Fastener Tightening Specifications
| Application | Specifications | |
|---|---|---|
| Metric | English | |
| Control Valve Body Assembly to Transmission Case | 12 N.m | 108 lb in |
| Flange/Yoke to Output Shaft | 123 N.m | 91 lb ft |
| Input Speed Sensor to Torque Converter Housing | 12 N.m | 108 lb in |
| Low and Reverse Clutch Piston Housing to Transmission Case | 56 N.m | 42 lb ft |
| Manual Shift Shaft Detent Lever/Internal Mode Switch (IMS) Assembly Bolt to Manual Shift Shaft | 10 N.m | 89 lb in |
| Manual Shift Shaft Detent Spring to Control Valve Body Assembly | 12 N.m | 108 lb in |
| Oil Pump Assembly to Transmission Oil Pump Cover Assembly | 26 N.m | 20 lb ft |
| Oil Pan to Transmission Case | 26 N.m | 20 lb ft |
| Output Speed Sensor to Low and Reverse Clutch Piston Housing | 12 N.m | 108 lb in |
| Power Take-Off (PTO) Cover to Transmission Case | 43 N.m | 32 lb ft |
| Shift Valve Body to Main Valve Body | 12 N.m | 108 lb in |
| Shipping Bracket to Torque Converter Assembly | 27 N.m | 20 lb ft |
| Transmission Fluid Pressure Switch to Main Valve Body Assembly | 12 N.m | 108 lb in |
| Transmission Oil Pump Cover Assembly to Torque Converter Housing | 56 N.m | 42 lb ft |
| Turbine Speed Sensor to Transmission Case | 12 N.m | 108 lb in |
Fastener Tightening Specifications
Fluid Capacity Specifications
| Transmission | Initial Fill | Refill | ||
|---|---|---|---|---|
| Liters | Quarts | Liters | Quarts | |
| Allison 1000 | 12 | 12.7 | 7 | 7.4 |
Fluid Quantities
End Play Specifications
| Application | Maximum End Play | |
|---|---|---|
| Metric | English | |
| New Torque Converter | 0.762 mm | 0.0300 in |
| Used Torque Converter | 1.015 mm | 0.0400 in |
| Input Carrier and Thrust Washer | 1.010 mm | 0.0400 in |
| Intermediate Carrier and Thrust Washer | 1.010 mm | 0.0400 in |
| Output Carrier and Thrust Washer | 1.010 mm | 0.0400 in |
| Turbine Shaft | 1.549 mm | 0.0610 in |
End Play Specifications
Selective Components Specifications
| Identification | Wear Limit | New Plate Thickness | |
|---|---|---|---|
| Metric | English | ||
| 2420 | 11.400 mm (0.4488 in) | 11.1-11.9 mm | 0.4370-0.4685 in |
| 8521 | 11.840 mm (0.4661 in) | 11.54-12.34 mm | 0.4543-0.4858 in |
| 8522 | 12.280 mm (0.4835 in) | 11.98-12.78 mm | 0.4717-0.5031 in |
| 8523 | 12.730 mm (0.5012 in) | 12.43-13.23 mm | 0.4894-0.5209 in |
| 8524 | 13.180 mm (0.5189 in) | 12.88-13.68 mm | 0.5071-0.5386 in |
1-2-3-4 Clutch Backplate
| Dimension C | Thickness | Identification | ||
|---|---|---|---|---|
| Metric | English | Metric | English | |
| 1.008-1.184 mm | 0.0397-0.0466 in | 0.245-0.295 mm | 0.0096-0.0116 in | 0 Holes |
| 1.185-1.414 mm | 0.0467-0.0557 in | 0.475-0.525 mm | 0.0187-0.0207 in | 1 Hole |
| 1.415-1.644 mm | 0.0557-0.0647 in | 0.705-0.755 mm | 0.0278-0.0297 in | 2 Holes |
| 1.645-1.874 mm | 0.0648-0.0738 in | 0.935-0.985 mm | 0.0368-0.0388 in | 3 Holes |
| 1.875-2.104 mm | 0.0738-0.0828 in | 1.165-1.215 mm | 0.0459-0.0478 in | 4 Holes |
| 2.105-2.334 mm | 0.0829-0.0919 in | 1.395-1.445 mm | 0.0549-0.0569 in | 5 Holes |
| 2.335-2.510 mm | 0.0919-0.0988 in | 1.625-1.675 mm | 0.0640-0.0659 in | 6 Holes |
Low and Reverse Clutch Piston Housing Selective Shim
| Minimum Thickness | Identification | |
|---|---|---|
| Metric | English | |
| 2.435 mm | 0.0959 in | 2 |
Low and Reverse Clutch Steel Plate Minimum Thickness
| Dimension C | Identification | |
|---|---|---|
| Metric | English | |
| 35.3-35.86 mm | 1.393-1.412 in | 1 |
| 35.87-36.36 mm | 1.413-1.431 in | 2 |
| 36.37-37.27 mm | 1.432-1.467 in | 3 |
Low and Reverse Clutch Steel Selective Plate
Oil Pump Specifications
| Part Measured | Specification | |
|---|---|---|
| Metric | English | |
