hub 13.
30. Separate C1 piston 24 and sealring 23 from C2
piston 19 and sealring 18 by tapping lightly on
the C1 piston.
b. Assembly Foldout 6,B)
1. If removed during disassembly, install
bushing 12 into drive hub assembly 11 using
tools J 37040 and J 8092.
2. Install piston sealring 16 on hub assembly 13
and piston sealring 18 into C2 piston 19. Install
piston sealring 17 on rotating clutch hub
assembly 13 and piston sealring 23 onto C1
piston 24.
3. With a mallet, lightly tap C2 piston 19 (with
sealring 18) onto hub assembly 11.
4. Align notch on C1 piston with any lubrication
orifice on the rotating drive hub. With a mallet,
lightly tap C1 piston 24 (with sealring 23) onto
the center of C2 piston 19 and over rotating
clutch hub assembly 13.
5. Install rotating clutch drum 9 over hub
assembly 11 and C1/C2 pistons 24 and 19.
6. Install C2 spring assembly 20. Align the spring
assembly with the rotating clutch hub 36 tangs
and the splines on the C2 piston 19. The C2
spring assembly must make contact with the
bottom of the slots in the C2 piston. If the spring
assembly does not reach the bottom, remove the
C2 spring assembly and re-index it in the next
spline on the rotating drum 9. Repeat this
process until the C2 spring assembly is in the
proper position.
7. Install C2 spring plate 21. Index the spring
plate with the drive hub tangs and the splines
on the C2 piston.
8. Place the rotating clutch on tool base J 37030-3
so that the rotating drum is supported by tool
tangs. Install tool J 37030-1 (Figure 59, View
B), J 35923-2, that includes the bearing,
washer, and handle. Tighten tool to compress
C2 spring assembly 20, and install retaining
ring 22. Remove tools.
9. Install sealring 27 onto balance piston 26.
10. Install C1 spring assembly 25. Aligning mark

on balance piston with slot on the C1 clutch
piston, install balance piston 26 onto the C1
piston.
11. Install tool J 35923-2 (Figure 59, View A),
that includes the bearing, washer, and handle.
Tighten tool to compress C1 spring assembly
and install retaining ring 28 into the hub of the
rotating clutch assembly. Remove tool.
12. If removed, install bushing 5 into turbine shaft
assembly 3 or 6 using tools J 37036 and
J 8092.
13. Install O-ring 2 onto the forward end of the turbine shaft.
14. Install each rotating sealring 8 into the
ground sleeve bore and measure the end gap.
Sealring end gap must be 0.651.01 mm
Install three rotating sealrings 8, with correct
end gap, onto the rear of the turbine shaft.
15. Install turbine shaft assembly 3 or 6. Retain the
turbine shaft with retaining ring 15.
CAUTION:
Be sure that thrust bearings are assembled to
function correctly. Make sure that the locating
lip on either the inner or outer thrust bearing
race is not preventing the race from contacting
the thrust surface of the mating part. Failure to
do this leads to premature thrust bearing failure
and incorrect shim selection to maintain proper
internal part clearance.
16. Install thrust bearing 14 onto the rotating
clutch hub assembly 13.
17. Install C1 clutch pack (Figure 510)one
clutch apply plate 29, seven friction plates 30,
six steel reaction plates 31, and one
backplate 32. Install clutch plates alternately,
starting with a friction plate 30. Install C1 retaining ring 33.
18. Install C1 drive hub 34. Be sure that the drive
hub passes over the external splines of all
seven plates 30.
19. Install a thrust bearing 35 on each side of C2
drive hub 36, and install this assembly over C1
drive hub 34.
511

20. Install C2 clutch platesseven friction
plates 38 and seven steel reaction plates 37. Install clutch plates alternately, starting with a
steel reaction plate 37.
21. Install C2 backplate 39. Install C2 retaining
ring 40.
22. If removed, install thrust bearing 42 on sun
gear assembly 41.
23. Install P1 sun-gear drive hub 41. Install retaining ring 43.
58.
C3/C4 AND MAIN HOUSING

MODULE
a. Disassembly (Foldout 7)
NOTE:
When replacing a nameplate, keep the original
identification plate. Stamp the information from the
original identification plate onto the replacement
identification plate.
1. Replace a damaged nameplateremove
retaining rivet 24 and nameplate 23.
2. Inspect the inner C5 clutch plate splines of
main housing 31. Maximum allowable spline
wear is 1.15 mm (0.045 inch).
3. Remove fourteen bolts 2 retaining the C3
backplate assembly 3 and C3 clutch housing
assembly 11.
assembly 3.
Remove
C3
4. Inspect four thrust plates 5 and clutch

backplate 4. Minimum allowable thrust plate 5
thickness at the contact surface is 2.82 mm
(0.111 inch). Maximum allowable distortion of
backplate 4 is 0.15 mm (0.006 inch).
Maximum allowable step wear of backplate 4
is 0.13 mm (0.005 inch).
5. Remove P1 ring gear 6. Inspect the clutch
splines of the P1 ring gear. Maximum
allowable spline wear is 0.38 mm (0.015 inch).
6. Remove the C3 clutch packfive friction
plates 7 and five steel reaction plates 8.
7. Measure the thickness and cone of each
friction plate 7. Minimum thickness is
reaction plate 8. Minimum allowable thickness
is 3.25 mm (0.128 inch). Maximum allowable
9. Remove piston return plate assembly 9.
10. Inspect plate 9. Minimum allowable thickness
of plate 9 is 4.91 mm (0.193 inch). Replace if
damaged.
11. Remove C3 housing assembly 11.
CLUTCH APPLY PLATE
BACKPLATE
V05566.00.01
Figure 510. C1 Apply Plate and Backplate
512
backplate
MODULE REBUILD
12. Inspect six thrust plates 12 in C3 housing 13.
Minimum allowable thrust plate 12 thickness
at the contact surface is 2.82 mm (0.111 inch).
Maximum allowable distortion of backplate 4
is 0.15 mm (0.006 inch). Maximum stepwear
of 0.13 mm (0.005 inch) is allowed. If replacement is necessary, remove the thrust plates. Inspect splines in C3 clutch housing 13.
(0.045 inch).
13. Remove C4 clutch packsix steel reaction
plates 14 and five friction plates 15.
tightly attached to the housing; no movement

is allowed.
5. Install C3 clutch piston 10 into C3 clutchhousing assembly 13.
6. Install C3 clutch housing assembly 11 with
clutch piston 10 on top of the assembled C4
clutch housing assembly. Make sure index
notches on the clutch housings are aligned.
7. Install piston return plate 9.
8. Install P1 ring gear 6.
14. Measure the thickness and cone of each friction plate 15. Minimum allowable thickness is
9. Install the C3 clutch pack. Starting with a

friction plate, alternately install five friction
plates 7 and five steel reaction plates 8.

reaction plate 14. Minimum allowable
thickness is 3.25 mm (0.128 inch). Maximum
allowable cone is 0.25 mm (0.010 inch).
10. To assemble the C3 backplate (if thrust plates

were removed), install six thrust plates 5 into
C3 backplate 4. The thrust plate must be
tightly attached to the housing; no movement
is allowed.
16. Remove piston return plate assembly 16. Inspect plate 16. Minimum allowable thickness
of plate 23 is 4.91 mm (0.193 inch)
11. Install C3 backplate assembly 3. Align the

notch on the C3 backplate with the notches on
the C3 and C4 housings.
17. Remove piston 17 from C4 housing 18. Inspect

splines in C4 clutch housing 18. Maximum
spline wear allowed is 1.15 mm (0.045 inch).
12. Install fourteen retaining bolts 2 into the C3/C4

clutch assembly. Tighten the bolts to 5161 Nm
(3845 lb ft).
13. If removed, install nameplate 23 and screw 24.
b. Assembly (Foldout 7)
1. Install piston 17 into C4 housing 18.
2. Install piston return plate assembly 16.
59.
MAIN SHAFT MODULE
a. Disassembly (Foldout 8)
3. Install C4 clutch pack. Starting with a friction

platealternately install five friction plates 15
and six steel reaction plates 14.
1. Remove external spiral retaining ring 4.
4. To assemble the C3 housing (if thrust plates

were removed), install six thrust plates 12 into
C3 clutch housing 13. The thrust plate must be
3. Remove bearing spacer 6.
2. Remove P2 sun gear 5.
4. Remove thrust bearing 2.
513

5. Remove selective shim 1. On 4700 and 4800
models, remove non-selective shim 1.
6. On close ratio transmissions, remove P3 sun
gear 7 from main shaft 8.
7. For all models, inspect main shaft 7 or 8 for
wear, damage, and evidence of chipped or
cracked splines or gear teeth. Measure the
journals as illustrated in Figure 511.
Maximum main shaft spline wear is
0.38 mm (0.015 inch).
b. Assembly (Except 4700 and 4800 Models)
(Foldout 8)
NOTE:
Do not install thrust bearing 2 or selective shim 1
until final transmission assembly. Measurement for
selective shim 1 is performed during final buildup.
1. On close ratio transmissions, install P3 sun
gear 7 onto main shaft 8.
2. Install bearing spacer 6.
3. Install P2 sun gear 5.

1. Remove internal retaining ring 2 from P2 ring
gear 15.
2. Remove P2 ring gear 15.
3. Measure P1 planetary carrier assembly 3 pinion
end play. Pinion end play must not exceed
0.94 mm (0.037 inch). Measure all six pinion
gears.
4. Remove retaining ring 4. Remove indexing
ring 5.
5. Remove six pinion spindles 6 from P1
carrier 8.
6. Slide pinion gear 11, thrust washers 10 and 13,
and two bearing assemblies 12 from the side of
P1 planetary carrier 8. Repeat the procedure
with the five remaining pinion gears.
7. Measure the thickness and any step wear for all
thrust washers 10 and 13. Minimum thrust
washer thickness allowed is 1.40 mm
(0.055 inch). Maximum allowable step wear is
0.12 mm (0.005 inch).
4. Install external spiral retaining ring 4

c. Assembly (4700 and 4800 Models) (Foldout 8)
1. Install P3 sun gear 7 onto main shaft 8.
2. Install bearing spacer 6.
3. Install P2 sun gear 5.
4. Install external spiral retaining ring 4.
5. Install non-selective shim 1.
6. Install thrust bearing 2.
35.92 mm
(1.414 in.)
9. Inspect bushing 9 inside P1 planetary carrier 8

for wear or damage. Maximum ID allowed is
89.32 mm (3.516 inch). If worn, remove
bushing 9.
10. Determine if there is spline wear between
P1 planetary carrier 8 and P2 planetary ring
gear 15. Maximum allowable spline wear is
0.38 mm (0.015 inch).
b. Assembly (Foldout 9,A)
52.98 mm
(2.085 in.)
35.92 mm
(1.414 in.)
V02524
Figure 511. Measurement of Main Shaft Journals
514
8. Remove thrust bearing assembly 14 from P1

planetary carrier 8.
1. If replacement is necessary, press a new

bushing 9 into P1 carrier 8 using a press,
installer J 37038, and drive handle J 8092.
Press bushing 9 flush to 0.40 mm (0.016 inch)
below the surface.
2. Install two bearing assemblies 12 into the
center of pinion gear 11. Install thrust
washers 10 and 13 inside P1 planetary
carrier 8, align thrust washer tangs with the
MODULE REBUILD
slots in the planetary, and retain them with oilsoluble grease.
3. Slide the pinion gear and bearing assemblies
into the side of the P1 planetary carrier
between the thrust washers.
4. Repeat the procedure for the five remaining
pinion gears.
5. Install six spindles 6 so the lower step is
positioned for proper installation of indexing
ring 5.
6. Install indexing ring 5 and retaining ring 4.
7. If components were replaced, measure pinion
gears.
8. Install P2 ring gear 15 over P1 planetary
carrier assembly 3.
9. Install internal retaining ring 2 into P2 ring
gear 15, connecting P1 planetary carrier
assembly 3 and the P2 planetary ring gear.
CAUTION:
Be sure that thrust bearings are assembled to
function correctly. Make sure that the locating
lip on either the inner or outer thrust bearing
race is not preventing the race from contacting
the thrust surface of the mating part. Failure to
do this leads to premature thrust bearing failure
and incorrect shim selection to maintain proper
10. Install thrust bearing assembly 14 on P1 planetary carrier assembly 3.

1. Remove retaining ring 2.
2. Remove P3 ring gear 15. Remove and inspect
thrust bearing assembly 14.
3. Measure P2 planetary carrier pinion end play.
Pinion end play must not exceed 0.94 mm
(0.037 inch). Measure all four pinion gears.
4. Remove internal retaining ring 4. Remove

indexing ring 5. Remove four pinion
spindles 13 from P2 carrier 7.
5. Slide a pinion gear 11, thrust washers 9 and 12,
and two roller bearings 10 from the side of P2
planetary carrier 7. Repeat the procedure with
the three remaining pinion gears.
6. Measure the thickness and any step wear for all
thrust washers 9 and 12. Minimum allowable
thickness of the thrust washers is 1.40 mm
(0.055 inch). Maximum allowable step wear is
0.12 mm (0.005 inch).
7. Inspect bushing 8 inside P2 planetary carrier 7
for wear or damage. Maximum ID of the
bushing is 53.23 mm (2.096 inch). Remove
bushing 8 if it is worn or damaged.
8. Determine whether there is spline wear
between P2 planetary carrier 7 and P3
planetary ring gear 15. Maximum wear
b. Assembly (Foldout 9,B and Figure 512)
1. If replacement is necessary, press a new
bushing 8 into P2 carrier 7 using a press,
installer J 37036, and driver J 8092.
2. Install two roller bearings 10 into the center of
pinion gear 11. Install thrust washers 9 and 12
in P2 planetary carrier 7, align thrust washer
tangs with slots in the planetary, and retain
them with oil-soluble grease. Slide the pinion
gear and two bearing sets, into the side of the
P2 planetary carrier between the thrust
washers. Repeat the procedure with the three
remaining pinion gears.
CAUTION:
If the wear on the indexing ring is minor, flip it
over to get a fresh reaction point for the spindle.
Replace the indexing ring if both corners of the
indexing ring are worn. Failure to take corrective
action may allow the spindle to rotate which may
reduce or shut off lubrication to the pinion
bearings and thrust washers.
3. Install four spindles 13 so the lower step is
ring 5.
4. Install indexing ring 5 and internal retaining
ring 4.
515
DIMENSION A
VIEW A
VIEW B
V06848
Figure 512. Planetary Spindle and Indexing Ring

0.94 mm (0.037 inch). Measure all four pinion
gears. Install thrust bearing 14.
6. Install thrust bearing 14.
7. Install P3 ring gear 15 over P2 carrier
assembly 3.
8. Install retaining ring 2 into P3 ring gear 15 so
that the P2 carrier and P3 ring gear are linked.
NOTE:
For 4000 Product Family models with retarder
(except 4700 and 4800 models) proceed to Paragraph 514.
For 4000 Product Family models without
retarder (except 4700 and 4800 models) skip
Paragraph 514 and 515 and proceed to
Paragraph 516.

a. Disassembly (Foldout 9,C)
1. Measure pinion end play of P3 carrier
assembly 1. Pinion end play must not exceed
0.94 mm (0.037 inch). Measure the three
remaining pinion gears 9.
516
2. Remove internal retaining ring 2. Remove

indexing ring 3. Remove four planetary
spindles 7.
3. Slide pinion gear 9, thrust washers 8, and two
bearing assemblies 10 from the side of P3
planetary carrier 4. Repeat the procedure for
three remaining pinion gears.
4. Measure the thickness and any step wear for
eight thrust washers 8. Minimum allowable
(0.055 inch). Maximum step wear allowed is
0.12 mm (0.005 inch).
b. Assembly (Foldout 9,C)
1. Install two roller bearing assemblies 10 into the
center of pinion gear 9. Install thrust washers 8
in P3 planetary carrier 4, align the thrust washer
tangs with the slots in the carrier, and retain
them with oil-soluble grease. Slide the pinion
gear and bearings into the side of the P3
planetary carrier between the thrust washers.
Repeat the procedure with the three remaining
pinion gears.
2. Install four planetary spindles 7 so the lower
step is positioned for proper installation of
indexing ring 3.
3. Install indexing ring 3. Install internal retaining
ring 2.
MODULE REBUILD
gears 9.
NOTE:
Do not install shim locating ring 6 or selective
shim 12 until final transmission assembly.
Measurement for selective shim is performed during
final buildup.
513. C6 ADAPTER HOUSING MODULE

(Foldout 9,C)
a. Disassembly of Ring Gear and Hub Assembly
1. Remove P4 ring gear and hub assembly 45.
2. Remove retaining ring 48 from P4 ring gear and
hub assembly 45 and separate P4 ring gear 46
and P4 ring gear hub 47.
7. Remove twelve thrust washers 40 and twelve

caged needle bearings 42 from the pinion gears.
twelve thrust washers 40. Minimum allowable
0.12 mm (0.005 inch).
9. Inspect bushing 38 in carrier 37 for wear or
damage. Maximum allowable bushing ID is
113.33 mm (4.462 inch). Remove bushing 38 if
it is worn or damaged.
d. Disassembly of Remaining C6 Parts
1. Lift C6 clutch pack from C6 adapter housing
assemblyeight friction plates 28 and nine
reaction plates 27.
2. Measure the thickness and cone of each friction
plate 28. Minimum thickness is 3.68 mm
(0.145 inch). Maximum allowable cone is
0.25 mm (0.010 inch).
3. Measure thickness and cone of each steel
reaction plate 27. Minimum thickness is

b. Disassembly
1. Remove C6 backplate 29.
2. Thread three M8 eye bolts into the three tapped
holes of P4 planetary carrier assembly 32.
3. Attach hoist and remove P4 planetary carrier
assembly 32 from C6 adapter housing 22.

5. Remove P4 sun gear 30.
6. Place special tool J 43025 onto return spring
assembly 17 (Figure 513).
c. Disassembly of P4 Planetary Carrier Assembly

1. Remove internal retaining ring 33 from C6
clutch drum hub 43.
2. Turn over P4 carrier assembly and remove
clutch drum hub 43.
J 35923
J 43025
3. Remove internal retaining ring 34 and indexing

ring 35 from P4 carrier assembly 32.
4. Remove six spindles 39 from P4 carrier 37.
5. Measure pinion end play. Pinion end play must
not exceed 0.94 mm (0.037 inch). Measure the
five remaining pinion gears.
6. Remove six P4 pinion gears 41 from P4 carrier
assembly 32.
V05581
Figure 513. Compressing Spring and

Retainer Assembly
517

7. Compress return spring assembly 17 using
J 35923-4 tool base, washer, bearing, handle,
and piston spring compressor J 43025
(Figure 514). Remove external retaining
ring 16 and slowly release the spring force.
8. Remove piston return spring assembly 17.
9. Remove C5 piston 18 from C6 adapter housing
module 14.
10. Remove internal sealring 20 from C5
piston 18. Remove external sealring 19 from
C5 piston 18.
11. Place C6 adapter housing module 21 on press
stand. Place special tool J 43047 and J 37034
onto ball bearing 26 (Figure 515). Support
ball bearing from falling with a block of wood.
NOTE:
Ball bearing assembly 26 is properly seated when it is
against the shoulder at the bottom of the bearing
bore and is 1.573.35 mm (0.0620.132 inch) below
the machined face of the adapter housing at the top
of the bearing bore.
4. Press ball bearing assembly 26 into C6 adapter
housing assembly 21 until it is properly seated.
J 37034
J 43047
12. Using press, remove ball bearing 26.