| Bushing, Maximum ID IMPORTANT: The pump bushing must have a complete burnt-orange color Teflon® coating. If any portion of the Teflon® coating is worn and bronze material is visible, replace the pump. | 58.391 mm | 2.3015 in |
| Drive Gear, Maximum Side Clearance | 0.066 mm | 0.0026 in |
| Driven Gear, Between Flats Maximum | 52.165 mm | 2.0537 in |
| Driven Gear, Minimum OD | 108.987 mm | 4.2908 in |
| Oil Pump Body Gear Cavity, Maximum ID | 109.216 mm | 4.2988 in |
| Driven Gear to Oil Pump Body, Maximum Diametrical Clearance | 0.204 mm | 0.0080 in |
| Driven Gear, Maximum Side Clearance | 0.056 mm | 0.0022 in |
| Driven Gear/Crescent Tooth, Maximum Clearance | 0.455 mm | 0.0179 in |
| Oil Pump Body Gear Cavity, Maximum Depth | 24.940 mm | 0.9819 in |
| Wear Plate, Minimum Thickness | 2.950 mm | 0.1161 in |
| IMPORTANT |
|---|
| The pump bushing must have a complete burnt-orange color Teflon® coating. If any portion of the Teflon® coating is worn and bronze material is visible, replace the pump. |
Oil Pump Specifications
Transmission General Specifications
| Sump Temperature | Resistance | |
|---|---|---|
| Degrees C | Degrees F | Ohms |
| 0 | 32 | 9.5 |
| 20 | 68 | 10.5 |
| 40 | 104 | 11.5 |
Torque Converter Clutch Pressure Control Solenoid (TCC PCS) Specifications
| Sump Temperature | Resistance | |
|---|---|---|
| Degrees C | Degrees F | Ohms |
| 0 | 32 | 20.0 |
| 20 | 68 | 22.0 |
| 40 | 104 | 24.5 |
Shift Solenoid 1 (SS1), SS2, SS3, and Modulated Main Pressure (MAIN MOD) Solenoid Specifications
| Part Measured | Specification | |
|---|---|---|
| Metric | English | |
| Torque Converter Pump Hub Minimum OD | 58.250 mm | 2.2933 in |
| Torque Converter Pump Hub Minimum Distance Between Flats | 51.816 mm | 2.0400 in |
| Torque Converter Cover Pilot, Minimum OD | 43.080 mm | 1.6960 in |
| Stator Shaft, Maximum ID at Turbine Shaft Seal Ring Bore | 45.450 mm | 1.7894 in |
| Stator Shaft, Maximum Spline Wear | No visible wear | No visible wear |
| Stator Shaft Bushing, Maximum ID | 33.850 mm | 1.3326 in |
| Transmission Oil Pump Cover Assembly Thrust Washer Thickness | 1.490 mm | 0.0590 in |
| 1-2-3-4, 4-5-6 Clutch Housing Bushing, Maximum ID | 78.170 mm | 3.0776 in |
| 1-2-3-4, 4-5-6 Clutch Housing Rotating Seal Bore, Maximum ID | 74.050 mm | 2.9154 in |
| 1-2-3-4 Clutch Fiber Plates Maximum Cone | 0.255 mm | 0.0100 in |
| 1-2-3-4 Clutch Fiber Plates Minimum Thickness | 2.375 mm | 0.0935 in |
| 1-2-3-4 Clutch Fiber Plates Minimum Oil Groove Depth | 0.200 mm | 0.0079 in |
| 1-2-3-4 Clutch Steel Plate Maximum Cone | 0.200 mm | 0.0079 in |
| 1-2-3-4 Clutch Steel Plate Minimum Thickness | 2.135 mm | 0.0841 in |
| 1-2-3-4 Clutch Backing Plate Maximum Cone | 0.000 mm | 0.0000 in |
| 4-5-6 Clutch Fiber Plates Maximum Cone | 0.225 mm | 0.0089 in |
| 4-5-6 Clutch Fiber Plates Minimum Thickness | 2.375 mm | 0.0935 in |
| 4-5-6 Clutch Fiber Plates Minimum Oil Groove Depth | 0.200 mm | 0.0079 in |
| 4-5-6 Clutch Steel Plate Maximum Cone | 0.240 mm | 0.0094 in |
| 4-5-6 Clutch Steel Plate Minimum Thickness | 2.135 mm | 0.0841 in |
| Turbine Shaft Bushing, Maximum ID | 20.150 mm | 0.7933 in |
| Turbine Shaft Thrust Washer | 2.590 mm | 0.102 in |
| 3rd, 5th and Reverse/2-6 Clutch Fiber Plate Maximum Cone | 0.225 mm | 0.0089 in |
| 3rd, 5th and Reverse/2-6 Clutch Fiber Plate Minimum Thickness | 2.375 mm | 0.0935 in |
| 3rd, 5th and Reverse/2-6 Clutch Fiber Plate Minimum Oil Groove Depth | 0.200 mm | 0.0079 in |
| 3rd, 5th and Reverse/2-6 Clutch Steel Plate Maximum Cone | 0.400 mm | 0.0157 in |
| 3rd, 5th and Reverse/2-6 Clutch Steel Plate Minimum Thickness | 2.440 mm | 0.0961 in |
| 3rd, 5th and Reverse/2-6 Clutch Spring Plate Maximum Cone | 0.400 mm | 0.0157 in |
| 3rd, 5th and Reverse/2-6 Clutch Spring Plate Minimum Thickness | 3.110 mm | 0.1224 in |
| 3rd, 5th and Reverse Clutch Backing Plate Maximum Cone | 0.000 mm | 0.0000 in |