13. Inspect ball bearing assembly 26. Refer to Paragraph 35d and 35e.
e. Assembly
1. Turn C6 adapter housing assembly 21 over and
place on press stand.
2. Place ball bearing 26 in C6 adapter housing
assembly 21.
3. Place special tool J 43047 and J 37034 on ball
bearing assembly 26 (Figure 516).
V05583
Figure 515. Removal of Ball Bearing From

C6 Adapter Housing
J 35923-4
J 37034
J 43047
V05584
V05582
Figure 514. Bottom View of C6 Adapter

Housing and J 35923-4
518
Figure 516. Installation of Ball Bearing

Into C6 Adapter Housing
MODULE REBUILD
5. Install piston ID lip-type sealring 20 onto C5
piston 18. Install external sealring 19 onto C5
piston 18.
6. Align the tang on the back of the C5 clutch
piston 18 with the notch in the C6 adapter
housing 22 before installing C5 clutch piston
18. Install C5 clutch piston 18 into C6 adapter
housing module 14. Use a rubber mallet to seat
the piston.
7. Place spring return assembly 17 in C6 adapter
housing assembly 21. Use alignment notch to
guide installation.
WARNING!
Piston springs are highly compressed. Be
extremely careful during installation. Personal
injury can occur if the spring force is not
controlled.
8. Place retaining ring 16 in C6 adapter housing
assembly 21.
9. Compress spring and retainer assembly 17
using J 35923-4 tool base, washer, bearing,
handle, and piston spring compressor J 43025.
Install retaining ring 16 and slowly release the
spring force (Figures 517 and 518).
f. Assembly of P4 Planetary Carrier Assembly

1. Install two caged needle bearings 42 into the
center of pinion gear 41. Install thrust washers
40 in P4 planetary carrier 37. Align thrust
washer tangs with slots in carrier 37 and retain
them with oil-soluble grease. Slide pinion gear
41 and two bearings 42 into the side of P4
planetary carrier 37 between thrust washers 40.
Repeat the procedure for the five remaining
pinion gears.
2. Install six spindles 39 so the lower step is
ring 35.
3. Install indexing ring 35 and internal retaining
ring 34.
gears. Install thrust bearing 44.
5. Install P4 planetary carrier assembly 32 into
the C6 clutch drum hub 43.
6. Support P4 planetary carrier hub 43 slightly off
of the work table so P4 planetary carrier
assembly 32 can fall through. Install retaining
ring 33 into C6 clutch hub 43
J 35923-4
J 35923
J 43025
V05582
V05581
Figure 517. Compressing Spring and

Retainer Assembly
Figure 518. Bottom View of C6 Adapter Housing

and J 35923-4
519

7. Thread three M10 eye bolts into the P4
planetary carrier assembly 32.
8. If replacing, install P4 carrier bushing 38 in P4
carrier 37 using special tool J 43023 and
J 37034 (Figure 519).
NOTE:
For 4700 and 4800 models with a retarder,
proceed to Paragraph 515.
For 4700 and 4800 models without a retarder,
proceed to Paragraph 517.
9. Install thrust bearing 31 on P4 sun gear 30.

10. With thrust bearing 31 facing up, place the
thrust bearing and P4 sun gear inside P4 planetary carrier assembly 32. While holding onto
P4 sun gear 30, carefully install both P4 sun
gear 30 and P4 carrier assembly 32 into C6
adapter housing 22 using a sling and hoist.
NOTE:
Do not install ring gear and hub assembly 45 in the
C6 adapter housing assembly 21 until final
transmission assembly. Measurement for selective
shim is performed during final buildup.
g. Assembly of C6 Clutch
1. Install the C6 clutch pack in the C6 adapter
housingnine reaction plates 27 and eight
friction plates 28, stacked alternately, starting
with a steel reaction plate 27. Stack all plates
so plate cone faces the same direction.
Reaction plates 27 mesh with the C6 adapter
housing 22 and friction plates 28 mesh with C6
clutch hub 43.
2. Install C6 backplate 29.
514. RETARDER AND P3 PLANETARY

MODULE
a. Disassembly of Retarder Valve Body
(Foldout 10,C)
1. Remove nine bolts 93 and three bolts 89
retaining retarder control body assembly 65 to
retarder housing 41 and remove control body
assembly 65.
2. Remove pressure tap plug 92 and discard
O-ring 91.
3. Remove separator plate 63.
4. Remove plug 81, O-ring 80, spring 78, and
regulator valve 77 from retarder valve body 75.
Discard O-ring 80.
relay valve 86 from retarder valve body 75.
Discard O-ring 84.
6. Remove retaining pin 76 from the back side of
the retarder valve body 75.
7. Remove solenoid and connector assembly 71
from retarder valve body 75.
8. Remove and discard O-ring seal 73 and Oring 74.
9. Measure the resistance of retarder solenoid 72.
Resistance must be 48 Ohms.
10. If replacement is necessary refer to the Allison
4th Generation Troubleshooting Guide,
TS3989EN.
J 37034
b. Disassembly of Temperature Sensor

(Foldout 10,C)
J 43023
1. Remove temperature sensor retainer bolt 48

and temperature sensor retainer 47. Carefully
remove temperature sensor assembly 45 from
retarder housing 41.
V05587
Figure 519. Installation of P4 Planetary Bushing
520
2. Determine retarder temperature sensor

resistance measured with an ohmmeter. Refer
to Figure 520.
MODULE REBUILD
1,000,000
SENSOR RESISTANCE ()
100,000
10,000
1,000
100
10
1
40
14
68
122
40
10
20
50
176
230
284
338
392
80
110
140
170
200
TEMPERATURE
V04641.01
Figure 520. Temperature Sensor Chart
c. Disassembly of Retarder Housing

(Foldout 10,C)
NOTE:
CAUTION:
Output seal 60 must be removed before retainer

locknut 59 can be removed.
Be sure to remove speed sensor 53. Failure to

remove the speed sensor will result in equipment
damage.
1. Remove output speed sensor bolt 56, sensor
retainer 55, and output speed sensor
assembly 53 from the retarder housing. Remove
O-ring 54 and discard. Measure output speed
Resistance
(Ohms)
250
340
450
Temperature
(C)
40
20
110
Temperature
(F)
40
68
230
5. If not removed, remove output oil seal

assembly 60 using seal removal tool
J 24171-A.
6. Remove bearing retaining locknut 59 using
special tool J 37035. Remove Belleville
washer 58.
3. Remove retaining ring 50 and valve plug 49.
7. Support retarder housing 41 so that P3

planetary carrier assembly 3 can be removed
from the retarder housing. Place special tool
J 37035 over the output shaft splines and
against the threaded shoulder of the P3
planetary carrier. Press on J 37035 with a
hydraulic press or drive on J 37035 with a
mallet until the P3 planetary carrier is
separated from the retarder housing.
4. Use J 42048 to compress vlave plug 33.

Remove retaining ring 32 and tool J 42048.
Remove valve plug 33, O-ring 34, spring 35,
and retarder valve 36. Remove spring pin 37
only if damaged.
8. Remove three bolts 52 to allow removal of

retarder stator assembly 18 from retarder
housing 41. Remove retarder housing
gasket 28.
2. Remove tachograph plug 39 and brass

washer 40.
521

9. Remove rotor assembly 29. Remove
sealrings 27 and 30 from rotor
assembly 29. Inspect splines inside rotor 29.
(0.015 inch).
10. If replacement is required, remove cone and
roller bearing assembly 57 from retarder housing 41. If necessary to replace, remove bearing
cup 51 using bearing tool J 3940.
11. Remove one bolt 99, three bolts 101, jumper
manifold 98, or remote side manifold 100, and
gasket 97 from rear of retarder housing 41.
12. Remove bolt 96, jumper manifold 95 or remote
side manifold 97, and gasket 94 from the rear
of retarder housing 41.
13. Remove nine bolts 44, cover 43, and gasket 42
from the bottom of retarder housing 41.
d. Disassembly of P3 Planetary
Carrier Assembly (Foldout 10,C)
WARNING!
Place the P3 planetary assembly on its side to
avoid possible injury while disassembling the
planetary.
1. Remove retaining ring 11 and thrust washer 10
from P3 planetary carrier assembly 3.
NOTE:
For 4500 models (wide ratio) transmissions,
skip to Step (3).
For close ratio models, proceed with Step (2).
2. On a close ratio transmission, remove output
shaft assembly 4. Inspect the splines on output
shaft assembly 4. Maximum spline wear
3. If replacement is necessary, remove cone and
roller bearing assembly 17.
522
the side of P3 planetary carrier 9. Repeat the

procedure with three remaining pinion gears.
eight P3 thrust washers 13 and 16. Minimum
allowable thickness of the thrust washers is
1.40 mm (0.055 inch). Maximum step wear
NOTE:
proceed with Step (8).
For close ratio models, skip Step (8) and proceed with Step (9).
8. On wide ratio transmissions, remove output
9. Inspect bushing 5 inside the end of output
shaft 6 for wear or damage. Measure the ID of
the output shaft bushing. Maximum allowable
ID is 36.14 mm (1.423 inch).
e. Disassembly of Retarder Stator Assembly
(Foldout 10,C)
1. Remove O-ring 26 from retarder stator
assembly 18.
WARNING!
extremely careful during removal and
installation. Personal injury can occur if the
spring force is not controlled.
2. Remove C5 clutch piston 21 from retarder
stator 25 by compressing spring and retainer
assembly 20 using J 37030-3 tool base, washer,
bearing, handle, and piston spring compressor
J 37030-2. Remove retaining ring 19 and
slowly release the spring force.
4. Measure pinion end play. Pinion end play must

not exceed 0.94 mm (0.037 inch). Measure the
3. Remove C5 piston outer sealring 22 from

C5 clutch piston 21.
5. Remove retaining ring 7. Remove P3 indexing

ring 8. Remove four P3 planetary spindles 12.
4. Remove C5 piston inner sealring 23 from

C5 clutch piston 21.
6. Slide P3 pinion gear 14, P3 thrust washers 13

and 16, and two bearing assemblies 15 from
5. If replacement is necessary, remove bearing

MODULE REBUILD
5. Install two roller bearing assemblies 15 into
the center of pinion gear 14.
f. Assembly of Retarder Stator

(Foldout 10,C)
1. If removed, install bearing cup 24 using
bearing tool J 37033 and drive sleeve J 37034.
2. Install C5 piston inner sealring 23 onto C5
clutch piston 21.
3. Install C5 piston outer sealring 22 onto C5
clutch piston 21.
4. Align the tang notch on the back of the C5
clutch piston with the tang on retarder stator
25. Install C5 clutch piston 21 into retarder
stator 25.
5. Install spring and retainer assembly 20, align
the tab in the spring and retainer assembly with
the notch in retarder stator 25.
WARNING!
controlled.
6. Install thrust washers 13 and 16 in P3 planetary

carrier 9, align the thrust washer tangs with the
slots in the carrier, and retain them with oilsoluble grease. Slide the pinion gear and
bearings into the side of the P3 planetary
carrier between the thrust washers. Repeat the
procedure with the three remaining pinion
gears.
7. Install four planetary spindles 12 so the lower
step is positioned for proper installation of
indexing ring 8.
8. Install indexing ring 8. Install internal retaining
ring 7.
gears.
h. Assembly of Retarder Housing Assembly
(Foldout 10,C)

handle, and piston spring compressor
J 37030-2. Install external retaining ring 19
and slowly release the spring force.

7. Install O-ring 26 on retarder stator 25.
3. Install remote side manifold 100 or jumper

manifold 98 and new gasket 97 to retarder
housing 41 using bolt 99. Tighten bolts to
5161 Nm (3845 lb ft).
g. Assembly of P3 Planetary Carrier Assembly

(Foldout 10,C)
1. If removed, install cone and roller bearing
assembly 17. Use drive sleeve J 37034 and
press the bearing against the shoulder on P3
carrier 3.
2. If removed, install bushing 5 inside the end of
output shaft 6 using installer J 37036, drive
handle J 8092, and a press.
3. Install output shaft assembly 4 into P3
4. Install thrust washer 10 and retaining ring 11
into P3 planetary carrier.
2. Install new gasket 42, cover 43, and nine

bolts 44. Tighten bolts to 2429 Nm (18
21 lb ft).
4. Place P3 carrier assembly 3 on the work table

(output shaft up) and place stator assembly 18
over the output shaft.
5. Install sealrings 27 and 30 onto rotor 29. Install
the rotor assembly over the output shaft.
6. Install two M8 guide bolts into retarder
stator 25. Install gasket 28 onto the guide
bolts. Place retarder housing 41 over the
output shaft and guide bolts, aligning the
holes of the housing with the holes of the
stator assembly. Remove the guide bolts as
you install three bolts 52. Tighten bolts 52 to
1215 Nm (911 lb ft).
523

assembly 57 using installer J 37034. Press
cone and roller bearing assembly 57 into
retarder housing 41 while rotating the retarder
housing.
NOTE:
Delay installing output oil seal assembly 60.
12. Install valve plug 49 and retaining ring 50.
NOTE:
When installing the Belleville washer, be sure that
the concave side of the washer at the inside diameter
contacts the inner race of the bearing and that the
anti-rotation tang engages the drilled hole in the P3
carrier. Tilt the Belleville washer, tang toward the
bearing, to engage the tang into the hole.
8. Install Belleville washer 58.
CAUTION:
Over-tightening bearing retainer locknut 59 will
damage cone and roller bearing assemblies 17
and 57 and cups 24 and 51.
9. Lubricate output shaft threads and install
locknut 59 so that the Verspel buttons are in
contact with the Belleville washer 58. Replace
current locknut if it does not exhibit 3 Nm
(7.5 lb ft) of running torque.
10. Using special tools J 37035 and J 43278, with
the torque wrench and breaker bar positioned
as shown in Figure 521, rotate the torque
wrench clockwise to tighten bearing retainer
locknut 59 to 185200 Nm (137147 lb ft).
Locknut torque values are for bench assembly
only. If the output module is mounted on the
transmission, tighten the bearing retainer
locknut to 7488 Nm (5564 lb ft).
11. Support retarder housing 41 so that the turning
torque of the P3 carrier assembly 3 can be
measured after installation of bearing retainer
locknut 59. Use tool J 37035 to measure turning torque. Maximum turning torque is 3 Nm
(27 lb inch).
524
13. If removed, install spring pin 37 into retarder

valve 36 and insert into valve bore. Install
spring 35, O-ring 34, plug 33, and retaining
ring 32. Use J 42048 to compress plug 33 and
install retaining ring 32.
14. Install output speed sensor assembly 53, with
new O-ring 54, and output speed sensor bolt 56.
Tighten the bolt to 2429 Nm (1821 lb ft).
15. Carefully install temperature sensor assembly 45
into retarder housing 41. Install temperature
sensor retainer 47 and retainer bolt 48. Tighten
16. Install brass washer 40 onto tachograph
plug 39. Install plug 39 into retarder housing 41.
Tighten the plug to 6067 Nm (4549 lb ft).
i. Assembly of the Retarder Valve Body
(Foldout 10,C)
1. Install new O-ring 74 and seal 73 on retarder
solenoid 72.
2. Insert solenoid and connector assembly 71 into
retarder valve body 75.
3. Install relay valve 86, valve spring 85,
O-ring 84, and plug 83 into retarder control
body 75.
4. Install regulator valve 77, valve spring 78,
body 75.
5. Install exhaust backfill valve 70, spring 69,
body 75.
MODULE REBUILD
6. Install guide pin 76 into the retarder control
body 75.
7. Install retarder control valve cover gasket 87
and retarder control valve cover 88 on
frontside and separator plate 63 on backside of
retarder control valve body 75.
8. Install O-ring 91 and pressure tap plug 92.
9. Install retarder control body assembly 65, nine
bolts 93, and three bolts 89 that retain it to retarder housing 41. Tighten bolts to 2429 Nm
(1821 lb ft).
b. Disassembly of Temperature Sensor

(Foldout 10,D)
1. Remove temperature sensor retainer bolt 38
and temperature sensor retainer 37. Carefully
remove temperature sensor assembly 35 from
retarder housing 31.
2. Measure retarder temperature sensor resistance
measured with an ohmmeter. Refer to
Figure 520.
c. Disassembly of Retarder Housing
(Foldout 10,D)
515. RETARDER AND OUTPUT

SHAFT MODULE (4700 and 4800
Models Equipped With Retarder)
a. Disassembly of Retarder Valve Body
(Foldout 10,D)
1. Remove three bolts 78 and nine bolts 82
retaining retarder control body assembly 54 to
retarder housing 31 and remove control body
assembly 54.
2. Remove pressure tap plug 81 and discard
O-ring 80.
3. Remove separator plate 52.
CAUTION:
Be sure to remove speed sensor 46. Failure to
remove the speed sensor will result in equipment
damage.
1. Remove output speed sensor bolt 49, sensor
retainer 48, and output speed sensor
assembly 46 from the retarder housing. Remove
O-ring 47 and discard. Measure output speed
Resistance
(Ohms)
Temperature
(C)
Temperature
(F)
250
40
40
340
20
68
450
110
230

valve 66 from retarder valve body 64. Discard
O-ring 69.
valve 75 from retarder valve body 64. Discard
O-ring 73.
6. Remove retaining pin 65 from the back side of
the retarder valve body 64.
7. Remove solenoid and connector assembly 60
from retarder valve body 64.
8. Remove and discard O-ring seal 62 and
O-ring 63.
9. Measure the resistance of retarder solenoid 61.
Resistance must be 48 Ohms.
10. If replacement is necessary refer to the Allison
4th Generation Troubleshooting Manual,
TS3989EN.
2. Remove tachograph plug 29 and brass

washer 30.
3. Remove retaining ring 40 and plug 39.
4. Use J 42048 to compress plug 23.
retaining ring 22 and tool J 42048.
plug 23, O-ring 24, spring 25, and
valve 26. Remove spring pin 27
damaged.
Remove
Remove
retarder
only if
NOTE:
525

5. If not removed, remove output oil seal
assembly 45 using seal removal tool
J 24171-A.
6. Remove locknut 44 using special tool J 37035.
Remove Belleville washer 43 (Foldout 10,D).
7. Support retarder housing 31 so that output
shaft 3 can be removed from retarder housing
31. Place special tool J 37035-3 over the
output shaft splines. Press on output shaft
assembly 3 with a press until output shaft
assembly 3 is separated from retarder
housing 31.
d. Completion of Retarder Housing Disassembly
(Foldout 10,D)
1. Remove three bolts 20 to allow removal of
retarder stator assembly 7 from retarder
housing 31. Remove and discard retarder
housing gasket 17.
2. Remove rotor assembly 18. Remove rotating
sealrings 16 and 19 from rotor assembly 18.
Inspect splines inside rotor 18. Maximum
spline wear allowed is 0.38 mm (0.015 inch).
roller bearing assembly 42 from the retarder
housing. If replacement is necessary, remove
bearing cup 41 using bearing tool J 3940.
4. Remove bolt 85 and three bolts 87, jumper
manifold 84 or remote side manifold 86, and
gasket 83 from the rear of retarder housing 31.
5. Remove nine bolts 34, cover 33, and gasket 32
from the bottom of retarder housing 31.
e. Disassembly of Output Shaft Assembly
(Foldout 10,D)
1. Inspect the splines on output shaft assembly 3.
(0.015 inch).
526
3. If replacement is necessary, remove output

shaft bushing 4. Maximum bushing ID allowed
is 36.14 mm (1.423 in.).
f. Disassembly of Retarder Stator Assembly
(Foldout 10,D)
1. Remove O-ring 15 from retarder stator
assembly 7.
WARNING!
2. Remove C5 clutch piston 10 from retarder
stator housing 14 by compressing piston return
spring and retainer assembly 9 using J 37030-3
tool base, washer, bearing, handle, and piston
spring compressor J 37030-2. Remove
retaining ring 8 and slowly release the spring
force.
3. Remove external sealring 11 from C5 clutch
piston 10.
4. Remove internal lip-type sealring 12 from C5
clutch piston 10.
5. If replacement is necessary, remove roller
bearing cup 13 using bearing tool J 3940.
g. Assembly of Retarder Stator (Foldout 10,D)
2. Install internal lip-type sealring 12 onto C5
clutch piston 10. Install external sealring 11
onto C5 clutch piston 10.
clutch piston with the tang on the retarder
stator before installing C5 clutch piston 10 into
retarder stator 14. Install C5 clutch piston 10
into retarder stator 14.
MODULE REBUILD
4. Install spring and retainer assembly 9, aligning
the tab in the spring and retainer assembly with
the notch in retarder stator 14.
WARNING!
controlled.
5. Compress piston return spring and retainer
J 37030-2. Install external retaining ring 8 and
slowly release the spring force.
j. Completion of Retarder Housing Assembly

(Foldout 10,D)
assembly 42 using installer J 37034. Press
cone and roller bearing assembly 42 into
retarder housing 31 while rotating retarder
housing 31.
NOTE:
When installing the Belleville washer, make sure
that the concave side of the washer at the inside
diameter contacts the inner race of the bearing and
that the anti-rotation tang engages the drilled hole
in the P3 carrier. Tilt the Belleville washer, tang
toward the bearing, to engage the tang into the hole.
6. Install O-ring 15 on retarder stator housing 14.