| 3rd, 5th and Reverse Clutch Backing Plate Minimum Thickness | 15.325 mm | 0.6033 in |
| Thrust Plate Inner Rim, Minimum Thickness | 3.000 mm | 0.1181 in |
| 2-6 Clutch Backing Plate Maximum Cone | 0.000 mm | 0.0000 in |
| 2-6 Clutch Backing Plate Minimum Thickness | 15.400 mm | 0.6063 in |
| Low and Reverse Clutch Fiber Plate Maximum Cone | 0.225 mm | 0.0089 in |
| Low and Reverse Clutch Fiber Plate Minimum Thickness | 2.375 mm | 0.0935 in |
| Low and Reverse Clutch Fiber Plate Minimum Oil Groove Depth | 0.200 mm | 0.0079 in |
| Low and Reverse Clutch Steel Plate Maximum Cone | 0.295 mm | 0.0116 in |
| Low and Reverse Clutch Backing Plate Maximum Cone | 0.000 mm | 0.0000 in |
| Low and Reverse Clutch Backing Plate Minimum Thickness | 17.900 mm | 0.704 in |
| Transmission Case Clutch Plate, Spline Wear (Notching) | 1.150 mm | 0.0450 in |
| Input Internal Ring Gear, Maximum Spline Wear (Notching) | 0.130 mm | 0.0051 in |
| Input Carrier Assembly Bushing, Maximum ID | 50.690 mm | 1.9957 in |
| Input Carrier Assembly Thrust Washers Thickness | 1.490 mm | 0.0590 in |
| Input Carrier Assembly Pinion Maximum End Play | 1.010 mm | 0.0400 in |
| Intermediate Internal Ring Gear, Maximum Spline Wear (Notching) | 0.130 mm | 0.0051 in |
| Intermediate Internal Ring Gear Thrust Washer Thickness | 1.490 mm | 0.0590 in |
| Intermediate Carrier Assembly Pinion Maximum End Play | 1.010 mm | 0.0400 in |
| Intermediate Carrier Bushing, Maximum ID | 36.575 mm | 1.4400 in |
| Output Carrier Internal Ring Gear, Maximum Spline Wear (Notching) | 0.130 mm | 0.0051 in |
| Output Carrier Assembly Pinion Maximum End Play | 1.010 mm | 0.0400 in |
| Main Shaft Pilot, Minimum OD (Turbine Shaft and Output Shaft) | 19.987 mm | 0.7869 in |
| Main Shaft Journal, Minimum OD (Intermediate Carrier Bushing) | 36.405 mm | 1.4333 in |
| Output Shaft Bushing (2WD and 4WD), Maximum ID | 20.150 mm | 0.7933 in |
| Output Shaft (2WD and 4WD), Minimum Bearing Surface OD | 44.978 mm | 1.7708 in |
| Park Pawl Gear Wear | 0.000 mm | 0.0000 in |
| Output Yoke, Output Seal Surface, Minimum OD | 65.080 mm | 2.5622 in |
Wear Limits
| Condition | Main Pressure at 600 RPM | Main Pressure at 2100 RPM |
|---|---|---|
| Forward/Rev Converter w/MAIN MOD Solenoid Active | 590-720 kPa (85-105 psi) | 634-758 kPa (92-110 psi) |
| Forward Converter w/MAIN MOD Solenoid Inactive | 700-138 kPa (101-200 psi) | 1515-1795 kPa (220-260 psi) |
| *Forward Lock-up w/MAIN MOD Solenoid Active | N/A | 510-627 kPa (74- 91 psi) |
| Forward Lock-up w/MAIN MOD Solenoid Inactive | N/A | 1000-1170 kPa (145-170 psi) |
| Neutral/Park w/MAIN MOD Solenoid Active | 590-720 kPa (85-05 psi) | N/A |
| Neutral/Park | 800-1655 kPa (130-240 psi) | 1515-1795 kPa (220-260 psi) |
| * Medium duty gasoline engines only. | ||
Modulated Main Pressure Schedule Table (Transmissions with MAIN MOD Solenoid)
Scheme 758
| Callout | Component Name |
|---|---|
| 1 | Torque Converter |
| 2 | Torque Converter Housing |
| 3 | Line Pressure Test Hole Plug |
| 4 | Line Pressure Test Hole Plug O-ring |
| 5 | Transmission External Oil Filter |
| 6 | Transmission External Oil Filter Magnet |
| 7 | Transmission External Oil Filter Adapter |
| 8 | Torque Converter Housing Bolt, M10 x 1.5 x 50, Flanged Head (18) |
| 9 | Torque Converter Housing Bolt, M10 x 1.5 x 70, Flanged Head (2) |
| 10 | Sensor Shipping Cover |
| 11 | Vehicle Speed Sensor Bolt |
| 12 | Input Speed Sensor |
| 13 | Vehicle Speed Sensor O-ring |
| 14 | Torque Converter Housing Bolt, M10 x 1.5 x 25 (10) |
| 15 | Transmission Oil Cooler Pipe Connector (2) |
| 16 | Torque Converter Housing Access Hole Cover |
Scheme 759
| Callout | Component Name |
|---|---|
| 1 | Torque Converter Housing/Oil Pump Cover Assembly |