2. Install Belleville washer 43 (Foldout 10,D).
h. Assembly of Retarder Housing (Foldout 10,D)
2. Install rotating sealrings 16 and 19 onto rotor
assembly 18. Install the rotor assembly 18 onto
the retarder housing 31.
3. Install two M8 guide bolts into retarder
stator housing 14. Install gasket 17 onto the
guide bolts. Place stator assembly 7, using the
guide bolts, aligning the holes of the retarder
housing 31 with the holes of the stator
assembly 7. Remove the guide bolts as you
install three bolts 20. Tighten bolts 20 to
1215 Nm (911 lb ft).
i. Assembly of Output Shaft Assembly
(Foldout 10,D)
assembly 6. Use special tools J 43202 with
J 37034 and press the bearing onto output
shaft 5 (Figure 523).
3. Support output shaft assembly 3. Place retarder
housing 31 over output shaft assembly 3.
CAUTION:
damage roller bearings 6 and 42 and bearing
cups 13 and 41. If the torque wrench and breaker
bar positions in Figure 524 are reversed, the
bearing retainer locknut will be overtorqued. Be
sure wrenches are positioned ONLY as shown in
Figure 524.
3. If using current locknut 44, lubricate the output

shaft threads and install locknut 44 so that the
Vespel buttons are in contact with Belleville
washer 43 (Foldout 10,D). Replace current
bearing retainer locknut if it does not exhibit
5 Nm (44 lb inch) of running torque.
the torque wrench and breaker bar positioned
as shown in Figure 524, rotate the torque
wrench clockwise to tighten bearing retainer
5. Support retarder housing 31 so that the turning
torque of the output shaft can be measured
after installation of bearing retainer locknut 44
527

(Figure 524). Use tool J 43278 to measure
turning torque. Maximum turning torque is
3 Nm (27 lb in.) (Figure 521).
NOTE:
Delay installing output oil seal assembly 45 until
final assembly.
6. Install plug 39 and retaining ring 40.
7. If removed, install spring pin 27 into retarder
valve 26 and insert into valve bore. Install
spring 25, O-ring 24, and plug 23. Use J 42048
to compress plug 23 and install retaining
ring 22.
Tighten the bolt to 2429 Nm (1821 lb ft).
9. Carefully install temperature sensor assembly 35
into retarder housing 31. Install temperature
sensor retainer 37 and retainer bolt 38. Tighten
10. If removed, install brass washer 30 onto tachograph plug 29. Install plug 29 into retarder
housing 31. Tighten plug 29 to 6067 Nm
(4549 lb ft).
k. Assembly of the Retarder Valve Body

(Foldout 10,D)
1. Install new O-ring 63 and O-ring seal 62 onto
retarder solenoid 61.
2. Insert solenoid and connector assembly 60 into
retarder valve body 64.
3. Install relay valve 75, valve spring 74, O-ring 73,
and plug 72 into retarder control body 64.
4. Install regulator valve 66, valve spring 67,
body 64.
5. Install exhaust backfill valve 59, spring 58,
body 64.
6. Install guide pin 65 into the retarder control
body 64.
7. Install retarder control valve cover gasket 76
and retarder control valve cover 77 on
frontside and separator plate 52 on backside of
retarder control valve body 64.
8. Install O-ring 80 and pressure tap plug 81.
9. Install retarder control body assembly 54, nine
bolts 82, and three bolts 78 that retain it to retarder housing 31. Tighten bolts to 6067 Nm
(4549 lb ft).
516. REAR COVER MODULE

(Models Equipped With Rear Cover,
Except 4700 and 4800 Models)
J 43278

1. Remove retaining bolt 35 and output speed
sensor assembly 32. Measure output speed
Resistance (Ohms) Temperature (C) Temperature (F)
V05592
Figure 521. Output Shaft Turning Torque

MeasurementRetarder Equipped
528
250
40
40
340
20
68
450
110
230
MODULE REBUILD
2. If used, remove the tachograph sensor. If
present, remove plug 29 and washer or
O-ring 28.
3. If not previously removed, remove output
seal assembly 40 using seal removal tool
J 24171-A.
NOTE:
4. Remove bearing retainer locknut 39 using
special tool J 37035.
2. On a close ratio transmission, remove output

4. Measure pinion end play. Pinion end play
should not exceed 0.94 mm (0.037 inch).
Measure the three remaining pinion gears.
5. Remove retaining ring 9. Remove indexing
ring 10. Remove four planetary spindles 14.
5. Remove Belleville washer 38.

6. Support rear cover assembly 27 so that P3
planetary carrier assembly 5 can be removed.
Place special tool J 37035 over output shaft
splines and against the threaded shoulder of the
P3 planetary carrier. Press on special tool
J 37035 with a hydraulic press or drive on
J 37035 with a mallet until the P3 planetary
carrier assembly is separated from the rear
cover assembly.
roller bearing 37 from rear cover assembly 27.
If necessary to replace, remove bearing cup 36
using bearing tool J 3940.
6. Slide pinion gear 16, thrust washers 15 and 18,

and two bearing assemblies 17 from the side of
P3 planetary carrier 11. Repeat the procedure
with three remaining pinion gears.
7. Measure the thickness and any step wear of
eight washers 15 and 18. Minimum allowable
0.12 mm (0.005 inch).
NOTE:
b. Disassembly of P3 Planetary Carrier
Assembly (Foldout 10,A)
proceed with Step (8).

For all other models, skip Step (8) and proceed
WARNING!
with Step (9).
Place the P3 planetary assembly on its side to

avoid possible hand injury during disassembly.
1. Remove external retaining ring 13 and thrust
washer 12 from P3 planetary carrier
assembly 5.
NOTE:
For 4500 (wide ratio) model transmissions,
skip to Step (3).
For all other models, proceed with Step (2).
8. On 4500 model transmissions, remove output

9. Inspect bushing 7 inside the end of output
shaft 8 for wear or damage. Measure the ID of
the output shaft bushing. Maximum allowable
ID is 36.14 mm (1.423 inch).
529

c. Completion of Rear Cover Disassembly
(Foldout 10,A)
assembly with the notch in rear cover

assembly 27.
WARNING!
WARNING!


controlled.
1. Remove C5 clutch piston 23 from rear cover

assembly 27 by compressing spring and
retainer assembly 22 using J 37030-3 tool
base, washer, bearing, handle, and piston
force.
2. Remove piston sealring 24 from C5 clutch
piston 23.
3. Remove internal sealring 25 from C5 clutch
piston 23.
5. If replacement is necessary, remove dowel
pins 31.
d. Beginning Rear Cover Assembly
(Foldout 10,A)
bearing tool J 37033, and bearing cup 36 using
2. If removed, install dowel pins 31.
3. Install internal sealring 25 onto C5 clutch
piston 23. Install piston sealring 24 onto C5
clutch piston 23.
clutch piston with the tang in the rear cover
before installing C5 clutch piston 23 into the
rear cover. Install C5 clutch piston 23 into rear
cover assembly 27.
5. Install spring and retainer assembly 22,
aligning the tab in the spring and retainer
530

handle, and piston spring compressor
J 37030-2. Install external retaining ring 21
and slowly release the spring force.
e. Assembly of P3 Planetary Carrier Assembly
(Foldout 10,A)
assembly 19. Use driver sleeve J 37034 and
press the bearing against the shoulder on the
P3 carrier.
2. If removed, press bushing 7 inside the end of
3. Install output shaft assembly 6 into P3
4. Install thrust washer 12 and external retaining
ring 13.
5. Install two roller bearing assemblies 17 into
the center of pinion gear 16. Install thrust
washers 15 and 18 in P3 planetary carrier 11.
Align the thrust washer tangs with the slots in
the carrier and retain them with oil-soluble
grease. Slide pinion gear 16 and bearings into
the side of the P3 planetary carrier between the
thrust washers. Repeat the procedure with the
CAUTION:
If the wear on the indexing ring is minor, flip it
over to get a fresh reaction point for the spindle.
Replace the indexing ring if both corners of the
indexing ring are worn. Failure to take corrective
action may allow the spindle to rotate which may
reduce or shut off lubrication to the pinion
bearings and thrust washers.
MODULE REBUILD
NOTE:
Replacement indexing rings should look like the
example in Figure 512. The ring is stamped with
HD5. Replacement spindles should look like the
example in Figure 512. The spindle has a 2
stamped on the rear end.
6. Install four pinion spindles 14 so the lower step
is positioned for proper installation of indexing
ring 10.
7. Install indexing ring 10. Install internal
retaining ring 9.
gears.
f. Completion of Rear Cover Assembly
(Foldout 10,A)
contact with Belleville washer 38. Replace

current bearing retainer locknut if it does not
exhibit 5 Nm (44 lb in.) of running torque.
the torque wrench and breaker bar positioned as
shown in Figure 522, rotate the torque wrench
clockwise to tighten current bearing retainer
6. Support rear cover assembly 4 so that turning
torque of P3 carrier assembly 5 can be
locknut 39 (Figure 522). Use tool J 37035 to
measure turning torque. Maximum turning
torque is 3 Nm (27 lb in.).
1. Place P3 carrier assembly 5 on the work table

(with the output shaft up) and place rear cover
assembly 27 over the output shaft.

Tighten bolt to 6067 Nm (4549 lb ft).

assembly 37 into rear cover assembly 27 using
drive sleeve J 37034.
8. If a tachograph is used, install tachograph

sensor and tighten to manufacturers
specification. If a tachograph is used and the
sensor is not installed, install brass washer 28
onto tachograph plug 29. Install plug 29
into the rear cover. Tighten plug to 6067 Nm
(4549 lb ft).
NOTE:
When installing the Belleville washer, make sure
that the concave side of the washer at the inside
diameter contacts the inner race of the bearing and
that the anti-rotation tang engages the drilled hole
in the P3 carrier. Tilt the Belleville washer, tang
toward the bearing, to engage the tang into the hole.
J 37035-1
CAUTION:
damage cone and roller bearing assemblies 19
and 37 and cups 26 and 36.
4. Lubricate the output shaft threads and install
locknut 39 so that the Vespel buttons are in
V00223.00.03
Figure 522. P3 Carrier Turning Torque

MeasurementRear Cover Equipped
531

517. REAR COVER AND OUTPUT
SHAFT MODULE (4700 and 4800
Models Equipped With Rear Cover)
a. Disassembly (Foldouts 10,B and 10,C)
1. Remove retaining bolt 23 and output speed
sensor assembly 22 (Foldout 10,B). The output
speed sensor must have a resistance of 270
330 Ohms.
2. If used, remove the tachograph sensor. If
present, remove plug 19 and washer 20.
3. If not previously removed, remove output
seal 29 using seal removal tool J 24171-A.
NOTE:
4. Remove bearing retainer locknut 28 using

special tool J 37035 and J 43278.
5. Remove Belleville washer 27.
6. Support rear cover assembly 17 so that output
shaft assembly 6 can be removed. Press on
output shaft assembly 6 until it is separated
from the rear cover assembly 17 (Figure 523).
b. Disassembly of Output Shaft Assembly

(Foldout 10,B)
1. Inspect splines on the output shaft assembly.
(0.015 inch).
2. If replacement is required, remove bushing 7
from output shaft 8. If replacement is needed,
remove bearing 9. Maximum bushing 10
allowed is 36.14 mm (1.423 in.).
c. Completion of Rear Cover Disassembly
(Foldout 10,C)
WARNING!
1. Remove C6 clutch piston 13 from rear
cover 18 by compressing C5 piston spring and
retainer assembly 12 using J 37030-3 tool
base, washer, bearing, handle, and piston
force.
2. Remove external sealring 14 from C6 clutch
piston 13.
3. Remove internal sealring 15 from C6 clutch
piston 13.
d. Beginning Rear Cover Assembly
(Foldout 10,B)
bearing tool J 37033, and bearing cup 21 using
2. Install internal sealring 15 onto C6 clutch
piston 13. Install external sealring 14 onto C6
clutch piston 13.
V05598
Figure 523. Removal of Output Shaft Assembly
532

clutch piston with the tang in the rear cover
before installing C6 clutch piston 13 into rear
cover 18. Install C6 clutch piston 13 into rear
cover 18.
MODULE REBUILD
4. Install C5 piston spring and retainer assembly
12, aligning the tab in the spring and retainer
assembly with the notch in rear cover 18.
J 37034
WARNING!
controlled.
5. Compress C5 piston spring and retainer

J 43025. Install retaining ring 11 and slowly
release the spring force. Remove the special
tools.
e. Assembly of Output Shaft Assembly
(Foldout 10,B)
assembly 9. Use special tools J 43202 with
J 37034 and press the bearing onto output
shaft 8 (Figure 524).
f. Completion of Rear Cover Assembly
(Foldout 10,B)
1. Support output shaft assembly 6 and place rear
cover 18 over the output shaft assembly 6.
assembly 27 into rear cover 18 using drive
sleeve J 37034.
NOTE:
When installing the Belleville washer, be sure that
the concave side of the washer at the inside diameter
contacts the inner race of the bearing and that the
anti-rotation tang engages the drilled hole in the
output shaft. Tilt the Belleville washer, tang toward
the bearing, to engage the tang into the hole.
J 43202
V05586
Figure 524. Installation of Cone and Roller Bearing

Onto Output Shaft

4. Lubricate the output shaft threads and install
locknut 28 so that the Vespel buttons are in
contact with Belleville washer 27 (Foldout
10,J). Replace current bearing retainer locknut
if it does not exhibit 5 Nm (44 lb in.) of running torque.
CAUTION:
damage roller bearings 9 and 27 and bearing
cups 16 and 21. If the torque wrench and breaker
bar positions in Figure 525 are reversed, the
bearing retainer nut will be overtorqued. Be sure
wrenches are positioned ONLY as shown in
Figure 525.

the torque wrench and breaker bar positioned as
shown in Figure 525, rotate the torque wrench
clockwise to tighten current bearing retainer
transmission, tighten bearing retainer
533

6. Support rear cover assembly 17 so that turning
torque of output shaft assembly 6 can be
locknut 28. Use tool J 43278 to measure
turning torque. Maximum turning torque is
3 Nm (27 lb inch) (Figure 525).
7. If removed, install tachograph sensor or
plug 19 and washer 20.
518. CONTROL VALVE MODULE

(Foldout 11)
CAUTION:
To help prevent transmission damage protect
control module parts during removal, cleaning, inspection, and installation. Keep them in
clean containers until they are installed.
Control valve module assembly springs and
NOTE:
Delay installing output oil seal assembly 29.
other parts can be mistakenly interchanged.

Tag each part with its item number as it is removed and use Valve Tray Set J 33163 to simplify correct valve body reassembly.
Control valve module parts fit together

Tighten bolt to 2429 Nm (1821 lb ft).
closely and have specific operating clearances.

They can bind if damaged. These parts depend upon smooth sealing surfaces and may
leak if the sealing surface is scratched. Valves,
when dry, must move freely by their own
weight in their bores. Carefully handle all
such parts.
NOTE:
Refer to the latest revision of SIL 18-TR-98 for detailed service information regarding suspected contamination from water or Glycol. The presence of
water and/or ethylene glycol coolant in the transmission fluid is detrimental to the internal components. Contaminated fluid has a deteriorating effect
on transmission components.
J 43278
J 37035
a. Removal of Filters
V05589.00.01
Figure 525. Bearing Retainer Locknut

TorqueRear Cover Equipped
534
1. If not previously removed, remove two filter

covers 146, two gaskets 147, two O-rings 148,
two O-rings 149, and two filters 150.
2. Remove three bolts 3 and face seal 6. Remove
suction filter 5 and gasket 7. Discard suction
filter 5 and gasket 7.
MODULE REBUILD
c. Disassembly of the Solenoid Valve Body
b. Removal of Electrical Components

and Sensors
1. Remove twelve bolts 57. Remove two bolts 48.