| 2 | Torque Converter Housing to Case Gasket |
| 3 | 1-2-3-4, 4-5-6 Clutch Assembly |
| 4 | Input Sun Gear Thrust Bearing |
| 5 | Internal Retaining Ring |
| 6 | 3rd, 5th, and Reverse Clutch Backing Plate |
| 7 | 3rd, 5th, and Reverse Clutch Fiber Plate (4) |
| 8 | 3rd, 5th, and Reverse Clutch Steel Plate (3) |
| 9 | 3rd, 5th, and Reverse Clutch Piston Return Spring Assembly (3) |
| 10 | 3rd, 5th, and Reverse Clutch Spring Plate |
| 11 | 3rd, 5th, and Reverse Clutch Piston Assembly (Bonded Seals) |
Scheme 760
| Callout | Component Name |
|---|---|
| 1 | Torque Converter Housing/Oil Pump Cover Assembly |
| 2 | Torque Converter Housing Bolt, M10 x 1.5 x 50, Flanged Head (10) |
| 3 | Torque Converter Housing Bolt Seal |
| 4 | Torque Converter Housing |
| 5 | Torque Converter Housing Gasket |
| 6 | Oil Pump Cover Assembly |
Scheme 761
| Callout | Component Name |
|---|---|
| 1 | Oil Pump Assembly |
| 2 | Oil Pump O-Ring Seal |
| 3 | Torque Converter Oil Seal |
| 4 | Oil Pump Bushing |
| 5 | Oil Pump Body |
| 6 | Oil Pump Driven Gear |
| 7 | Oil Pump Drive Gear |
| 8 | Locating Pin |
| 8 | Locating Pin |
| 9 | Oil Pump Wear Plate |
Scheme 762
| Callout | Component Name |
|---|---|
| 1 | Oil Pump Cover Assembly |
| 2 | Oil Pump Cover Assembly Bearing |
| 3 | Oil Pump Cover |
| 4 | Bushing, 33.8 mm (1.33 in) ID |
| 5 | Stator Shaft |
| 6 | Torque Converter Clutch Valve |
| 7 | Torque Converter Clutch Valve Spring |
| 8 | Torque Converter Clutch Valve Stop |
| 9 | Torque Converter Clutch Valve Retainer |
| 10 | Torque Converter Clutch Relief Valve |
| 11 | Torque Converter Clutch Relief Valve Spring |
| 12 | Torque Converter Clutch Relief Valve Retainer |
| 13 | Oil Pump Lube Regulator Valve |
| 14 | Oil Pump Lube Regulator Valve Spring |
| 15 | Oil Pump Lube Regulator Valve Stop |
| 16 | Oil Pump Lube Regulator Valve Stop Retainer |
| 17 | 1-2-3-4 Clutch Backfill Valve |
| 18 | 1-2-3-4 Clutch Backfill Valve Spring |
| 19 | Retaining Clip |
| 20 | Pressure Regulator Valve |
| 21 | Pressure Regulator Valve Spring |
| 22 | Pressure Regulator Valve Stop |
| 23 | Pressure Regulator Spring Stop Retainer |
Scheme 763
| Callout | Component Name |
|---|---|
| 1 | Oil Pump Cover Module |
| 2 | Oil Pump Assembly |
| 3 | Torque Converter Housing to Case Channel Plate |
| 4 | Overlap Seal Ring, End |
| 5 | Overlap Seal Ring, Middle |
| 6 | Oil Pump Cover Assembly |
| 7 | Oil Pump Cover Assembly Bolt, M8 x 1.25 x 55, Flanged Head (5) |
| 8 | Oil Pump Cover Assembly Thrust Washer |
| 9 | Overlap Seal Ring (3) |
Scheme 764
| Callout | Component Name |
|---|---|
| 1 | 1-2-3-4, 4-5-6 Clutch Assembly |
| 2 | Overlap Seal Ring (2) |
| 3 | Turbine Shaft Assembly |
| 4 | Turbine Shaft |
| 5 | Bushing, 20 mm (0.8 in) ID |
| 6 | 1-2-3-4, 4-5-6 Clutch Piston Housing Assembly |
| 7 | Power Take-Off (PTO) Gear |
| 8 | Turbine Tone Wheel |
| 9 | 1-2-3-4, 4-5-6 Clutch Housing Assembly |
| 10 | 1-2-3-4, 4-5-6 Clutch Bushing |
| 11 | 1-2-3-4, 4-5-6 Clutch Housing |
| 12 | O-ring |
| 13 | External Retaining Ring |
| 14 | 4-5-6 Clutch Piston Inner Seal |
| 15 | 4-5-6 Clutch Piston Outer Seal |
| 16 | 4-5-6 Clutch Piston |
| 17 | 4-5-6 Clutch Return Spring Assembly |
| 18 | 1-2-3-4 Clutch Piston Outer Seal |
| 19 | 1-2-3-4 Clutch Piston Housing |
| 20 | 4-5-6 Clutch Piston Return Spring Retainer |
| 21 | 1-2-3-4 Clutch Piston Inner Seal |
| 22 | 1-2-3-4 Clutch Piston Outer Seal |
| 23 | 1-2-3-4 Clutch Piston |
| 24 | 1-2-3-4 Clutch Piston Return Spring Assembly |
| 25 | 1-2-3-4 Clutch Balance Piston |
| 26 | 1-2-3-4 Clutch Hub Internal Retainer Ring |
| 27 | 1-2-3-4 Clutch Steel Plate (6) |
| 28 | 1-2-3-4 Clutch Fiber Plate (6) |
| 29 | 1-2-3-4 Clutch Selective Backing Plate 5.84-6.04 mm (0.2299-0.2378 in) |
| 30 | 1-2-3-4 Clutch Backing Plate External Retainer Ring |