NOTE:
Refer to Troubleshooting Manual TS3989EN
(Allison 4th Generation Controls) for inspection and
repair procedures.
1. If present remove two bolts 133 and oil level
sensor assembly (OLS) 134. Clean the OLS
with a soft cloth. Refer to TS3989EN for
sensor operation.
2. Disconnect all connectors. Release connectors
in the wire harness by pushing in the center tab
with a small screw driver as shown in Figure
526.
3. Remove three
assembly 13.
bolts
46
4. Remove standoff assembly.
from
standoff
2. Remove bracket 56 with diagnostic pressure

switch 55. Inspect switch for glycol
contamination (refer to latest revision of SIL
18TR-98). Maximum resistance of pressure
switch 55 must not exceed 2 Ohms. Minimum
resistance of pressure switch (open) must be at
least 20,000 Ohms. The switch should close
between 159255 kPa (2337 psi).
3. Remove bracket 47.
4. Remove three face seals 49.
5. Lift solenoid valve body 60 and separator
plate 93 from main valve body 115 being careful not to lose the four springs 50 and 53 and
accumulators 51 and 52. Set the solenoid valve
body 60 on a flat work surface.
V09556.00.00
Figure 526. Disconnecting Connectors
535

6. Remove PCS2 72 with O-rings 73 and 74. Remove valve 75 and spring 76.
7. Remove PCS1 67 with O-rings 68 and 69. Remove valve 70 and spring 71.
8. Remove TCC solenoid 62, O-rings 63 and 64,
valve 65, and spring 66.
9. Insert tool J 47942 tool into slot to push in diagnostic valve 78 and release clip 77, remove
spring 79 and valve 78.
WARNING!
Valve springs are highly compressed. Be extremely careful during disassembly. Personal injury can occur if the spring force is not
controlled.
10. Remove PCS3 80, two O-rings 81 and 82,
11. Remove PCS4 85, two O-rings 86 and 87,
12. Remove Main Mod solenoid 90 and two
O-rings 91 and 92.
13. Measure resistance of each solenoid by using
chart in Figure 520.
d. Disassembly of C6 Control Valve Body
NOTE:
C6 control valve body is only in 4700 and 4800 model transmissions.
1. Remove four bolts 154 remove C6 valve body
bracket 153, spring 152, accumulator 151, and
valve body 156.
2. Remove pin 158 for C6 Enable solenoid 160.
Remove nut 164 and plate 163, remove C6 enable solenoid 160, two O-rings 161 and 162,
3. Remove screw 171 and bracket 170. Remove
C6 Clutch solenoid 167, O-rings 168 and 169,
536
4. Inspect both valves and bores for nicks, wear,

and damage.
e. Disassembly of Main Valve Body
1. Remove two bolts 94 and main valve body assembly 95.
2. Lift Main Control Valve body 115 and set on
flat work space.
3. Remove solenoid retention pin 111 from bottom of control valve body.
4. Remove solenoid assembly 112 with O-rings
113 and 114. Measure resistance of the solenoid by using the chart in Figure 520.
5. Remove valve retention pin 96.
6. Remove stop 99, spring 98, and convertor flow
valve 97.
8. Remove stop 103, spring 102, and lube regulator valve 101.
WARNING!
Valve springs are highly compressed. Be extremely careful during disassembly. Personal injury can occur if the spring force is not
controlled.
9. Install spring compressor J 35924 (Figure 527).
Compress spring 106, remove valve retention
pin 104, and carefully remove compressor
J 35924 after turning handle counterclockwise
to release spring force.
10. Remove stop 107, spring 106, and main regulator valve 105.
12. Remove clip 110, spring 109, and control main
valve 108.
14. Remove stop 119, spring 118, and C2 latch
valve 117.
MODULE REBUILD
3. Install drain plug 141. Tighten plug to
2532 Nm (1824 lb ft).
4. If removed, install two pins 139.
5. Install gasket 137 and separator plate 136.
h. Assembly of the Main Valve Body
1. Install converter regulator
spring 130, and stop 131.
valve
129,
2. Install valve retention pin 132.

3. Install C1 latching valve 125, spring 126, and
stop 127.
Figure 527. Use of Tool to Release Main-Pressure
Valve Spring Force

16. Remove stop 123, spring 122, and exhaust
back valve 121.
18. Remove stop 127, spring 126, and C1 latch
valve 125.
20. Remove stop 131, spring 130, and converter
regulator valve 129. Inspect stop 131 for battering. Replace the stop if it is battered.
21. Remove gasket 172, separator plate 136, and
channel plate gasket 137.
f. Disassembly of the Channel Plate
1. If damaged, remove two pins 139.
2. Remove drain plug 141 and O-ring 142.
3. Remove nine pressure tap plugs 145 with
O-ring 144.
4. Remove O-rings from all tap plugs 145.
5. Install exhaust-back valve 121, spring 122, and

stop 123.
7. Install C2 latch valve 117, spring 118, and
stop 119.
9. Install control main valve 108, spring 109, and
clip 110.
10. Install O-rings 113 and 114 on solenoid 112
and install solenoid.
11. Install solenoid retention pin 116 through bottom of main valve body assembly.
12. Install main regulator valve 105, spring 106,
and stop 107.
13. Install spring compressor J 35924 (Figure 527).
Compress spring 106, install valve retention
pin 104, and remove J 35924 after turning handle counterclockwise until the tool clears
pin 104.
14. Install lube regulator valve 101, spring 102,
and stop 103.
16. Install converter flow valve 97, spring 98, and
stop 99.
g. Assembly of the Channel Plate

1. Install new O-rings on all tap plugs 45.
2. Install nine pressure tap plugs 145. Tighten plugs to
1013 Nm (710 lb ft).
18. Install main valve body assembly 95 onto seperator plate 136, channel plate gasket 137, and
channel plate assembly 138.
19. Install solenoid separator plate 93 onto main
valve body assembly 115.
537

i. Assembly of C6 Control Valve Body
NOTE:
Apply transmission fluid to the control module bolts
as they are installed. This will provide lubrication
during the installation and tightening and prevent
thread seizure.
NOTE:
C6 control valve body is only available in 4700 and
4800 model transmissions.
1. Install spring 157, valve 159, two O-rings 161
and 162, C6 enable solenoid 160, solenoid protective plate 163, push-on nut 164, and solenoid retention pin 158 into C6 valve body 156.
2. Install spring 165, valve 166, two O-rings 168
and 169, solenoid 167, bracket 170 and secure
to C6 valve body 156 with screw 171.
3. Install accumulator plug 151 and spring 152 into
C6 valve body 156.
4. Position C6 control valve body assembly 155
onto separator plate 136, channel plate
assembly 137, and channel plate assembly 138.
5. Install bracket 153 and four bolts 154. Tighten
the bolts to 1013 Nm (710 lb ft).
j. Assembly of the Solenoid Valve Body
1. Install Main Mod solenoid 90, two O-rings 91
and 92.
2. Install spring 89, valve 88, O-rings 86 and 87
and PCS4 85.
3. Install spring 84, valve 83, two O-rings 81 and
and 82, and PCS3 80.
8. Install three face seals 49.

9. Install four accumulators 51 and 52 and
springs 50 and 53.
10. Install bracket 47.
11. Install bracket 56 with diagnostic pressure
switch 55. Inspect switch for glycol contamination, refer to the latest revision of SIL 18-TR-98.
Maximum resistance of pressure switch 55
must not exceed 2 Ohms. Minimum resistance
of pressure switch (open) must be at least
20,000 Ohms. The switch should close between 159255 kPa (2337 psi).
12. Position solenoid body assembly 59 onto solenoid separator plate 93, and control valve
body 115.
13. Install twelve bolts 57. Install two bolts 48.
Tighten bolts to 1013 Nm (710 lb ft).
k. Installation of Electrical Components
and Sensors
1. Position wire harness assembly 8 onto control
valve module.
2. Install wire harness assembly 8. Secure
standoff assembly 13 with three bolts 46.
Connect all connectors. Tighten bolts 46 to 5
8 Nm (46 lb in.).
3. Postion oil level sensor assembly 134, if
present onto control valve module.
4. If present install two bolts 133, two Ferrule
Vitton 135, and oil level sensor assembly 134.
l. Install Filters
4. Install diagnostic valve 78 and spring 79. Insert

tool J 47942 tool into slot to push in valve and
install clip 77.
1. Install suction filter 5, gasket 7, and face

seal 6. Install three bolts 3. Tighten bolts to
1013 Nm (710 lb ft).
5. Install spring 66, valve 65, and TCC

solenoid 62 with two O-rings 63 and 64.
2. Install case gasket 172.
6. Install spring 71, valve 70, and PCS1 67 with

two O-rings 68 and 69.
538
7. Install spring 76, valve 75, and PCS2 72 with

O-rings 73 and 74.
3. Install two filters 150, two O-rings 149

and 148, two gaskets 147, and two filter
covers 146.
SECTION 6TRANSMISSION ASSEMBLY

61.
SCOPE
a. Section. This section covers the assembly of 4000

Product Family transmissions. The assembly sequence
is continuous and includes all models.
b. Procedures. When a procedure does not apply to
your specific model, go to the next applicable
procedure.
c. Illustrations. Illustrations will not always show
your model, but when an operation is identical for all
models, the correct procedure is shown.
d. General Information. Refer to Section 3 for
general information as follows:
Paragraph
Description
32
Tools, Equipment
33
Replacement Parts
34
Careful Handling
36
Assembly Procedures
e. Foldouts. Refer to Foldouts 4 through 12 for

disassembled views and torque specifications.
1. Install C3/C4 clutch assembly 1 through the

input end of main housing 2, aligning the bolt
holes in the clutch assembly with the holes in
the main housing.
2. Install two bolts 3, 180 degrees from each
other, to hold clutch assembly 1 in place.
3. Rotate the transmission housing using repair stand
controls and install remaining twelve bolts 3.
Tighten all bolts to 5161 Nm (3845 lb ft).
b. Installation of Rotating Clutch Module
(Figure 62). Use repair stand controls to put main
housing in the vertical position. Use a hoist and an
M16 eye bolt to insert rotating clutch module 1 in the
front of the main housing.
NOTE:
All parts must be cleaned and lubricated before
assembly.
E01274.01
Figure 61. Main Housing and C3/C4 Clutch Installation
62.
ASSEMBLY OF TRANSMISSION
a. Assembly of Main Housing Module

(Figure 61)
1
CAUTION:
Before beginning assembly, attach bracket
J 41445 and holding fixture J 35926 to the main
housing. Use a hoist to mount the fixture and
housing on repair stand J 29109.
CAUTION:
E01273.01
Be sure that main housing is horizontal when

installing the C3/C4 clutch module.
Figure 62. Rotating Clutch Module Installation
61

c. Installation of Front Support/Charging
Pump Module (Figure 63)
f. Installation of C5 Clutch Pack (Figure 65)
1. Lower front support and charging pump

module 3 over the top of the turbine shaft.
NOTE:
2. Align bolt holes in front support 3 with the

threaded holes in the main housing.
The correct combination of C5 friction clutch plates

and P3 ring gear must be used. Refer to
SIL 12-WT-03 to determine the correct P3 ring gear
and C5 friction clutch plates combination.
3. Install seven bolts 1 and seven bolts 2. Tighten

bolts to 5161 Nm (3845 lb ft).
4. Rotate the repair stand so the rear of the main
housing is facing upward.
d. Installation of P1 Planetary Module
(Figure 64)
1. Install P1 planetary module 1consisting of
the P1 carrier and P2 ring gear.
2. Mesh the P1 pinion gears with the P1 ring gear
inside the C3/C4 clutch assembly.
Install the C5 clutch pack in the main housingnine

steel reaction plates 2 and eight friction plates 3,
stacked alternately, starting with a steel reaction plate.
Stack all plates so plate cone faces the same direction.
Steel plates mesh with the main housing and reaction
plates mesh with the P3 ring gear.
g. Installation of Main Shaft Module (Except
4700 and 4800 Models) (Figure 66). Install main
shaft 1 as assembled in Section 5, without selective
shim 2 and thrust bearing 3
e. Installation of P2 Planetary Module

(Figure 65)
1. Install P2 planetary module 1consisting of
the P2 carrier and the P3 ring gear.
2. Mesh the P2 pinions with the P2 ring gear
during installation.
2
3
E01271.01
Figure 64. P1 Planetary Module Installation
1
1
C5
2
3
E02516.01
V01272
Figure 63. Front Support/Charging

Pump Module Installation
62
Figure 65. P2 Planetary Module and

C5 Clutch Installation
TRANSMISSION ASSEMBLY
2. Measure dimension A, from top of the straight
edge to the selective shim thrust surface on the
main shaft bearing spacer.
3. Measure dimension B, thickness of straight
edge. Subtract dimension B from dimension
Athe remainder is dimension C.
4. Place the retarder or rear cover module output
end down (facing the bench top). Install an
uncompressed gasket on the retarder or rear
cover mounting surface and place a straight
edge across the P3 planetary carrier.
5. Measure dimension D, from top of the straight
edge to the gasket.
6. Measure dimension E from the top of the
straightedge to the thrust bearing contact
surface on the P3 planetary carrier. Subtract
dimension E from dimension Dthe
remainder is dimension F.
7. Dimension G is the remainder of C minus F
and determines the thickness of the selective
shim.
8. Install the proper thickness selective shim and
the thrust bearing.
WIDE RATIO MODELS
CLOSE RATIO MODELS
V01737.00.06
Figure 66. Main Shaft Module Installation
h. Installation of Main Shaft Module (4700 and

4800 Models). Install main shaft module as assembled in Section 5.
i. Main Shaft Selective Shim Measurement
(Close Ratio Models) (Figure 67)
1. Place a straight edge across the retarder or rear
cover mounting surface of the main housing.
BEARING AND
SHIM REMOVED
STRAIGHT EDGE
DIM. A
UNCOMPRESSED
GASKET IN PLACE
STRAIGHT EDGE
DIM. E
DIM. B
DIM. C
DIM. F
DIM. D
MAIN SHAFT MODULE
RETARDER
MODEL
NONRETARDER
MODEL
PROCEDURE: FORMULA (C)(F)=G

DIM. G
5.71356.033 mm
0.2310.237 in.
6.0346.303 mm
0.2380.247 in.
6.3046.573 mm
0.2480.258 in.
6.5746.843 mm
0.2590.269 in.
USE P/N
SHIM ID
29501117
1 NOTCH
29501118
2 NOTCHES
29501119
3 NOTCHES
29501120
4 NOTCHES
DIM. G
6.8447.113 mm
0.2700.280 in.
7.1147.383 mm
0.2810.290 in.
7.3847.484 mm
0.2910.295 in.
USE P/N
SHIM ID
29501121
5 NOTCHES
29501122
6 NOTCHES
29512774
0 NOTCHES
V03210.01.00
Figure 67. Main Shaft Selective Shim Measurement for 4000 Product FamilyClose Ratio
63
1. Place a straight edge across the retarder or rear

cover mounting surface of the main housing.

straightedge to the thrust bearing contact
surface on the P3 planetary carrier. Subtract
dimension E from dimension Dthe
remainder is dimension F.

main shaft bearing spacer.

shim.
j. Main Shaft Selective Shim Measurement

(Wide Ratio Models) (Figure 68)
8. Install the proper thickness selective shim and

the thrust bearing.

Athe remainder is dimension C.
CAUTION:
4. Place retarder or rear cover output end down

(facing the bench top). Install an
uncompressed gasket on the retarder or rear
cover mounting surface and place a straight
edge across the P3 planetary carrier.
To help prevent premature thrust bearing

failure, make sure that the locating lip on either
the inner or outer thrust bearing race is not
preventing the race from contacting the thrust
surface of the mating part. Failure to do this
leads to premature thrust bearing failure and
incorrect shim selection to maintain proper
5. Measure dimension D, from top of the straight

edge to the gasket.
BEARING AND
SHIM REMOVED
STRAIGHT EDGE
DIM. A
UNCOMPRESSED
GASKET IN PLACE
STRAIGHT EDGE
DIM. E
DIM. B
DIM. C
DIM. F
DIM. D
MAIN SHAFT MODULE
RETARDER
MODEL
NONRETARDER
MODEL
PROCEDURE: FORMULA (C)(F)=G

DIM. G
4.61774.843 mm
0.1800.190 in.
4.8445.113 mm
0.1920.201 in.
5.1145.383 mm
0.2020.212 in.
5.3845.653 mm
0.2130.223 in.
USE P/N
SHIM ID
29503218
1 NOTCH
29503219
2 NOTCHES
29503220
3 NOTCHES
29503221
4 NOTCHES
DIM. G
5.6545.923 mm
0.2240.233 in.
5.9246.193 mm
0.2340.244 in.
6.1946.380 mm
0.2450.254 in.
USE P/N
SHIM ID
29503222
5 NOTCHES
29503223
6 NOTCHES
29503224
7 NOTCHES
V03211.01.00
Figure 68. Main Shaft Selective Shim Measurement for 4000 Product FamilyWide Ratio
64
k. Installation of P3 Planetary Module (4700 and
4800 Models With Retarder) (Figure 69)
1. Thread special tool J 43020 onto P3 Planetary
Module 2 and use chain hoist to install P3
Planetary Module 2 in Main Housing
Module 1.
2. Install P4 shaft flange 3.
NOTE:
Do not install shim locating ring or selective shim
until final transmission assembly. Measurement for
selective shim is performed during final buildup.
CAUTION:
Over-tightening bolt 3 will damage the bolt. Use
the torque formula in Figure 612 to find the
correct torque value to apply to bolt 3.
3. Install fourteen bolts 3 through C6 adapter
housing module 4 into main housing 1. Tighten
bolts in a star pattern using special tool J 43046
and torque wrench to produce 100120 Nm
(7488 lb ft) at the bolt (Figure 611). Use the
formula in Figure 612 to find the correct
torque wrench value that will apply to the
required torque bolt 3.
1
J 43046
l. Installation of C6 Adapter Housing Module

(4700 and 4800 Models With Retarder)
(Figure 610)
2
3
4
1. Install new C6 adapter housing gasket 2.
WARNING!
Get help when lifting the C6 adapter housing
module. Assistance from a hoist or another
person may be required. The C6 adapter housing
module weighs approximately 68 kg (150 lb).
5
2. Thread two M12 bolts and attach a sling to the

C6 adapter housing module 4 by positioning
the housing connections equal distance from
each other. Using a chain hoist, carefully lift
and install the C6 adapter housing 4 onto the
transmission.
V05374
Figure 610. Installation of C6 Adapter

Housing Module
J 43046
2
3
4
5
J 43020
V05590
V05375
Figure 69. Installation of P3 Planetary Module
Figure 611. Tightening C6 Adapter Housing

to Main Housing Bolts
65
BOLT
(C6 adapter housing
to main housing)
A
TORQUE WRENCH
J 43046
Tw
Ta
CLOCKWISE
ROTATION
L
C6 ADAPTER HOUSING
TOP VIEW
L
L+A
L = Effective length of torque wrench
A = Effective length of special tool
Tw = Torque applied at the wrench (adjusted torque value to be applied with wrench)
Ta = Torque applied at the bolt (ACTUAL torque value specified by service manual)
Tw = Ta X
V05591
Figure 612. C6 Adapter Housing to Main Housing Bolt Torque Formula
m. P3 Planetary Selective Shim Measurement

(Figure 613)
1. Place a straight edge across the rear face of the
C6 adapter housing with uncompressed
retarder housing gasket.
P3 carrier face.
Athe
remainder
is
dimension
C
(measurement between rear face of adapter
housing with uncompressed gasket and P3
carrier face).
66
surface. Place the P4 ring gear hub over the

output shaft. Place two measuring blocks
included in special tool J 43922 on the front
face of retarder. Place the straight edge
included in J 43922 across the top of the
measuring blocks included in J 43922.
6. Measure dimension D from top of the straight
edge to the face of the retarder.
straight edge J 43922 to the face of the P4 ring
gear hub.
4. Remove retarder housing gasket.
8. Subtract dimension E from dimension D

remainder is dimension F (measurement
between front face of retarder and P4 ring gear
hub face)
5. Place the retarder module output end down

(facing the bench top) on supports, so the
output shaft is not contacting the bench

shim, dimension G.

(measurement between rear face of adapter
housing with uncompressed gasket and P3
carrier face).
n. P3 Planetary Selective Shim Measurement

(4700 and 4800 Models With Rear Cover)
(Figure 614)
4. Remove rear cover gasket.
1. Place a straight edge across the rear face of the

C6 adapter housing with uncompressed rear
cover gasket.
5. Place the rear cover module output end down

(facing the bench top) on supports, so the
output shaft is not contacting the bench
surface. Place the P4 ring gear hub over the
output shaft. Place the two measuring blocks
included in special tool J 43922 on the front
face of rear cover. Place the straight edge
included in J 43922 across the top of the
measuring blocks included in J 43922.

P3 carrier face.
Athe
remainder
is
dimension
C
DIM. B
STRAIGHT EDGE
J 43922
GASKET
INSTALLED
STRAIGHT EDGE
J 43922
DIM. A
DIM. C
MEASURING
BLOCK (2), J 43922
DIM. E
DIM. F
DIM. D
No Gasket
SUPPORTS
C6 ADAPTER HOUSING MODULE
RETARDER AND OUTPUT SHAFT MODULE
PROCEDURE: FORMULA CF=G

DIM. G
0.88301.1534 mm
0.03470.0454 in.
1.15351.4234 mm
0.04550.0560 in.
1.42351.6934 mm
0.05610.0666 in.
1.69351.9634 mm
0.06670.0772 in.
1.96352.2334 mm
0.07730.0879 in.
2.23352.5034 mm
0.08800.0985 in.
2.50352.7734 mm
0.09860.1091 in.
2.77353.0434 mm
0.10920.1198 in.
3.04353.3134 mm
0.11990.1304 in.
USE P/N
SHIM ID
29530516
29530517
1 NOTCH
29530518
2 NOTCHES
29530519
3 NOTCHES
29530520
4 NOTCHES
29530521
5 NOTCHES
29530522
6 NOTCHES
29530523
7 NOTCHES
29530524
8 NOTCHES
V05380.00.03
Figure 613. P3 Planetary Shim Measurement (4700 and 4800 Models With Retarder)
67
DIM. B
STRAIGHT EDGE
J 43922
GASKET
INSTALLED
STRAIGHT EDGE
J 43922
DIM. A
DIM. C
MEASURING
BLOCK (2), J 43922
DIM. E
DIM. F
DIM. D
No Gasket
SUPPORTS
C6 ADAPTER HOUSING MODULE
REAR COVER AND OUTPUT SHAFT MODULE
PROCEDURE: FORMULA CF=G

DIM. G
0.88301.1534 mm
0.03470.0454 in.
1.15351.4234 mm
0.04550.0560 in.
1.42351.6934 mm
0.05610.0666 in.
1.69351.9634 mm
0.06670.0772 in.
1.96352.2334 mm
0.07730.0879 in.
2.23352.5034 mm
0.08800.0985 in.
2.50352.7734 mm
0.09860.1091 in.
2.77353.0434 mm
0.10920.1198 in.
3.04353.3134 mm
0.11990.1304 in.
USE P/N
SHIM ID
29530516
29530517
1 NOTCH
29530518
2 NOTCHES
29530519
3 NOTCHES
29530520
4 NOTCHES
29530521
5 NOTCHES
29530522
6 NOTCHES
29530523
7 NOTCHES
29530524
8 NOTCHES
V05612.00.03
Figure 614. P3 Planetary Shim Measurement (4700 and 4800 Models With Rear Cover)
6. Measure dimension D from top of the straight

edge to the face of the rear cover.
straight edge J 43922 to the face of the P4 ring
gear hub.
8. Subtract dimension E from dimension D
remainder is dimension F (measurement
between front face of rear cover and P4 ring
gear hub face).
shim dimension G.
68
o. Installation of Remainder of P3 Planetary

Module and C6 Adapter Housing Module
(4700 and 4800 Models) (Foldout 9,C)
1. Install shim locating ring 6.
2. Install the proper selective shim 12 from
previous step m or n.
3. Install retaining ring 48 into P4 ring gear 46 to
complete hub assembly 45.
4. Install ring gear and hub 45.
3. Thread an M14 eye bolt into the retarder output shaft and lift retarder module 1 onto main
housing module 8. If used, install the rear support bracket.
p. Installation of Tolerance Rings Module

1. Insert eleven tolerance rings 49 (Foldout 9,C)
in counterbores flush to slightly below rear
mounting surface at locations shown in
Figure 615.
4. Install twelve bolts 2, three bolts 3, two bolts 4,

four bolts 5, and four bolts 6 that secure retarder module 1 to main housing module 8.
Tighten bolts 2, 4, and 5 to 100120 Nm (74
88 lb ft). Tighten bolts 3 and 6 to 5161 Nm
(3845 lb ft).
q. Installation of Retarder Module

(Models Equipped With Retarder,
Except 4700 and 4800 Models) (Figure 615)
1. Install guide bolts to ease retarder module 1
installation and keep gasket 7 in place.
2. Install retarder gasket 7 over the guide bolts
and against the main housing module 8.
5. Retighten bearing retainer locknut 59

(Foldout 10,E) using tool J 37035 to 7488 Nm
(5564 lb ft).
WARNING!
6. Install output shaft oil seal assembly 60, using

tool J 37031.
2
2
1
2
8
7
4
6
3
6 5
2
5
5
3
OR
3
V06844
Figure 615. Retarder Module Installation
69

r. Installation of Retarder and Output Shaft
Module (4700 and 4800 Models With
Retarder)
NOTE:
DO NOT reuse a tang once it has been bent. Use a
new locknut retainer 43 (Foldout 10,A).
1. Thread an M10 eye bolt into the output shaft

assembly 3 (Foldout 10,D).
8. Install output shaft oil seal 45 (Foldout 10,A)

using special tools J 43024 and J 37034, and
rubber mallet (Figure 616).
2. Install new retarder stator housing gasket 1.

3. Install guide bolts to ease retarder and output
shaft module 5 installation, and keep the gasket
in place (Figure 617).
4. Install twelve bolts 4, two bolts 7, and four
bolts 8 (Figure 617). Tighten bolts to 100120
Nm (7488 lb ft).
J 37034
J 43024
5. Install four bolts 9 and three bolts 6 (Figure

617). Tighten bolts to 5161 Nm (3845 lb ft).
6. Lift with hoist, and install retarder and output
shaft module onto C6 adapter housing
module 2.
7. Use special tool J 43278 and J 37035 and tighten
bearing retainer locknut 39 to 7488 Nm
(5564 lb ft) (Foldout 10,A).
V05594
Figure 616. Installation of Output Shaft Oil Seal

4
2
4
4
4
3
5
7
4
7
9
8
6
6
OR
7 8
V06845
Figure 617. Installation of Retarder and Output Shaft Module (4700 and 4800 Models)
610
s. Installation of Rear Cover Module
(Except 4700 and 4800 Models) (Figure 618)
1. Install guide bolts to ease rear cover 2
2. Install a NEW rear cover gasket 1 on main
housing 4.
3. Place rear cover module 2 on main housing 4
using a hoist and sling as a lifting fixture.
Install rear support bracket 3 (Foldout 10,B), if
used.
4. Install nineteen bolts 3 (Figure 618).
t. Installation of Rear Cover Module

1. Install guide bolts to ease rear cover 6
2. Install a NEW rear cover gasket 3 on C6
adapter housing 2.
3. Place rear cover module 6 on adapter
housing 2 using a hoist and sling as a lifting
fixture. Install rear support bracket, if used.
5. Retighten the spanner nut using tool J 37035 to

7488 Nm (5564 lb ft).
CAUTION:
Do not reuse a tang once it has been bent. Install
a new locknut retainer 38 (Foldout 10,A).
6. Install output shaft oil seal 5 (Figure 618)
using tool J 37031.
4. Install fourteen bolts 4 and install five bolts 5

(Figure 620). Tighten bolts to 100120 Nm
(7488 lb ft).
5. Retighten bearing retainer locknut using tool
J 37035 and J 43278. Tool J 43278 holds the
bearing retainer locknut while tool J 37035
turns the shaft counterclockwise to retighten
the bearing retainer locknut. Tighten the
CAUTION:
Do not reuse a tang once it has been bent. Install
a new locknut retainer 28 (Foldout 10,D).
4
1
3
2
V06867
Figure 618. Rear Cover Module Installation
6. Install output shaft oil seal 29 (Foldout 10,B)

using tool J 43024 and J 37034 and rubber
mallet (Figure 622).
611
1
2
J 43278
J 37035
6
7
5
V05589.00.01
V05580
Figure 619. Installation of Rear Cover and Output

Shaft Module
BOLT, M12 x 1.75 x 45

(14) MARKED 4
Figure 621. Tightening Bearing Retainer

LocknutRear Cover Equipped
4
4
J 37034
4
J 43024
4
4
BOLT,
METRIC HEAVY
(5) MARKED 5
4
4
5
5
V05595
V07494
Figure 620. Rear Cover and Output Shaft

Module Bolts
612
Figure 622. Installation of Output Shaft Oil Seal

(4700 and 4800 Models With Rear Cover)
u. Installation of Converter Housing Module
(Figure 623)
1. Install guide bolts to ease converter housing 1
2. Position the transmission input end up. Install a
NEW converter housing gasket 2 on main
housing module 4.
3. Lower converter housing 1 onto main
housing 4. If the transmission is PTO
equipped, rotate the PTO drive gear to align the
gear tangs with the charging pump.
4. Install seven bolts 3 into the inside of converter
housing 1. Use mechanical fingers, or a similar
tool, when installing these bolts.
5. Remove the two guide bolts and install the
remaining bolts 3. Tighten all bolts 3 to 5161 Nm
(3845 lb ft).
v. Installation of Torque Converter Module

(Figure 624)
1. The torque converter is installed over the
turbine shaft which rotates inside the stator
shaft or ground sleeve. The splines on the
ground sleeve engage the converter stator. The
splines on the turbine shaft engage the
converter turbine. The end of the turbine shaft
is threaded and machined to accept the
converter retaining bolt and lockup sealring.
2. The splines of the ground sleeve and turbine
shaft must engage with their respective splines
in the torque converter module. The tangs on
the converter-pump hub must engage the
charging pumps drive gear or the PTO oil
pump drive hub.
3. Using a hoist and sling, install torque converter
module 6 into the converter housing module
4. Make sure that the torque converter is properly
seated. If PTO equipped, rotate the PTO gear to
engage the pump hub with the charging pump.
Proceed with the selective shim measurement.
5. Install converter end play gauge J 38548
and tighten the attaching bolt to 2734 Nm
(2025 lb ft). Prevent turbine shaft rotation by
using one of the following methods:
Insert a screwdriver into the vanes on the
rotating clutch module (Figure 624,

View B).
If the control module is in place, apply air

2
V06868
Figure 623. Converter Housing Module Installation
pressure through the lockup pressure tap

and use a heel bar, screwdriver, and bolts.
Insert the heel bar into a torque converter
housing bolt hole. Insert two bolts into the
flexplate adapter bolt holes. Then place a
screwdriver at an angle to prevent converter
rotation (Figure 624, View C).
613
CUPPED END DOWN
5
1
RESTRICT MOVEMENT
USE HOIST AND SLING
J 38564
VIEW A
VIEW B
VIEW C
VIEW D
Figure 624. Torque Converter Module Installation and Selective Shim Measurement
614
VL06869.01.00
NOTE:
Dimension C shown in Table 61 includes a
correction due to internal deflection caused by the
2734 Nm (2025 lb ft) bolt torque applied to gauge
J 38548. Correct torque value is critical to selection
of the proper shim.
6. Measure from top of tool J 38548 to face of
turbine shaft and record it as dimension B
(Figure 624, View D). Subtract dimension B
from dimension A to determine dimension C.
(Dimension A is the height of tool J 38548,
100.00 mm; 3.937 inch.)
7. Use dimension C and Table 61 to determine

proper selective shim part number. Remove
tool J 38548 and continue with installation of
the torque converter.
8. Keep the torque converter cover from turning
by using a heel bar, two bolts, and a screwdriver (Figure 624, View C).
9. Install threaded plug 7 and O-ring 8 using a
34 inch Allen socket. Tighten plug to 5060 Nm
(3744 lb ft).
10. Install converter shipping brackets 1
(Foldout 12,B), or equivalent, to prevent
torque converter movement. Tighten the shipping bracket bolts to 5161 Nm (3845 lb ft).
Table 61. Torque Converter Selective Shims

Dimension C
Use P/N
Shim Thickness (Ref.)
ID
No.
0.41290.6598 mm (0.01630.0259 inch)
29505688
4.000 mm (0.157 inch)
0.65990.8378 mm (0.02600.0329 inch)
29505681
4.203 mm (0.165 inch)
0.83791.0158 mm (0.03300.0399 inch)
29505682
4.381 mm (0.172 inch)
1.01591.1938 mm (0.04000.0469 inch)
29505683
4.559 mm (0.179 inch)
1.19391.3708 mm (0.04700.0539 inch)
29505684
4.736 mm (0.186 inch)
1.37091.5488 mm (0.05400.0609 inch)
29505685
4.914 mm (0.193 inch)
1.54891.7268 mm (0.06100.0679 inch)
29505686
5.092 mm (0.200 inch)
1.72691.9048 mm (0.06800.0749 inch)
29507793
5.270 mm (0.207 inch)
1.90491.9733 mm (0.07500.0776 inch)
29507794
5.448 mm (0.214 inch)
615

w. Installation of Control Module (Figure 625)
NOTE:
Apply transmission fluid to the control module bolts
as they are installed. This will provide lubrication
during the installation and tightening and prevent
thread seizure.
1. Place the transmission in a vertical position,

front end upward.
2
2. Install two guide pins in two main housing bolt

holes.
WARNING!
Get help when lifting the control module.
Assistance from another person may be
required. The control module weighs
3. Lubricate the feedthrough hole in the main

housing with oil-soluble grease.
4
V09785.00.00
4. Guide control module 1 onto the main housing

and pass feedthrough harness connector
through the feedthrough hole in the main
housing.
5. Align the control module bolt holes with the
guide pins. Make sure the feedthrough harness
standoff is aligned with the feedthrough hole in
the main housing.
Figure 625. Control Module Installation
x. Installing Integral Oil Cooler (Figure 626)

1. Install nine washers 6 on nine M10 x 1.5 x 70
bolts 7.
2. Install two bolts 7 into the upper corners of
cooler housing 3.
3. Install gasket 1 over bolts 7.
6. Lower the control module over the guide pins

until it seats against the main housing.
7. Install filter cover assemblies prepared in
Paragraph 518.
616
4. Position cooler housing

transmission main housing.
against
the
5. Tighten two bolts 7 finger tight, making sure

gasket 1 is properly positioned.
6. Install the remaining seven bolts 7 into cooler
housing 3. Tighten nine bolts 7 to 5161 Nm
(3845 lb ft).
4. Install cooler manifold 16 over the headless

guide bolts.
5. Install three M12 x 1.75 x 195 bolts 10.
7. Install two O-rings 8 onto plate assembly 9.

8. Install plate assembly 9 into cooler housing 3
so that O-rings 8 seal against the transmission
main housing.
6. Remove the two headless guide bolts.
9. Install two bolts 12 into the upper corners of

cover 13.
8. Install M10 x 1.5 x 50 bolt 8. Tighten bolt to

5161 Nm (3845 lb ft).
7. Install seven M10 x 1.5 x 187.5 bolts 9.

9. Rotate the transmission so that the breather is

facing up.
10. Install gasket 14 over bolts 12.

11. Install cover 13 onto cooler housing 3. Tighten
two bolts 12 finger tight.
12. Install the fifteen remaining bolts 12. Tighten
bolts 12 to 5161 Nm (3845 lb ft).
13. Install two bolts 11. Tighten two bolts 11 to
100120 Nm (7488 lb ft).
y. Installing Integral Retarder Sump Oil Cooler
(Foldout 12,C)
1. Rotate the transmission so that the retarder is
facing up.
2. Install two headless guide bolts into the
retarder housing.
3. Install gasket 4 over the headless guide bolts.
10. Install two headless guide bolts into each manifold to cooler mating surface.
11. Install gaskets 6 over the headless guide bolts.
WARNING!
To help avoid personal injury, securely support
the cooler in its installed position before
installing the bolts retaining the cooler to the
manifold. The cooler weighs 30 kg (64 lb); use
care when handling the cooler.
12. Install cooler 7 over the headless guide bolts
and install two M10 x 1.5 x 60 bolts 1 so that
the cooler is retained to the cooler manifold.
Do not install bolts into the inlet or outlet hose
adapter bolt holes. Tighten bolts finger tight.
4
3
1
11
4
5
8
2
6 7
8
19
18 17
19
18 17
11
15
9
10
10
16
11
12
14
13
11
V06843
Figure 626. Integral Oil Cooler Installation
617

20. If used, install the retarder accumulator hose
onto the fitting on cooler manifold 16.
13. Remove the two headless guide bolts.

14. Install two gaskets 3.
z. Installation of Externally Mounted Parts

(Figure 627)
15. Align and install two inlet or outlet hose adapters 2.
1. If
not
previously
installed,
install
transmission breather 20. Tighten breather to
1216 Nm (912 lb ft).
16. Install the remaining fourteen M10 x 1.5 x 60

bolts 1.
17. Evenly tighten sixteen M10 x 1.5 x 60 bolts 1
to 5161 Nm (3845 lb ft).
2. Install fill tube seal 9, fill tube 8, bracket 6,

and screw 5. Tighten screw to 2429 Nm
(1821 lb ft). Install dipstick 7.
18. Install six bolts 5. Tighten bolts to 2429 Nm

(1821 lb ft).
3. If used, install new cooler port gasket 10. Install

remote mount manifold 11 and six bolts 12.
19. Install water inlet and outlet hoses.
20
ENGINE
SPEED
SENSOR
2
TURBINE 1
SPEED
SENSOR
7
5
9
OUTPUT
SPEED
SENSOR
15
13
16
10
11
17
18
19
12
14
V06837.03.00
Figure 627. Installation of Externally Mounted Parts
618
ab. Removal of Transmission From Repair Stand
4. If removed, use special tool J 46150 to press a

new slinger 13 onto the flange or yoke.
WARNING!
5. Install output flange 15 or yoke 14.
Dry weight of 4000 Product Family

transmissions with PTO provision and retarder
is 439 kg (968 lb); with PTO provision is 405 kg
(893 lb). The dry weight of 4700 and 4800 models
with PTO provision and retarder is 555 kg
(1224 lb), dry weight of 4700 and 4800 models
with PTO provision is 521 kg (1149 lb).
6. Install O-rings 16 on plug 18.