| 31 | 1-2-3-4 Clutch Backing Plate Internal Retainer Ring |
| 32 | 1-2-3-4 Clutch Hub Thrust Bearing Assembly |
| 33 | 1-2-3-4 Clutch Hub |
| 34 | 4-5-6 Clutch Hub Thrust Bearing |
| 35 | 4-5-6 Clutch Steel Plate (7) |
| 36 | 4-5-6 Clutch Fiber Plate (6) |
| 37 | 4-5-6 Clutch Hub |
| 38 | Input Sun Gear Thrust Washer |
| 39 | Input Sun Gear |
| 40 | Input Sun Gear Flange |
| 41 | Input Sun Gear External Retaining Ring |
Scheme 765
| Callout | Component Name |
|---|---|
| 20 | Torque Converter Housing |
| 50 | Transmission Case |
| 70 | Transmission Fill Tube Plug |
| 71 | Transmission Fill Tube Seal (2) |
| 72 | Transmission Internal Oil Filter Seal |
| 73 | Transmission Internal Oil Filter |
| 74 | Transmission Oil Pan Gasket |
| 75 | Transmission Oil Pan Magnet |
| 76 | Transmission Oil Pan |
| 77 | Transmission Oil Pan Drain Plug O-ring |
| 78 | Transmission Oil Pan Drain Plug |
| 79 | Transmission Oil Pan Bolt, M8 x 1.25 x 20 Flanged Head |
| 81 | Low and Reverse Clutch Housing, 2WD |
Scheme 766
| Callout | Component Name |
|---|---|
| 1 | Automatic Transmission Case |
| 2 | Transmission Case Locating Pin |
| 3 | Transmission Vent Assembly |
| 4 | Transmission Vent Cap |
| 5 | Transmission Vent |
| 6 | Nameplate Rivet |
| 7 | Nameplate |
| 8 | Vehicle Speed Sensor Bolt, M6 x 1.0 x 13 |
| 9 | Sensor Shipping Cover |
| 10 | Turbine Speed Sensor |
| 11 | Vehicle Speed Sensor O-Ring |
| 12 | Power Take-Off (PTO) Cover Gasket (2) |
| 13 | PTO Cover (2) |
| 14 | PTO Cover Bolt, M10 x 1.5 x 20, Flanged Head, Coated (12) |
| 16 | Manual Shift Shaft |
| 17 | Manual Shift Shaft Seal |
| 18 | Manual Shift Shaft Pin |
| 19 | Manual Shift Shaft Detent Lever/Internal Mode Switch (IMS) Assembly |
| 20 | Park Pawl Assembly |
| 21 | Control Valve Body Locating Pin |
| 22 | Detent Lever/IMS Bolt |
| 23 | Connector Shipping Cover |
| 24 | Control Valve Body Assembly |
| 25 | Control Valve Body Bolt, M6 x 1.0 x 50, Flanged Head (15) |
| 26 | Manual Shift Shaft Detent Spring |
| 27 | Manual Shift Shaft Detent Spring Bolt M6 x 1.0 x 12. Flanged Head (2) |
| 28 | Transmission Wiring Harness Assembly |
Scheme 767
| Callout | Component Name |
|---|---|
| 1 | 2-6 Clutch Piston Assembly, Bonded Seals |
| 2 | Input and 3rd, 5th, and Reverse Clutch Ring Gear |
| 3 | 2-6 Clutch Spring Plate |
| 4 | Piston Return Spring Assembly (3) |
| 5 | 2-6 Clutch Fiber Plate (5) |
| 6 | 2-6 Clutch Steel Plate (4) |
| 7 | 2-6 Clutch Backing Plate |
| 8 | Internal Retaining Ring |
| 9 | Internal Retaining Ring |
| 10 | Low and Reverse Clutch Backing Plate |
| 11 | Low and Reverse Clutch Fiber Plate (6) |
| 12 | Low and Reverse Clutch Steel Plate (5) |
| 13 | Low and Reverse Clutch Steel Plate, Selective |
Scheme 768
| Callout | Component Name |
|---|---|
| 1 | Input Carrier and Ring Gear Assembly |
| 2 | Input Carrier Thrust Bearing |
| 3 | Intermediate Carrier and Ring Gear Assembly |
| 4 | Intermediate Carrier Thrust Bearing |
| 5 | Main Shaft |
| 6 | Intermediate Sun Gear |
| 7 | Intermediate Sun Gear Spacer |
| 8 | Output Sun Gear |
| 9 | Output Shaft Thrust Bearing |
Scheme 769
| Callout | Component Name |
|---|---|
| 1 | Input Carrier and Ring Gear Assembly |
| 2 | Input Carrier Thrust Washer |
| 3 | Input Carrier Internal Retaining Ring |
| 4 | Input Carrier Assembly |
| 5 | Intermediate and 2-6 Clutch Ring Gear |
Scheme 770
| Callout | Component Name |
|---|---|
| 1 | Intermediate Carrier and Ring Gear Assembly |
| 2 | Intermediate Carrier Internal Retaining Ring |
| 3 | Intermediate Carrier Assembly |
| 4 | Output Carrier and Low and Reverse Clutch Ring Gear |
Scheme 771
| Callout | Component Name |
|---|---|
| 1 | Input Carrier Assembly |
| 2 | Bushing, 53.0 mm (2.09 in) ID |
| 3 | Input Carrier |
| 4 | Input Carrier Spindle (4) |
| 5 | Input Carrier Thrust Washer (4) |
| 6 | Input Carrier Roller Bearing Assembly (8) |
| 7 | Input Carrier Pinion Gear (4) |
| 8 | Input Carrier Thrust Washer (4) |
Scheme 772
| Callout | Component Name |
|---|---|
| 1 | Intermediate Carrier Assembly |
| 2 | Intermediate Carrier |
| 3 | Intermediate Carrier Bushing, 36.0 mm (1.42 in) ID |
| 4 | Intermediate Carrier Thrust Washer (4) |
| 5 | Intermediate Carrier Roller Bearing Assembly (8) |
| 6 | Intermediate Carrier Pinion Gear (4) |
| 7 | Intermediate Carrier Thrust Washer (4) |
| 8 | Intermediate Carrier Spindle (4) |
Scheme 773
| Callout | Component Name |
|---|---|
| 1 | Park Pawl Cam Guide |
| 2 | Park Pawl Support Pin |
| 3 | Park Pawl |
| 4 | Park Pawl Return Spring |
| 5 | Low and Reverse Clutch Piston Return Spring Assembly |
| 6 | Bushing, 20 mm (0.8 in) ID |
| 7 | Output Shaft, 2WD |
| 8 | Output Shaft, 4WD |
| 9 | Output Carrier Assembly |
Scheme 774
| Callout | Component Name |
|---|---|
| 1 | Low and Reverse Clutch Housing Gasket |
| 2 | Low and Reverse Clutch Housing, 2WD |
| 3 | Low and Reverse Clutch Housing, 4WD |
| 4 | Low and Reverse Clutch Housing Bolt, M10 x 1.5 x 40, Flanged Head (16) |
| 5 | Prop Shaft Front Slip Yoke Oil Seal |
| 6 | Output Nut, 4WD |
| 7 | Rear Shipping Cover, 2WD |
| 8 | Rear Shipping Cover, 4WD |
Scheme 775
| Callout | Component Name |
|---|---|
| 1 | Output Carrier Assembly |
| 2 | Output Carrier |
| 3 | Output Carrier Thrust Washer (4) |
| 4 | Output Carrier Roller Bearing Assembly (4) |
| 5 | Output Carrier Pinon Gear (4) |
| 6 | Output Carrier Thrust Washer (4) |
| 7 | Output Carrier Planetary Spindle (4) |
| 8 | Output Carrier Bearing Race |
Scheme 776
| Callout | Component Name |
|---|---|
| 1 | Low and Reverse Clutch Housing Assembly, 2WD |
| 2 | Low and Reverse Clutch Piston |
| 3 | Low and Reverse Clutch Outer Piston Seal |
| 4 | Low and Reverse Clutch Inner Piston Seal |
| 5 | Internal Retaining Ring |
| 6 | Output Carrier Support Bearing |
| 7 | Output Speed Sensor Reluctor Wheel |
| 8 | Low and Reverse Clutch Housing, 2WD |
| 9 | Vehicle Speed Sensor Bolt, M6 x 1.0 x 13 |
| 10 | Sensor Shipping Cover |
| 11 | Output Speed Sensor |
| 12 | Vehicle Speed Sensor O-Ring |
| 13 | Low and Reverse Clutch Selective Spacer |
| 14 | Low and Reverse Clutch External Retaining Ring |
| 15 | Output Shaft Support Bearing |
| 16 | Low and Reverse Clutch Internal Retaining Ring |
Scheme 777
| Callout | Component Name |
|---|---|
| 1 | Low and Reverse Clutch Housing Assembly, 4WD |
| 2 | Low and Reverse Clutch Piston |
| 3 | Low and Reverse Clutch Outer Piston Seal |
| 4 | Low and Reverse Clutch Inner Piston Seal |
| 5 | Internal Retaining Ring |
| 6 | Output Carrier Support Bearing |
| 7 | Output Shaft Bearing Spacer |
| 8 | Low and Reverse Clutch Housing, 4WD |
| 9 | Selective Spacer |
| 10 | External Retaining Ring |
| 11 | Output Shaft Support Bearing |
| 12 | Internal Retaining Ring |
| 13 | Output shaft Retaining Nut, 4WD |
Scheme 778
| Callout | Component Name |
|---|---|
| 1 | Control Valve Body Assembly |
| 2 | Shift Valve Body Assembly |
| 3 | Separator Plate |
| 4 | Main Valve Body Assembly |
| 5 | Transmission Fluid Pressure (TFP) Switch |
| 6 | Main Valve Body Assembly Bolt, M6 x 10 x 50, Flanged Head (23) |
| 7 | Reverse Signal Pipe |
| 8 | Reverse Signal Pipe Bolt, M6 x 10 x 50, Flanged Head |
| 9 | Retaining Clip |
| 10 | Modulated Main Valve Body |
| 11 | Bolt, M6 x 10 x 65 |
| 12 | Bolt, M6 x 10 x 50 |
| 13 | O-Rings |
| 14 | Modulated Main Pressure (MAIN MOD) Solenoid |
| 15 | 6 Speed Pipe |
Scheme 779
| Callout | Component Name |
|---|---|
| 1 | Shift Valve Body Assembly |
| 2 | Retaining Clip |
| 3 | Shift Solenoid 2 (SS2) Shift Plug |
| 4 | SS2 Shift Spring |
| 5 | SS2 Shift Valve |