7. Insert bolt 19 into plug 18.
8. Install O-ring 17 over the threaded end of
bolt 19, so that the O-ring seats against the
retainer plug.
9. Install retainer plug 18 into the yoke or flange.
Tighten bolt 19 to 7080 Nm (5160 lb ft).
Using hoist, remove transmission and holding fixture

from repair stand and prepare for vehicle installation.
aa. Installation of Power Takeoff

(Figure 628)
1. If removed, install two PTO pilot screws 4.
NOTE:
2. Install PTO gasket 3 and PTO assembly 2. Insert

one bolt 1 into each of the 6 oclock and
12 oclock positions. Install the remaining six
bolts. Tighten bolts to 5161 Nm (3845 lb ft).
Refer to Mechanics Tips MT4015EN for preparing

transmission for installation and installing the
transmission into a vehicle.
2
4
3
1
2
4
V06836
Figure 628. PTO Installation
619

NOTES
620
SECTION 7WEAR LIMITS AND SPRING DATA

71.
WEAR LIMITS DATA
which do not meet the load height specifications

according to Table 72, Spring Data.
a. Maximum Variations. Wear limit information in

this Section shows the maximum wear at which
components are expected to function satisfactorily.
Table 71 lists the Wear Limits Data and is referenced
to the exploded views (Foldouts 4 through 12) in the
b. Inspection. Inspection criteria (load vs. height)

and identification characteristics of the springs are
presented in Table 72. The Spring Data are keyed to
the exploded views (Foldouts 4 through 12) in the
b. Cleaning And Inspection. Parts must be clean to

permit effective inspection for wear or damage. Refer
to Section 3.
NOTE:
72.
SPRING DATA
a. Spring Replacement. Springs should be replaced

if there are signs of overheating, wear due to rubbing
adjacent parts, or permanent set. Discard springs
When more than one spring part number is listed

for the same location, refer to the 4000 Product
Family Parts Catalog PC2456EN to determine
which spring is used in your specific assembly
number.
Table 71. Wear Limits Data

Wear Limit
Illustration
Description
Foldout 4,B
TORQUE CONVERTER MODULE
mm
(inches)
66.91
2.634
10
Converter Cover Bushing, Maximum ID
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
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
89.19
3.511
14, 18
Foldout 5,B
6
TORQUE CONVERTER HOUSING MODULEPTO EQUIPPED

Bearing Retainer Bushing, Maximum ID
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
Oil Pump Drive Hub, Maximum Tang Wear
0.31
0.012
13
71

Table 71. Wear Limits Data (contd)
Wear Limit
Illustration
Description
mm
(inches)
Foldout 6,A
FRONT SUPPORT AND CHARGING PUMP MODULE

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
Ground Sleeve, Minimum OD In Bushing Area
66.67
2.625
0.13
0.005
119.81
4.717
16, 17
16, 17, 20
20
Front Support, Minimum OD
25
Front Support Seal, Minimum End Gap
1.00
0.040
25
Front Support Seal, Maximum End Gap
1.44
0.056
36.14
1.423
Foldout 6,B
ROTATING CLUTCH MODULE
Turbine Shaft Bushing, Maximum ID
Turbine Seal, Minimum End Gap
0.65
0.026
Turbine Seal, Maximum End Gap
1.01
0.039
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
C1, C2 Drive Hub, Maximum Spline Wear
0.38
0.015
C2 Backplate, Minimum Thickness
7.90
0.311
34, 36
39
72
Spline OD, Maximum Total Runout
WEAR LIMITS AND SPRING DATA

Wear Limit
Illustration
Foldout 7
Description
mm
(inches)
MAIN HOUSING MODULE
Backplate, Maximum Step Wear
0.13
0.005
Backplate, Maximum Distortion
0.15
0.006
P1 Ring Thrust Plate, Minimum Thickness At Wear Point
2.82
0.111
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
C3, C4 Friction Plate, Maximum Friction Material Erosion Around

Lubrication Slots
4.00
0.157
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
3.25
0.128
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
Main Housing, Maximum Spline Wear
1.15
0.045
5, 18
7
8, 21
43
Foldout 8
MAIN SHAFT MODULEWIDE 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
7, 8
Main Shaft Spines, Maximum Wear
0.38
0.015
0.94
0.037
89.32
3.516
Foldout 9,A
P1 PLANETARY MODULE
P1 Planetary Carrier Assembly, Maximum Pinion End Play
P1 Carrier Bushing, Maximum ID
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
0.38
0.015
0.94
0.037
53.23
2.096
15
Foldout 9,B
P2 PLANETARY MODULE
9, 12
1.40
0.055
9, 12
0.12
0.005
0.38
0.015
15
73

Wear Limit
Illustration
Description
Foldout 9,C
P3 PLANETARY AND C6 ADAPTER HOUSING MODULE (4700 and 4800 models)
(inches)
P3 Carrier Module, Maximum Pinion End Play
0.94
0.037
1.40
0.055
0.12
0.005
27
C6 Reaction Plate, Minimum Thickness
3.24
0.128
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
38
113.33
4.462
40
P4 Planetary Thrust Washer, Minimum Thickness
1.40
0.055
40
P4 Planetary Thrust Washer, Maximum Step Wear
0.12
0.005
0.94
0.037
27, 28
Foldout 10,A
REAR COVER AND P3 MODULE (except 4700 and 4800 models)
P3 Planetary Carrier Assembly, Maximum End Play
Output Shaft Bushing, Maximum ID
36.14
1.423
Output Shaft, Maximum Spline Wear
0.38
0.015
15, 18
1.40
0.055
15, 18
0.12
0.005
Foldout 10,B
REAR COVER AND OUTPUT SHAFT MODULE (47000 and 4800 models)
36.14
1.423
0.38
0.015
0.94
0.037
36.14
1.423
Foldout 10,C
RETARDER AND P3 MODULE (except 4700 and 4800 models)
13, 16
1.40
0.055
13, 16
0.12
0.005
27, 30
Retarder Rotor Sealring, Maximum ID
139.72
5.501
0.38
0.015
29
74
mm
Rotor Hub, Maximum Spline Wear

Wear Limit
Illustration
Description
Foldout 10,D
RETARDER AND OUTPUT SHAFT MODULE (4700 and 4800 models)
mm
(inches)
36.14
1.423
0.38
0.015
139.72
5.501
0.38
0.015
85.0
3.346
16, 19
18
Foldout 12,A
1, 4, 5, 6, 9,
10, 11, 12
Retarder Rotor Sealring, Maximum ID

Rotor Hub, Maximum Spline Wear
OUTPUT FLANGE AND YOKE
Output Seal Journal, Minimum OD
75
76
Ref.
26
22
20
25
25
10
22
17
22
12
20
35
25
70
Foldout
4,B
6,A
6,B
6,B
6,B
9,C
10,A
10,B
10,C
10,D
10,C
10,D
10,C
Exhaust Backfill
Retarder Flow Valve
Retarder Flow Valve
C5 Return
C5 Return
C5 Return
C5 Return
C5 Return
C4 Return
C3 Return
C1 Return
C1 Return
C2 Return
Main Relief
Stator
Spring
23049391 No Code
29515692 No Code
29515692 No Code
29503036 No Code
29503036 No Code
29503036 No Code
29503036 No Code
29530488 No Code
29542504 Pink
29542504 Pink
29537301 No Code
29509453 No Code
29505719 No Code
29507709 No Code
29501300 No Code
Part No.
Color
Code
20.40
11.4
11.4
12*
12*
12*
12*
11.6*
13.8
13.8
11.8*
12*
11.5*
10
N/A
No. of
Coils
N/A
17.96
(0.707)
19.06*
(0.750)
16.0*
(0.630)
16.8*
(0.661)
15.0*
(0.590)
15.0*
(0.590)
17.00*
(0.669)
17.00*
17.00*
17.00*
17.00*
36.17
(1.424)
36.17
(1.424)
8.00
(0.315)
3.25
(0.128)
2.04*
(0.080)
2.10*
(0.083)
2.17*
(0.085)
2.10*
(0.083)
2.10*
(0.083)
2.03*
(0.080)
2.10*
(0.083)
2.10*
(0.083)
2.10*
(0.083)
2.10*
(0.083)
4.12
(0.162)
4.12
(0.162)
0.61
(0.024)
Spring
OD
mm (in.)
N/A
Wire Dia
mm (in.)
Table 72. Spring Data
29.2
(1.15)
114.3
(4.500)
114.3
(4.500)
57.3*
(2.26)
57.3*
(2.26)
57.3*
(2.26)
57.3*
(2.26)
53.80
(2.11)
55.55*
(2.187)
55.55*
(2.187)
52.89*
(2.082)
57.53*
(2.265)
70.76*
(2.786)
18.2
(0.716)
91.1
(3.587)
91.1
(3.587)
37.6
(1.48)
37.6
(1.48)
37.6
(1.48)
37.6
(1.48)
37.7
(1.48)
39.25
(1.545)
39.25
(1.545)
34.5
(1.358)
34.8
(1.37)
28.2
(1.110)
40.7
(1.60)
5.7
(0.224)
17.8
(0.70)
52.4
(2.06)
mm
(in.)
2.67
(0.60)
213.3
(47.95)
213.3
(47.95)
3086**
(693.8)
3086**
(693.8)
3086**
(693.8)
3086**
(693.8)
3611**
(811.8)
143.5**
(32.3)
143.5**
(32.3)
4893**
(1100.0)
4649**
(1045.4)
5185**
(1165.6)
474
(106.5)
0.9
(0.2)
N
(lb)
Length under load
Approx.
Free
Length
mm (in.)
Ref.
59
78
67
85
74
50
130
123
175
180
100
112
134
Foldout
10,D
10C
10D
10C
10D
11
11
11
11
11
11
11
11
Converter Regulator
Control Main
Connector Flow
C6 Clutch
C6 Enable
C2 Latch
C1 Latch
Accumulator
Relay Valve
Relay Valve
Regulator Valve
Regulator Valve
Exhaust Backfill
Spring
12.19
(0.480)
7.43
(0.293)
16.26
(0.640)
11.43
(0.450)
10.75
(0.423)
11.05
(0.435)
14.10
(0.555)
14.8
(0.583)
11.00
(0.433)
0.97
(0.038)
0.97
(0.038)
0.97
(0.038)
0.97
(0.038)
0.94
(0.037)
1.37
(0.054)
1.32
(0.052)
1.22
(0.048)
0.67
(0.026)
1.37
(0.054)
1.83
(0.072)
1.53
(0.060)
Lt. Green/
10.45
Silver
Lt. Green/
10.45
Silver
Lt. Green/
10.45
Silver
Lt. Green/
10.45
Silver
Dk. Green
15.90
Dk. Blue
29507456 Pink
29542926 Orange
23049326 No Code
29542936 No code
29542949 No code
29542929 Lt. Green
29542929 Blue
8678805
29529310
29529310
29529310
29529310
10.20
10
10
6.90
11
12
12.19
(0.480)
12.19
(0.480)
12.19
(0.480)
8.00
(0.315)
0.61
(0.024)
20.40
23049391 No Code
Part No.
No. of
Coils
Spring
OD
mm (in.)
Color
Code
Wire Dia
mm (in.)
Table 72. Spring Data (contd)
30.3
(1.19)
44.6
(1.76)
42.1
(1.66)
6.5
(0.26)
16.71
(0.658)
41.3
(1.63)
46.2
(1.82)
30.82
(1.213)
38.15
(1.502)
38.15
(1.502)
38.15
(1.502)
38.15
(1.502)
29.2
(1.15)
Approx.
Free
Length
mm (in.)
22.8
(0.90)
24.2
(0.95)
17.0
(0.67)
3.45
(0.14)
12.84
(0.506)
19.0
(0.75)
29.2
(1.15)
18.20
(0.717)
17.70
(0.697)
17.70
(0.697)
17.70
(0.697)
17.70
(0.697)
18.2
(0.716)
mm
(in.)
53.759.3
(12.113.3)
131145
(29.532.6)
49.260.2
(11.0613.53)
3.24.2
(0.720.94)
18.1421.86
(4.084.91)
64.178.3
(14.417.6)
16.718.9
(3.754.25)
27.59
(6.20)
14.70
(3.31)
14.70
(3.31)
14.70
(3.31)
14.70
(3.31)
2.67
(0.60)
N
(lb)
Length under load
77
78
79
104
108
71
76
84
89
66
11
11
11
11
11
11
11
11
TCC
PCS4
PCS3
PCS2
PCS1
Main Regulator
Lube Regulator
Diagnostic
Spring
* Individual Springs
** For the complete Spring Assembly
OD at larger end
Ref.
Foldout
29542938 No Code
29542936 No Code
29542936 No Code
29542936 No Code
29542936 No code
29500963 Lt. Blue
23049327 Red
29542941 No Code
Part No.
Color
Code
15
13
No. of
Coils
Spring
OD
mm (in.)
10.50
(0.433)
11.10
(0.437)
22.0
(0.866)
11.05
(0.435)
11.05
(0.435)
11.05
(0.435)
11.05
(0.435)
11.05
(0.435)
Wire Dia
mm (in.)
1.30
(0.039)
1.22
(0.048)
2.87
(0.113)
0.67
(0.026)
0.67
(0.026)
0.67
(0.026)
0.67
(0.026)
0.67
(0.026)
Table 72. Spring Data (contd)
6.5
(0.26)
6.5
(0.26)
6.5
(0.26)
6.5
(0.26)
6.5
(0.26)
98.5
(3.88)
46.3
(1.82)
27.03
(1.06)
Approx.
Free
Length
mm (in.)
3.45
(0.14)
3.45
(0.14)
3.45
(0.14)
3.45
(0.14)
3.45
(0.14)
54.6
(2.15)
23.5
(0.93)
15.49
(1.02)
mm
(in.)
3.24.2
(0.720.94)
3.24.2
(0.720.94)
3.24.2
(0.720.94)
3.24.2
(0.720.94)
3.24.2
(0.720.94)
305337
(68.675.8)
46.551.3
(10.511.5)
2.45
(0.78)
N
(lb)
Length under load
SECTION 8CUSTOMER SERVICE

81.
OWNER ASSISTANCE
The satisfaction and goodwill of the owners of Allison

transmissions are of primary concern to Allison
Transmission, its distributors, and their dealers.
As an owner of an Allison transmission, you have service locations throughout the world that are eager to
meet your parts and service needs with:
Expert service by trained personnel
Emergency service 24 hours a day in many
areas
Complete parts support
Sales teams to help determine your
transmission requirements
Product information and literature.
Normally, any situation that arises in connection with
the sale, operation, or service of your transmission will
be handled by the distributor or dealer in your area.
Check the telephone directory for the Allison
Transmission service outlet nearest you or utilize
Allison Transmissions Sales and Service Locator tool
on the Allison Transmission web site at
www.allisontransmission.com. You may also refer to
Allison Transmissions Worldwide Sales and Service
Directory (SA2229EN).
We recognize, however, that despite the best intentions
of everyone concerned, misunderstandings may occur.
To further assure your complete satisfaction, we have
developed the following three-step procedure to be
followed in the event a problem has not been handled
satisfactorily.
Step OneDiscuss your problem with a member of
management from the distributorship or dealership.
Frequently, complaints are the result of a breakdown
in communication and can quickly be resolved by a
member of management. If you have already
discussed the problem with the Sales or Service
Manager, contact the General Manager. All Allison
Transmission dealers are associated with an Allison
Transmission distributor. If the problem originates
with a dealer, explain the matter to a management
member of the distributorship with whom the dealer
has his service agreement. The dealer will provide his
Allison Transmission distributors name, address, and
telephone number on request.
Step TwoWhen it appears the problem cannot be

readily resolved at the distributor level without
additional assistance, contact the Allison Technical
Assistance Center at 800-252-5283. They will place
you in contact with the Regional Customer Support
Manager for your area.
For prompt assistance, please have the following information available.
Name and location of authorized distributor or
dealer
Type and make of vehicle/equipment
Transmission model number, serial number,
and assembly number (if equipped with

electronic controls, also provide the TCM
assembly number)
Transmission delivery date and accumulated
miles and/or hours of operation

Nature of problem
Chronological summary of your transmissions
history
Step ThreeIf you are still not satisfied after contacting the Regional Customer Support Manager, present
the entire matter to the Home Office by writing to the
following address:
Allison Transmission
Manager, Warranty Administration
P.O. Box 894, Mail Code 462-470-PF9
Indianapolis, IN 46206-0894
The inclusion of all pertinent information will assist
the Home Office in expediting the matter.
When contacting the Home Office, please keep in
mind that ultimately the problem will likely be resolved at the distributorship or dealership utilizing
their facilities, equipment, and personnel. Therefore, it
is suggested that Step 1 be followed when experiencing a problem.
Your purchase of an Allison Transmission product is
greatly appreciated, and it is our sincere desire to
assure complete satisfaction.
81

82.
SERVICE LITERATURE
(Table 81)
Additional service literature is available. This service

literature provides fully illustrated instructions for
operation, maintenance, service, overhaul, and parts
support for your transmission. To be sure that you get
maximum performance and service life from your
transmission, you may order publications from:
SGI, Inc.
Attn: Allison Literature Fulfillment Desk
8350 Allison Avenue
Indianapolis, IN 46268
TOLL FREE: 888-666-5799
INTERNATIONAL: 317-471-4995
Table 81. 4000 Product Family

Service Literature
Publication Type
Allison DOC For PCService Tool User
Guide
Automatic Transmission Fluid
Technicians Guide
*Operators Manual (Bus Series)
*Operators Manual (Emergency
Vehicle Series)
*Operators Manual (Highway Series)
*Operators Manual (International Models)
*Operators Manual (Motorhome Series)
*Operators Manual (Rugged Duty Series)
*Operators Manual (Specialty Series)
*Operators Manual (Truck Recreational
Vehicle Series)
*Mechanics Tips
*Mechanics Tips (T Series)
Parts Catalog
Parts Catalog CD-ROM
Principles of Operation
Service Manual
Troubleshooting Manual
*Worldwide Sales And Service Directory
Literature
Number
GN3433EN
GN2055EN
OM3749EN
OM3656EN
OM3750EN
OM4119EN
OM3349EN
OM3752EN
OM3753EN
OM3654EN
MT4015EN
MT4085EN
PC2456EN
CD2456EN
PO4016EN
SM4014EN
TS3989EN
SA2229EN
* Also Available On The Internet At www.allisontransmission.com
82
F OLDOUT 1
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
10
11
12
13
14
Lockup clutch/ damper

Converter turbine
Converter stator
Converter pump
Oil pump
Front support
Main housing
Main shaft
C3 clutch
C4 clutch
P2 sun gear
C5 clutch
P3 sun gear
Output shaft
Rear cover
C5 piston
P3 module
Oil level sensor
Control module
P2 module
P1 module
C2 clutch
C1 clutch
Turbine shaft
Ground sleeve
Converter housing module
26
25
24
23
22
21
20
Foldout 1. 4000 Product Family Transmission (Close Ratio)Cross Section
19
18
17
16
15
V05513.01.02
F OLDOUT 2
1
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
28
10
11
12
13
14
15
Lockup clutch/damper
Converter turbine
Converter stator
Converter pump
Charging oil pump
Front support
Breather
Main housing
Main shaft
C3 clutch
C4 clutch
P2 sun gear
C5 clutch
P3 sun gear
Output shaft
Rear cover
C5 piston
P3 module
Oil level sensor
Control module
P2 module
P1 module
C2 clutch
C1 clutch
Turbine shaft
PTO drive gear
Ground sleeve
28
27
26
25
24
23
22
21
Foldout 2. 4500 Model (Wide Ratio) Transmission With PTO ProvisionCross Section
20
19
18
17
16
V05515.01.02
F OLDOUT 3
1
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
10
11
12
13
14 15
16
17
Lockup clutch/ damper

Converter turbine
Converter stator
Converter pump
Charging oil pump
Front support
Main housing
Main shaft
C3 clutch
C4 clutch
P2 sun gear
C5 clutch
P3 sun gear
Retarder stator
Retarder rotor
Retarder module
Retarder housing
C5 piston
P3 module
Control module
P2 module
P1 module
C2 clutch
C1 clutch
Turbine shaft
Ground sleeve
27
Foldout 3.
26
25
24
23
22
21
4000 Product Family (Close Ratio) Transmission With RetarderCross Section
20
19
18
V05514.01.01
Legend For Foldout 3,A Is On The Opposite Side Of This Page.
Foldout 3,A