| 6 | Retaining Clip |
| 7 | SS3 Shift Plug |
| 8 | SS3 Shift Spring |
| 9 | SS3 Shift Valve |
| 10 | Retaining Clip |
| 11 | SS1 Shift Spring |
| 12 | SS1 Shift Valve |
| 13 | Retaining Clip |
| 14 | Control Main Spring |
| 15 | Control Main Valve |
| 16 | Shift Valve Body |
| 17 | Shift Solenoid Retainer |
| 18 | Shift Solenoid Screen |
| 19 | SS1 |
| 20 | Shift Solenoid O-Ring |
| 21 | Shift Solenoid O-Ring |
| 22 | Manual Valve |
| 23 | Manual Valve Pin |
Scheme 780
| Callout | Component Name |
|---|---|
| 1 | Main Valve Body Assembly |
| 2 | Retaining Clip |
| 3 | Exhaust Pressure Regulator Valve Spring |
| 4 | Exhaust Pressure Regulator Valve |
| 5 | Retaining Clip |
| 6 | Control Relief Spring |
| 7 | Control Relief Valve |
| 8 | Main Valve Body |
| 9 | Locating Pin (4) |
| 10 | Locating Pin |
| 11 | Pressure Control Solenoid 1 (PCS1) Spring |
| 12 | PCS1 Valve |
| 13 | PCS1 Spring |
| 14 | Trim Gain Valve |
| 15 | PCS1 |
| 16 | PCS1 O-Ring |
| 17 | PCS2 Spring |
| 18 | PCS2 Valve |
| 19 | Trim Gain Valve |
| 20 | PCS2 |
| 21 | PCS2 O-Ring |
| 22 | Shift Solenoid (SS) 3 |
| 23 | SS3 O-Ring |
| 24 | SS3 O-Ring |
| 25 | SS2 |
| 26 | SS2 O-Ring |
| 27 | SS2 O-Ring |
| 28 | Torque Converter Clutch Pressure Control Solenoid (TCC PCS) Spring |
| 29 | TCC PCS Valve |
| 31 | TCC PCS |
| 32 | TCC PCS O-Ring |
| 33 | TCC PCS O-Ring |
| 34 | TCC PCS Retaining Bracket |
| 35 | SS2 and SS3 Retainers (2) |
| 36 | Accumulator Plug (2) |
| 37 | Accumulator Spring (2) |
| 38 | PCS1 and PCS2 Retaining Bracket |
Scheme 781
| Callout | Component Name |
|---|---|
| 1 | Transmission Control Module |
| 2 | Transmission Control Module Connector |
| 3 | Radiator Fan Shroud |
Scheme 782
| Callout | Component Name |
|---|---|
| 1 | Turbine Sensor Harness Connector |
| 2 | Power Take-Off (PTO) Connector |
| 3 | Output Speed Sensor Harness Connector |
| 4 | Transfer Case Selector Shift Control Switch |
| 5 | Transmission Connector Harness |
| 6 | Allison Transmission |
| 7 | Engine Harness |
| 8 | Automatic Transmission Input Shaft Speed (ISS) Sensor |
Scheme 783
| Callout | Component Name |
|---|---|
| 1 | Stator Shaft Bushing |
| 2 | Oil Pump Bushing |
| 3 | 1-2-3-4, 4-5-6 Clutch Piston Housing Bushing |
| 4 | Oil Pump Cover Assembly Needle Bearing |
| 5 | Turbine Shaft Bushing |
| 6 | 1-2-3-4 Clutch Drive Hub Thrust Bearing |
| 7 | 4-5-6 Clutch Hub Thrust Bearing |
| 8 | Input Carrier Thrust Bearing |
| 9 | Intermediate Carrier Bushing |
| 10 | Intermediate Carrier Thrust Bearing |
| 11 | Intermediate Carrier Thrust Bearing |
| 12 | Output Sun Gear Thrust Bearing |
| 13 | Output Carrier Needle Bearing |
| 14 | Low and Reverse Clutch Housing Ball Bearing |
| 15 | Output Shaft Bushing |
| 16 | Input Carrier Bushing |
Scheme 784
| Callout | Component Name |
|---|---|
| 1 | Stator Shaft Overlap Seal Ring |
| 2 | Stator Shaft Overlap Seal Ring |
| 3 | Oil Pump Lip Seal |
| 4 | Input Speed Sensor O-Ring |
| 5 | Pump Body O-Ring |
| 6 | 4-5-6 Clutch Piston Inner Seal |
| 7 | 4-5-6 Clutch Piston Outer Seal |
| 8 | 1-2-3-4 Clutch Piston Assembly Outer Seal |
| 9 | 1-2-3-4 Clutch Piston Inner Seal |
| 10 | 1-2-3-4 Clutch Piston Outer Seal |
| 11 | 1-2-3-4 Clutch Assembly Outer Seal |
| 12 | 1-2-3-4 Clutch Balance Piston |
| 13 | Turbine Speed Sensor O-Ring |
| 14 | 3rd, 5th, and Reverse Clutch Piston Seal Assembly |
| 15 | 2-6 Clutch Piston Seal Assembly |
| 16 | Low and Reverse Clutch Piston Outer Seal |
| 17 | Low and Reverse Clutch Piston Outer Seal |
| 18 | Drain Plug O-Ring |
| 19 | Stator Shaft Overlap Seal Ring (3) |
| 20 | Transmission Internal Oil Filter Seal |
| 21 | Turbine Shaft Seal, 2 |
Torque Converter Leak Test
Tools Required
- J 43763 Torque Converter Leak Test Plug. See «Special Tools»(ref-246434-S09644350722006122100000) .