Legend For Foldout 3,A
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
28
29
30
31
32
33
34
35
Foldout 3,A
Converter turbine
Converter stator
Converter pump
Charging oil pump
Front support
Main housing
Main shaft
C3 clutch
C4 clutch
P2 sun gear
Shim
C5 clutch
P3 sun gear
C5 piston assembly
C6 adapter housing module
C6 clutch
P4 ring gear
Rear cover
Output shaft
C6 piston
P4 planetary
P4 sun gear
Selective shim
P4 shaft flange
P3 planetary
Oil level sensor
Control valve assembly
P2 planetary
P1 planetary
C2 clutch
C1 clutch
Turbine shaft
Converter ground sleeve
Converter housing
F OLDOUT 3,A
1
35
34
10
11
12
13
14
15
33
16
25
32
31
30
29
28
27
26
Foldout 3,A. 4700 and 4800 Model TransmissionCross Section
17
18
24 23 22
19
20
21
V05265.05.00
Legend For Foldout 3,B Is On The Opposite Side Of This Page.
Foldout 3,B

Legend For Foldout 3,B
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
28
29
30
31
32
33
34
35
36
Foldout 3,B
Converter turbine
Converter stator
Converter pump
Charging oil pump
Front support
Main housing
Main shaft
C3 clutch
C4 clutch
P2 sun gear
Shim
C5 clutch
P3 sun gear
C5 piston assembly
C6 clutch
P4 ring gear
Retarder stator
Retarder rotor
Retarder and output shaft module
Output shaft
C6 piston
P4 planetary
P4 sun gear
Selective shim
P4 shaft flange
P3 planetary
P2 planetary
P1 planetary
C2 clutch
C1 clutch
Turbine shaft
Converter housing
F OLDOUT 3,B
1
36
35
10
11
12
13
14
15
34
16
27
33
32
31
30
29
28
Foldout 3,B. 4700 and 4800 Model Transmission With RetarderCross Section
17
18
26 25 24
19
20
21
22
23
V09805.00.00
Legend For Foldout 3,C Is On The Opposite Side Of This Page.
Foldout 3,C

Legend For Foldout 3,C
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
28
29
30
31
32
33
34
35
36
37
38
Foldout 3,C
Converter turbine
Converter stator
Converter pump
Charging oil pump
Front support
Oil vent assembly
Main housing
Main shaft
C3 clutch
C4 clutch
P2 sun gear
Shim
C5 clutch
P3 sun gear
C5 piston assembly
C6 clutch
P4 ring gear
Retarder stator
Retarder rotor
Retarder and output shaft module
Output shaft
C6 piston
P4 planetary
P4 sun gear
Selective shim
P4 shaft flange
P3 planetary
P2 planetary
P1 planetary
C2 clutch
C1 clutch
Turbine shaft
PTO drive gear
Converter housing
F OLDOUT 3,C
1
38
37
36
35
34
10
11 12
13
33
14
15
16
29
32
31
17
28
18
27
30
Foldout 3,C. 4700 and 4800 Model Transmission With Retarder and PTO ProvisionCross Section
19
26
20
25
21
22
23
24
V05646.05.00
F OLDOUT 4,A
3
2
4
5
6
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
Crank hub adapter

Bolt, M8 x 1.25 x 20 (12), A
Flexplate assembly
Bolt plate (6)
Flexplate
Flexplate (3)
Bolt, M8 x 1.25 x 25 (28), A
Flexplate adapter assembly
Ring gear
Flexplate adapter
Wear plate
Bolt, M8 x 1.25 x 45 (12), A
Ring gear assembly
Ring gear
Flexplate
Flexplate (3)
Bolt, M8 x 1.25 x 25 (28), A
Flexplate adapter
Wear plate
Bolt, M8 x 1.25 x 25 (12), A
Flexplate assembly
Bolt plate (6)
23
24
25
26
27
28
29
30
31
32
33
34
35
36
37
38
39
40
41
Flexplate
Flexplate
Bolt, M8 x 1.25 x 25 (28), A
Ring gear
Flexplate adapter
Wear plate
Bolt, 516-18 x 2 (6), A
Bolt, M8 x 1.25 x 25 (12), A
Flexplate assembly
Bolt plate (6)
Flexplate
Flexplate
Bolt, M8 x 1.25 x 25 (16 or 28), A
Ring gear
Flexplate adapter
Wear plate
Bolt (2), A
Torque
A
Nm
2429
lb ft
1821
8
9
10
11
13
12
14
15
16
17
18
20
19
21
22
23
24
25
26
27
28
31
32
33
29
34
30
35
36
37
38
39
40
41
L00182
Foldout 4,A. Flexplate and AdapterExploded View
F OLDOUT 4,B
1
2
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
Converter end plug

O-ring
Converter end plug, A
Torque converter module
Nut (36), B
Torque converter cover assembly
Converter cover
Bushing
Lockup piston sealring
Lockup piston assembly
Lockup piston sealring
Damper assembly
Lockup clutch backplate
Bolt, M8 x 1.25 (44), C
Thrust bearing assembly
Turbine hub sealring
Turbine hub assembly
Thrust bearing assembly
Star plate
Stator assembly
Retaining ring
22
23
24
25
26
27
28
29
30
31
32
33
34
Stator thrust plate assembly

LH stator thrust washer
Stator race
Stator spring (13)
Stator roller (13)
Stator and cam assembly
Shim, 0.27 mm (0.011 inch)
Shim, 0.48 mm (0.019 inch)
Shim, 0.711 mm (0.028 inch)
Thrust bearing race
Pump thrust bearing assembly
O-ring
Thrust bearing race
Torque converter pump assembly
T-head bolt (36)
10
4
11
5
12
16
13
17
15
18
19
21
22
23
24
26
27
14
28
Torque
A
B
C
Nm
5060
3035
2429
lb ft
3744
2226
1821
29
25
30
31
20
32
33
34
V06850.01.00
Foldout 4,B. Torque Converter ModuleExploded View
Legend For Foldout 5 Is On The Opposite Side Of This Page.
Foldout 5

Legend For Foldout 5
1 Converter housing module
1 Converter housing module
2 Breather assembly, M12 x 1.5, A
2 Bolt, M10 x 1.5 x 35 (11), A
3 Converter housing
3 Bearing retainer assembly
4 Speed sensor assembly
4 Oil seal assembly
5 O-ring
5 Bearing retainer/bushing assembly
6 Speed sensor retainer
6 Bushing
7 Bolt, M8 x 1.25 x 20, B
7 Bearing retainer
8 Sensor shipping cover
8 Sealring
9 Converter housing gasket
9 Sealring
10 Bolt, M10 x 1.5 x 35 (25), C

Torque
A
B
C
Nm
1216
2429
5161
10 PTO gear assembly

lb ft
912
1821
3845
11 Ball bearing (2)

12 PTO gear
13 Oil pump drive hub
14 Sealring
16 O-ring
18 Bolt, M8 x 1.25 x 20, B
19 Converter housing
20 Breather assembly, M12 x 1.5, C
21 Bolt, M10 x 1.5 x 35 (25), A
22 Converter housing gasket
24 Bolt, M10 x 1.5 x 25 (10), A
25 PTO cover
26 PTO cover gasket
27 Bolt, M10 x 1.5 x 25 (10), A
28 PTO cover
29 PTO cover gasket
Torque
A
B
C
Foldout 5
Nm
5161
2429
1216
lb ft
3845
1821
912
F OLDOUT 5
A
B
1
1
4
24
25
26
6
7
8
4
9
20
15
10
10
16
11
9
7
17
18
12
21
13
11
14
23
19
22
29
28
27
V05395
Foldout 5,A. Converter Housing ModuleExploded View
V03918.02
Foldout 5,B. Converter Housing Module With PTO ProvisionExploded View
Foldout 6

A
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
Bolt, M10 x 1.5 x 65 (7), A

Bolt, M10 x 1.5 x 35 (7), A
Front support module
O-ring
Oil seal assembly
Bolt, M10 x 1.5 x 65 (8), A
Pump housing assembly
Bushing
Pump housing
Pump housing (PTO)
Pump gear set
Bushing
Wear plate
Bolt, M10 x 1.5 x 25 (14), A
Front support assembly (complete)
Ground sleeve (PTO)
Ground sleeve
Front support assembly
Dowel pin, 10 x 32 (2)
Front support
Front support sleeve
Spring
Ball
Dowel pin
Sealring (3)
Roller bearing assembly
Torque
A
Nm
5161
lb ft
3845
B
1
2
3
4
5
6
Rotating clutch module

O-ring
Turbine shaft assembly
Turbine shaft
Turbine shaft bushing
Turbine shaft assembly (PTO)
Foldout 6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
28
29
30
31
32
33
34
35
36
37
38
39
40
41
42
43
Turbine shaft (PTO)

Sealring (3)
Rotating clutch drum
Thrust bearing
Rotating clutch hub assembly (complete)
Rotating clutch hub bushing
Rotating clutch hub assembly
Thrust bearing
Turbine shaft retaining ring
C2 piston sealring
C1 piston sealring
External sealring
C2 piston
C2 spring assembly
C2 spring plate
Internal retaining ring
C1 sealring
C1 piston
C1 spring assembly
Rotating clutch balance piston
Rotating clutch balance piston sealring
Balance piston retaining ring
C1 clutch apply plate
C1 friction plate (7)
C1 reaction plate (6)
C1 clutch backplate
External retaining ring
C1 drive hub
Thrust bearing (2)
C2 drive hub
C2 reaction plate (7)
C2 friction plate (7)
C2 clutch backplate
Sun gear assembly (complete)
Thrust bearing
F OLDOUT 6
A
3
4
8
5
7
12
11
10
13
21
14
22
15
23
10
16
17
18
24
11
19
25
12
13
16
20
26
15
27
28
14
17
29
33
18
20
30
34
19
31
35
36
21
35
37
25
26
38
32
23 22
24
39
40
41
42
V02818.01
Foldout 6,A. Front Support and Oil Pump ModuleExploded View
43
Foldout 6,B. Rotating Clutch ModuleExploded View
V06870.01.00
F OLDOUT 7
2
4
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
C3/C4 clutch assembly

Bolt, M10 x 1.5 x 90 (14), A
C3 backplate assembly (complete)
Clutch backplate assembly
P1 ring thrust plate (6)
P1 planetary ring gear
C3 clutch friction plate (5)
C3 clutch reaction plate (5)
C3 piston return plate assembly
C3 clutch piston assembly
C3 clutch housing assembly
(complete)
P1 ring thrust plate (6)
C3 clutch housing
C4 piston return plate assembly
C4 clutch piston assembly
C4 clutch housing
Bolt, M10 x 1.5 x 35 (14), A
22
23
24
25
26
27
28
29
30
31
32
33
34
35
36
37
Internal harness connector cap

Identification plate
Rivet
Bolt, M8 x 1.25 x 20, B
Speed sensor assembly
O-ring
Speed sensor bracket
Speed sensor shipping cover
Main housing assembly
Main housing
Recoil insert
Fill tube seal
Oil fill tube
Tapping screw, M8 x 25, B
Oil fill tube bracket
Oil level indicator
Torque
A
B
Nm
5161
2429
1
5
6
7
8
14
11
15
9
29
10
12
26
16
27
13
17
25
28
34
37
18
35
23 24
36
lb ft
3845
1821
33
22
31
21
19
20
30
32
V04763.06.00
Foldout 7. Main Housing ModuleExploded View
F OLDOUT 8
WIDE RATIO
4
1
5
2
6
1
1
1
1
1
1
1
1
2
Shim (non-selective)4700 and 4800 models

Shim (selective)except 4700 models, 0.2450.295 mm (0.00970.0116 inch) (marked with 1 slot)
Shim (selective)except 4700 models 4070, 0.5150.565 mm (0.021030.0222 inch) (marked with 2 slots)
Shim (selective)except 4700 models, 0.7850.835 mm (0.03100.0328 inch) (marked with 3 slots)
Shim (selective)except 4700 models, 1.8651.915 mm (0.07350.0753 inch) (not marked with slots)
Thrust bearing
Wide Ratio
3
4
5
6
7
Main shaft module

External retaining ring (spiral)
P2 sun gear
Bearing spacer
Main shaft
Close Ratio
3
4
5
6
7
8
Main shaft module

External retaining ring (spiral)
P2 sun gear
Bearing spacer
P3 sun gear
Main shaft
CLOSE RATIO
4
1
5
2
6
V06878
Foldout 8. Main Shaft ModuleExploded View
Foldout 9

1 P1 planetary module
1 P2 planetary module
2 Internal retaining ring
2 Retaining ring
3 P1 planetary carrier assembly
4 Retaining ring
5 P1 indexing ring
5 P2 indexing ring
6 P1 pinion spindle (6)
6 Carrier and bushing assembly
7 P1 planetary carrier/bushing assembly
7 P2 planetary carrier
8 Bushing
9 P1 carrier bushing
9 Thrust washer (4)
10 P1 thrust washer (6)
10 Roller bearing (8)
11 P1 pinion gear (6)
12 Roller bearing assembly (12)
12 Thrust washer (4)
13 P2 pinion spindle (4)
14 Thrust bearing assembly
15 P2 ring gear
15 P3 planetary ring gear
Foldout 9
F OLDOUT 9,A,B
A
1
2
14
15
3
5
4
5
6
7
7
15
8
9
14
6
9
13
10
10
11
11
12
12
13
V06852
V03630.01
Foldout 9,A. P1 Planetary ModuleExploded View
Foldout 9,B. P2 Planetary ModuleExploded View
F OLDOUT 9,C
1 P3 carrier module
24 Pressure tap plug
2 Internal retaining ring, 219 OD
25 O-ring, 8.92 ID
3 P3 indexing ring
26 Ball bearing assembly
27 C6 reaction plate (9)
5 P4 shaft flange
28 C6 friction plate (8)
6 Shim locating ring
29 C6 backplate
7 P3 planetary spindle (4)
30 P4 sun gear
31 Thrust bearing
32 P4 carrier assembly
18 Piston
19 Piston OD sealring
20 Piston ID lip-type sealring
21 Adapter housing assembly
22 Adapter housing
23 Plug assembly (2), B
13
10
8
35 Indexing ring
17 Piston return spring assembly
20
12
16 External retaining ring
19
6
8
34 Internal retaining ring, 235 OD
15 Piston assembly
18
11 Flange head bolt, M12 x 1.75 x 45 (14), A
14 C6 adapter housing module
15
13 Adapter housing gasket
17
4
10 Roller bearing assembly (8)

Shim, (selective), 0.27 mm
14
16
12
3
11
36 P4 carrier and bushing assembly

37 P4 carrier
22
38 P4 carrier bushing
26
27
21
28
40 P4 planetary thrust washer (12)

23

42 Caged needle bearing (12)
24
43 C6 clutch drum hub
25
23
25
24
30
45 P4 ring gear and hub assembly
29
46 P4 ring gear
31
32
47 P4 ring gear hub

48 Retaining ring
43
49 Star tolerance ring

Torque
A
B
Nm
100120
1013
44
lb ft
7488
710
46
45
47
33
34
37
35
39
38
36
48
49
41
42
40
V06854.01.00
Foldout 9,C. P3 Planetary Module and C6 Adapter Housing Module (4700 and 4800 Models)Exploded View
F OLDOUT 10,A
1 Rear cover gasket
25 Internal sealring
2 Bolt, M12 x 1.7 x 45 (19), A
26 Roller bearing cup
3 Washer
27 Rear cover assembly
4 Rear cover and P3 planetary module
28 Brass washer
29 Plug, 34-16 straight thread, B
6 Output shaft assembly
29 Tachograph plug, C
7 Bushing
30 Rear cover
8 Output shaft
31 Dowel pin (2)
21
12 Thrust washer
35 Bolt, M8 x 1.25 x 20, B
37 Cone and roller bearing assembly
38 Belleville washer
39 Bearing retainer locknut, D
17 Roller bearing assembly (4 groups of 2)
40 Output seal assembly
41 Speed sensor shipping cover
22 Spring and retainer assembly

23 C5 clutch piston
24 Piston sealring
20
24
23
33 O-ring
1
22
10 P3 indexing ring
19
35
25
32
26
34
27
41
33
30
9
10
31
11
29
28
12
13
31
Torque
A
B
C
D
Nm
100120
2429
6067
7488
lb ft
7488
1821
4549
5565
14
36
15
16
37
17
38
18
39
40
V06856.01.00
Foldout 10,A. Rear Cover and P3 Planetary ModuleExploded View
F OLDOUT 10,B
1 Rear cover gasket
2
2 Bolt, M12 x 1.75 x 45 (14), A

3 Bracket
4 Bolt, M12 x 1.75 x 222.5 (5), A

5 Rear cover module
1
7 Bushing
8 Output shaft
9 Roller bearing assembly

12 C5 piston spring return retainer assembly
13 C5 clutch piston
8
9
11
14 External sealring
12
15 Internal lip-type sealring

13
14
10
18 Rear cover
23
15
19 Tachograph plug, B
22
16
20 Washer
24
17
30
25
18

23 Self-locking bolt, M8 x 1.25 x 20, C
25 O-ring
26
27
26 Roller bearing assembly
19 20
28
28 Bearing retainer locknut
29
21
29 Output seal assembly

Torque
A
B
C
Nm
100120
6067
2429
lb ft
7488
4450
1821
V06858.01.00
Foldout 10B. Rear Cover and Output Shaft Module (4700 and 4800 Models)Exploded View

Legend For Foldout 10,C
1 Stator housing gasket
31 Retarder housing assembly
2 Retarder and P3 planetary module
32 Retaining ring
33 Valve plug
34 O-ring
5 Bushing
35 Valve spring
6 Output shaft
36 Retarder valve
37 Spring pin
8 P3 indexing ring
38 Retarder housing subassembly
39 Tachograph plug, A
10 Thrust washer
40 Washer
41 Retarder housing
42 Gasket
43 Cover
44 Bolt, M8 x 1.25 x 25 (9), B
15 Roller bearing assembly (4 groups of 2)
45 Temperature sensor assembly (TID2)
46 O-ring
47 Retainer
18 Retarder stator assembly
48 Bolt, M8 x 1.25 x 20, B
49 Valve plug
20 Spring and retainer assembly
50 Retaining ring
21 C5 clutch piston
22 C5 piston outer sealring
52 Bolt, M8 x 1.25 x 25 (3), C
23 C5 piston inner sealring
54 O-ring
25 Retarder stator
26 O-ring
56 Bolt, M8 x 1.25 x 20, B
27 Retarder sealring
28 Retarder housing gasket
29 Rotor assembly
59 Bearing retainer locknut, D
30 Retarder sealring
60 Oil seal assembly
Foldout 10,C

Legend For Foldout 10,C (contd)
87 Retarder control valve cover gasket
62 Bolt, M12 x 1.75 x 55 (12), E
88 Retarder control valve cover
63 Separator plate
89 Bolt, M8 x 1.25 x 30 (3), B
64 Retarder connector cover
90 Pressure tap plug assembly
65 Retarder control valve assembly

66 Straight thread plug assembly
91 O-ring
92 Pressure tap plug, F
67 Straight thread plug
93 Bolt, M8 x 1.25 x 115 (9), B
68 O-ring
94 Bolt, M12 x 1.75 x 165 (4), E
69 Spring
70 Exhaust backfill valve
95 Bolt, M12 x 1.75 x 105 (2), E
71 Solenoid and connector assembly
96 Bolt, M10 x 1.5 x 160 (4), G
72 Solenoid
97 Gasket
73 O-ring seal
98 Jumper manifold
74 O-ring
99 Bolt, M10 x 1.5 x 30, G
75 Retarder control valve body
100 Remote side manifold
76 Solenoid retaining pin
101 Bolt, M10 x 1.5 x 160 (3), G
77 Regulator valve
78 Spring
80 O-ring
Torque
A
B
C
D
E
F
G
Nm
6067
2429
1215
*
100120
1013
5161
lb ft
4549
1821
911
*
7488
710
3845
84 O-ring
85 Spring
86 Relay valve
Foldout 10,C
* Before module is installed 193207 Nm (143152 lb ft);

After Module is installed 7488 Nm (5564 lb ft)
F OLDOUT 10,C
1
17
19
20
21
18
22
3
2
4
23
24
25
6
7
8
26
9
10
11
12
13
14
15
65
16
66 67
68
69
71 70
62
48
52
27
45
72
73
74
47
46
90
89
64
91
92
93
75
61
88
28
87
63 76
54 55 56
30
29
38
39
41
49
40
50
51
37
86
77
78
79
80
81
53
85 82
84
83
57
58
59
31
35
32
36
33
34
60
42
43
44
96
94
91
95
100
97
101
98
99
Foldout 10,C. Retarder and P3 ModuleExploded View
V06859.01.01
F OLDOUT 10,D
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
28
29
30
31
32
33
34
35
36
37
38
39
40
41
42
43
44
45
46
47
48
49
50
51
52
Stator housing gasket

Retarder module
Output shaft assembly
Bushing, 28 ID
Output shaft
Cone and roller bearing assembly
Retarder stator assembly
External retaining ring, 181 ID
C5 piston return spring and retainer assembly
C5 clutch piston
External sealring, 315.17 ID
Internal lip-type sealring, 214.06 OD
Roller bearing cup
Retarder stator housing
O-ring, 11.48 ID
Rotating sealring, 146 OD
Retarder housing gasket
Rotor assembly
Rotating sealring, 146 OD
Flange head bolt, M8 x 1.25 x 25 (3), A
Retarder housing assembly
Internal retaining ring, 45.82 OD
Valve plug
O-ring, 34.6 ID
Valve spring, 36.17 OD x 114.3
Retarder valve
Spring pin, 5 x 45
Plug and retarder housing assembly
Tachograph plug, M18 x 1.5, B
Washer, M18
Retarder housing
Gasket
Cover
Bolt, M8 x 1.25 x 25 (9), D
Temperature sensor assembly
O-ring
Thermistor protection bracket
Self-locking bolt, M8 x 1.25 x 20, D
Valve plug
Internal retaining ring, 45.82 OD
Roller bearing cup
Cone and roller bearing assembly
Belleville washer
Bearing retainer locknut, C
Oil seal assembly
Speed sensor assembly
O-ring, 15.37 ID
Speed sensor retainer
Self-locking bolt, M8 x 1.25 x 20, D
Sensor cover
Flange head bolt, M12 x 1.75 x 55 (12), E
Separator plate
53
54
55
56
57
58
59
60
61
62
63
64
65
66
67
68
69
70
71
72
73
74
75
76
77
78
79
80
81
82
83
84
85
86
87
88
89
90
Retarder connector cover

Retarder control valve assembly
Straight thread plug assembly
Straight thread plug
O-ring
Spring
Exhaust backfill valve
Solenoid and connector assembly
Solenoid
O-ring seal
O-ring
Retarder control valve body
Solenoid retaining pin
Regulator valve
Spring
O-ring
O-ring
Spring
Relay valve
Retarder control valve cover gasket
Retarder control valve cover
Bolt, M8 x 1.25 x 30 (3), B
Pressure tap plug assembly
O-ring
Pressure tap plug, F
Bolt, M8 x 1.25 x 115 (9), B
Gasket
Jumper manifold
Bolt, M10 x 1.5 x 30, G
Remote side manifold
Bolt, M10 x 1.5 x 354 (3), G
Bolt, M10 x 1.5 x 345 (7), G
Bolt, M12 x 1.75 x 350 (4), E
Bolt, M12 x 1.75 x 105 (2), E
Torque
A
B
C
D
E
F
G
Nm
1215
6067
*
2429
100120
1013
5161
lb ft
911
4549
*
1821
7488
710
3845
1
4
3
5
6
9
10
7
11
2
12
13
14
15
54
55 56
57
58
60 59
38
20
16
35
61
62
63
51
37
36
50
79
78
53
80
81
82
64
77
17
76
52 65
47 48 49
19
18
28
29
31
39
30
40
75
66
68 67
69
70
46
41
27
74 71
73
72
42
43
44
21
25
22
26
23
24
* Before module is installed 193207 Nm (143152 lb ft);

After Module is installed 7488 Nm (5564 lb ft)
45
32
33
34
89
88
86
83
90
84
85
Foldout 10D. Retarder and Output Shaft Module (4700 and 4800 Models)Exploded View
87
V06860.01.01

1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
28
29
30
31
32
33
34
35
36
37
38
39
40
41
42
43
44
45
46
47
48
49
50
Control valve module

Suction filter assembly kit
Bolt, M6 x 1.0 x 30, A
Suction filter assembly
Suction filter
Face seal
Suction filter gasket
Control harness assembly
Connector assembly
Electronic connector
Seal
Sealring
Standoff assembly
Cavity plug
Bolt, 20F connector, C
Temperature sensor (OILT)
Connector assembly
Connector, 2-Way
Pin terminal
Pin terminal
Secondary lock
Connector Assembly (OLS)
Terminal
Terminal
Connector, 2-way
Connector assembly (SS1)
Terminal
Terminal
Connector, 2-way
Channel
Solenoid connector assembly (SS2)
Connector, 2-way
Terminal
Terminal
2-Way solenoid connector (PCS4)
2-Way connector (C3 pressure switch)
Terminal
Terminal
2-Way connector
2-Way solenoid connector (TCC)
Shoulder bolt, M6 1.0 x 45 (3), B
Bracket
Bolt, M6 1.0 x 45 (2), A
Face Seal
Accumulator spring (2)
51
52
53
54
55
56
57
58
59
60
61
62
63
64
65
66
67
68
69
70
71
72
73
74
75
76
77
78
79
80
81
82
83
84
85
86
87
88
89
90
91
92
93
94
95
96
97
98
99
Accumulator plug (2)

Accumulator plug (2)
Accumulator spring (2)
Switch assembly
Switch
Bracket
Bolt, M6 x 1.0 x 95 (12), A
Solenoid body assembly
Body assembly valve and pin
Valve body
Pin (3)
Variable bleed solenoid (TCC)
O-ring
O-ring
TCC valve
Spring
Variable bleed solenoid (PCS1)
O-ring
O-ring
PCS1 valve
Spring
O-ring
O-ring
PCS2 valve
Spring
Clip
Diagnostic valve
Spring
O-ring
O-ring
PCS3 valve
Spring
O-ring
O-ring
PCS4 valve
Spring
Variable bleed solenoid (Main Mod)
O-ring
O-ring
Solenoid separator plate
Bolt, M6 x 1.0 x 60 (2), A
Main valve body assembly
Retention pin 5 OD x 43
Converter flow valve
Spring
Valve stop
Foldout 11

Legend For Foldout 11 (contd)
100
101
102
103
104
105
106
107
108
109
110
111
112
113
114
115
116
117
118
119
120
121
122
123
124
125
126
127
128
129
130
131
132
133
134
135
136
137
138
139
140
141
142
143
Retention pin 3 OD 43
Lube regulator valve
Spring
Valve stop
Main regulator valve
Spring
Valve stop
Control main valve
Spring
Clip
Retention pin, 2.5 OD x 40
Solenoid assembly
O-ring
O-ring
Control valve body
Spring pin, 5 OD x 55
C2 latch valve
Spring
Valve stop
Retention pin, 5 OD x 43
Exhaust backfill valve
Spring
Valve stop
C1 latch valve
Spring
Valve stop
Converter regulator valve
Spring
Valve stop
Bolt M6 x 1.0 x 45 (2), A
Oil level sensor assembly
Ferrule Viton (2)
Separator plate
Channel plate gasket
Channel plate assembly
Dowel pin (2)
Channel plate
Oil drain plug assembly, D
O-ring
Pressure tap plug assembly
Foldout 11
144
145
146
147
148
149
150
151
152
153
154
155
156
157
158
159
160
161
162
163
164
165
166
167
168
169
170
171
172
173
174
O-ring
Pressure tap plug (9), A
Filter cover (2)
Filter cover gasket (2)
O-ring (2)
O-ring (2)
Oil filter (2)
Accumulator plug
Accumulator spring
Accumulator retaining bracket
Bolt, M6 x 1.0 x 60 (4), A
C6 clutch body assembly
C6 clutch body
Spring
Retention pin 2.5 OD x 30
C6 enable valve
Solenoid assembly
O-ring
O-ring
Solenoid protective plate
Push-on nut
Spring
C6 clutch trim valve
Solenoid assembly
O-ring
O-ring
Solenoid retaining bracket
Screw
Case gasket
Bolt, M10 x 1.5 x 55 (34), E
Bolt, M10 x 1.5 x 100 (25, 4 inch sump), E
Torque
Nm
lb ft
A
B
C
D
E
1013
58
2.53.5
2532
5161
710
46
2231 lb inch
1824
3845
F OLDOUT 11
1 (Cont'd)
93
99
95
98
10
9
96
100
128
11
132
8
12
104
43
44
39
42
103
101
107
135
106
111
14
133
134
102
124
120
94
97
110
105
46
109
45
40 41
108
13
112
3
30
129
38
26
6
5
126
23
36
34
33
123
117
118
20
19
119
18
150
16
17
31
116
122
24
32
172
121
21
22
35
115
127
15
25
114
125
131
29
28
27
37
113
130
136
137
149
57
54
47
154
62
48
55
64
49
66
53
56
67
139
146
151
68
51
140
69
70
91
92
61
72
157
73
74
59
85
86
60
76
87
159
160
161
75
171
158
162
141
89
143
88
80
155
156
71
90
81
170
167
82
84
83
138
147
152
52
58
153
65
50
148
63
169
168
163 164
166
78
144
142
145
165
79
77
173
V09483.00.00
174
Foldout 11. Control Valve ModuleExploded View
V09482.00.00
Foldout 12

11 Temperature gauge kit
1 Output flange
12 Temperature sender adapter
2 Output flange assembly
13 Shipping plug (2)
3 Slinger
14 Straight fitting
4 Output flange
15 Shipping plug assembly
5 Output flange
16 Cooler port plug (2)
6 Output flange
17 Pilot screw (2)
7 Output yoke assembly
18 PTO gasket
8 Slinger
19 Bolt, M10 x 1.5 x 35 (8), A
9 Output yoke
20 Clutched drive PTO assembly
10 Output yoke
21 Hose assembly
11 Output yoke
22 90 degree hose fitting
12 Dropbox coupling
23 Pilot screw (2)
13 Shipping cover
24 PTO gasket
14 Shipping cover
25 Bolt, M10 x 1.5 x 25 (8), A
15 O-ring, 75.9 mm ID
26 Hose assembly
16 O-ring, 9.1 mm ID
27 90 degree fitting
17 Retaining plate
28 Bolt, tie rod, 38-24 x 7 (4) for use with steel

end cap
18 Bolt, M14 x 2 x 70, B

Torque
A
B
Nm
3035
7080
28 Bolt, tie rod, 38-16 x 758 (4) for use with

aluminum end cap
lb ft
2226
5160
29 Steel gas cap

29 Aluminum gas cap
30 O-ring (2) 91.7 mm ID for use with steel end
cap
30 O-ring (2) 101.6 mm ID for use with
aluminum end cap
B
1 Converter shipping bracket (3)
31 Steel hydraulic cap
2 Bolt, M10 x 1.5 x 25 (3), A
31 Aluminum hydraulic cap
3 Rear support bracket (front)
32 External lip-type seal, 312 inch ID
4 Rear support bracket (rear)
33 Sealring
5 Remote mount cooler
34 Piston
5 Retarder oil cooler
35 Cylinder body for use with steel end cap
6 Remote mount gasket
35 Cylinder body for use with aluminum end cap
7 Remote mount manifold

8 Cooler port cover
9 Bolt, M10 x 1.5 x 28 (6), A
Torque
A
10 90 degree fitting
Foldout 12
Nm
5161
lb ft
3845
F OLDOUT 12A,B
B
3
1
4
5
2
13
14
15
16
5
11
8
10
12
120
250
10
0
0
12
31
19
17
29
28
TRANS
OIL
TEMP
20
30
C
300
F
30
8
150
18
32
10
33
13
21
22
34
32
33
11
15
24
16
25
1
17
18
12
14
27
23
26
V07331.01.00
V07030.03.00
Foldout 12,A. Output Flange And YokeExploded View
Foldout 12,B. Support EquipmentExploded View
F OLDOUT 12,C
1
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
Bolt, M10 x 1.5 x 60 (16), B

Hose adapter
Gasket, manifold to water (2)
Gasket, integral cooler
Bolt, M8 x 1.5 x 25 (6), A
Gasket, manifold to cooler (2)
Cooler, integral
Bolt, M10 x 1.5 x 50, B
Bolt, M10 x 1.5 x 187.5 (7), B
Bolt, M12 x 1.75 x 195 (8), C
Manifold assembly, integral cooler
Plug assembly, shipping, SAE No. 16
O-ring
Plug assembly, pressure tap
O-ring, 11.6 mm ID
Manifold, integral, strapped
O-ring, 8.9 mm ID
Plug, pressure tap
O-ring, 9.3 mm ID
O-ring, 8.9 mm ID
3
11
12
4
13
24
15
14
23
16
21
22
17
18
19
10
20
9
5
Torque
A
B
C
Nm
2429
5161
100120
lb ft
1821
3845
7488
8
6
6
V07034.01.00
Foldout 12,C. Integral Retarder Sump CoolerExploded View
F OLDOUT 13
LOCKUP
LUBE
FILTER
COOLER
CONVERTER OUT
LUBE
LUBE
CONVERTER IN
TORQUE
CONVERTER
ALLISON 4th GENERATION

HYDRAULIC SCHEMATIC NEUTRAL
3000 AND 4000 PRODUCT FAMILIES
Orifice
EX
EX
CONVERTER
REGULATOR
CONVERTER
FLOW
EX
LUBE
REGULATOR
REAR
SPLITLINE
TCC *
EX
EX
PCS1
N/O
N/C
EX
PCS2
N/O
EX
PCS4
N/C
EX
PCS3
N/C
EX
EX
EX
EX
Accumulator
Accumulator
Accumulator
EX
EX
CONTROL
MAIN
Accumulator
EX
EX
MAIN
EX
EX
MAIN
FILTER
SS1
N/C
Pressure
Relief
EX
Orifice
***
PS1
DIAGNOSTIC
EX
PCS6
N/C
EX
EX
SS2
N/C
EX
MAIN
REGULATOR
PUMP
EX
6-Speed
Only
EX
EXHAUST
BACKFILL
Accumulator
MAIN
MOD **
N/C
EX
C2
LATCH
EX
EX
C1
LATCH
EX
SUCTION
FILTER
EX
C1
C2
C1
C3
C2
C4
C3
C5
C4
SUMP
C6
C5
C6
NOTES:
LEGEND:
* TCC Solenoid is generally ON from 2nd-range thru 6th-range
MAIN
** Main Mod Solenoid may be ON in Reverse, Neutral, Low (7-speed),
CONTROL MAIN
1st, or 2nd as determined by calibration.
EXHAUST
*** PS1 = Diagnostic Pressure Switch
SUCTION
MAIN MOD
= 7-Speed Transmissions only
Foldout 13. 4000 Product Family Hydraulic SchematicNeutral
COOLER/LUBE
EX. BACKFILL
CONVERTER
C5
V09253.00.00

4K Service Manual 4th Gen SM4014EN 200510

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4K Service Manual 4th Gen SM4014EN 200510

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Service

Allison Transmission, General Motors Corporation

Copyright 2005 General Motors Corporation

of General Motors Corp.

Copyright 2005 General Motors Corp.

IMPORTANT SAFETY NOTICE

WARNINGS, CAUTIONS, AND NOTES

Copyright 2005 General Motors Corp.

493 kg (1087 lbs)

Copyright 2005 General Motors Corp.

Copyright 2005 General Motors Corp.

Copyright 2005 General Motors Corp.

Section 1. GENERAL INFORMATION

110. RESTORING TRANSMISSION

Section 2. PREVENTIVE MAINTENANCE

Copyright 2005 General Motors Corp.

4000 PRODUCT FAMILIES SERVICE MANUALALLISON 4 th GENERATION

210. FLUID AND FILTER

217. OUTPUT FLANGE/YOKE AND OIL

211. FLUID CONTAMINATION

218. ON-VEHICLE MAINTENANCE . . . . . . . 218

212. FLUID AND FILTER CHANGE

216. FLUID LEAK DIAGNOSIS

Section 3. GENERAL OVERHAUL

32. TOOLS AND EQUIPMENT

Copyright 2005 General Motors Corp.

36. ASSEMBLY PROCEDURES

Section 4. TRANSMISSION DISASSEMBLY

j. Removal Of Retarder And Output Shaft

Section 5. MODULE REBUILD

Copyright 2005 General Motors Corp.

4000 PRODUCT FAMILIES SERVICE MANUALALLISON 4 th GENERATION

56. FRONT SUPPORT AND OIL PUMP MODULE

512. P3 PLANETARY MODULE

515. RETARDER AND OUTPUT SHAFT

513. C6 ADAPTER HOUSING MODULE

516. REAR COVER MODULE (Models Equipped

514. RETARDER AND P3 PLANETARY MODULE

517. REAR COVER AND OUTPUT SHAFT

59. MAIN SHAFT MODULE

Copyright 2005 General Motors Corp.

c. Completion Of Rear Cover

Section 6. TRANSMISSION ASSEMBLY

i. Main Shaft Selective Shim

Copyright 2005 General Motors Corp.

4000 PRODUCT FAMILIES SERVICE MANUALALLISON 4 th GENERATION

Section 7. WEAR LIMITS AND

Section 8. CUSTOMER SERVICE

71. WEAR LIMITS DATA

82. SERVICE LITERATURE . . . . . . . . . . . . . . 82

72. SPRING DATA

Copyright 2005 General Motors Corp.

4000 PRODUCT FAMILIES SERVICE MANUALALLISON 4 th GENERATION

LIST OF FOLDOUT ILLUSTRATIONS

4000 Product Family Transmission (Close Ratio)Cross Section

Flexplate and Adapter

Copyright 2005 General Motors Corp.

4000 PRODUCT FAMILIES SERVICE MANUALALLISON 4 th GENERATION

Copyright 2005 General Motors Corp.

SECTION 1GENERAL INFORMATION

a. Content and Organization. This Service

disassembly in Section 4, rebuild in Section 5,

functions are explained in 3000 and 4000

or a Distributor training facility.