- J 21369-F Torque Converter Leak Test Fixture. See «Special Tools»(ref-246434-S09644350722006122100000) .
Scheme 785
- Position the torque converter (6) on the work table so that the pump hub is facing up.
- Move the nut (3) to the middle of the center body (1) of J 43763 . See «Special Tools»(ref-246434-S09644350722006122100000) .
- Install J 43763 into the torque converter hub. See «Special Tools»(ref-246434-S09644350722006122100000) .
- Install J 21369-F (3) onto the torque converter (8) and onto J 43763 (4). See «Special Tools»(ref-246434-S09644350722006122100000) .
- Firmly tighten the nut (6) in order to seal J 43763 into the torque converter.
- Firmly tighten the nut (5) in order to securely attach the torque converter to J 21369-F (3). See «Special Tools»(ref-246434-S09644350722006122100000) . Connect an air hose to the air fitting (1) of J 43763 . See «Special Tools»(ref-246434-S09644350722006122100000) .
- Pressurize the converter to 517 kPa (75 psi) maximum.
- Disconnect the air hose. Submerge the torque converter in water.
- Closely observe the torque converter for bubbles that indicate leakage. If the torque converter leaks, replace the torque converter.
- Push on the pressure relief valve (2) of J 43763 and release the air from the torque converter. See «Special Tools»(ref-246434-S09644350722006122100000) .
- Remove the J tools from the torque converter.
Scheme 786
Scheme 787
- Measure the OD of torque converter hub (1) at dimension A, the bushing wear area. Torque Converter Hub OD: Dimension A must equal or exceed 58.250 mm (2.293 in).
- Measure the distance between the flats of the torque converter hub at dimension A. Torque Converter Hub Flats: Dimension A must equal or exceed 51.816 mm (2.040 in).
- Measure the OD of the torque converter cover pilot at dimension A. Torque Converter Pilot: Dimension A must equal or exceed 43.080 mm (1.696 in).
Scheme 788
- Remove the transmission fluid from torque converter (1).
- Examine the transmission fluid for the following. Evidence of foreign matter Metal particles Other contaminates
- If the torque converter is damaged, replace the torque converter.
Torque Converter End Play Inspection
Tools Required
- J 43764 Torque Converter End Play Gauge. See «Special Tools»(ref-246434-S09644350722006122100000) .
- J 5959 Dial Indicator Clamp and Adjuster. See «Special Tools»(ref-246434-S09644350722006122100000) .
- J 7872 Magnetic Base Dial Indicator
Scheme 789
- Position the torque converter (3) on the work table so that the pump hub is facing up.
- Install J 43764 (2) into the torque converter hub. See «Special Tools»(ref-246434-S09644350722006122100000) .
- Hold J 43764 (2) in the converter hub and rotate the center screw until J 43764 is locked into the converter hub. See «Special Tools»(ref-246434-S09644350722006122100000) . Do not over tighten J 43764 . See «Special Tools»(ref-246434-S09644350722006122100000) .
- Assemble the following tools and install the tools onto the torque converter as shown: J 5959 (1). See «Special Tools»(ref-246434-S09644350722006122100000) . Extension rod (7) Clamp (6) J 7872 (4) Adaptor rod (5)
- Adjust the clamp (6) so that the dial indicator (1) firmly contacts the top of J 43764 (2). See «Special Tools»(ref-246434-S09644350722006122100000) .
- Set the J 5959 (1) to read zero. See «Special Tools»(ref-246434-S09644350722006122100000) .
- Lift J 43764 (2) upward as far as possible. See «Special Tools»(ref-246434-S09644350722006122100000) .
- Read the J 5959 (1) to determine torque converter end play. See «Special Tools»(ref-246434-S09644350722006122100000) .
- Compare the measured end play with the torque converter end play specifications. Refer to «End Play Specifications»(ref-246434-S26386571042006122100000) .
- If the measured torque converter end play exceeds the value listed, replace the torque converter.
- Remove the J tools from the converter housing.
Torque Converter Housing/Pump Assembly Removal
- Remove 18 bolts (1), one bolt (2), and one bolt (3).
- Attach a sling to the converter housing (1).
- Attach a hoist to the sling.
- Remove the converter housing/oil pump cover assembly (1) from the transmission case (4) and the turbine shaft (2).
- Place the converter housing/oil pump cover assembly on the work table.
- Remove the sling.
- Remove and discard the main housing/separator plate gasket (3).
Scheme 790
- Lift and remove the 1-2-3-4, 4-5-6 clutch piston assembly (1).
- Remove thrust bearing assembly (1) from the 1-2-3-4, 4-5-6 clutch piston assembly or the input carrier assembly.
Torque Converter Housing/Pump Assembly Installation
Tools Required
- J 36850 Transjel® Lubricant
- J 45023 Control Main Filter Wrench. See «Special Tools»(ref-246434-S09644350722006122100000) .
Scheme 791
- Install 2 M10 x 1.5 guide bolts (5) into the transmission case (4).
- Install a new torque converter housing to case gasket (3) onto the transmission case.
- Attach a sling to the converter housing (1).
- Attach a hoist to the sling.
- Align the converter housing (1) with the guide bolts (5).
- Apply J 36850 or equivalent lubrication to the 3 seal rings on the rear of the oil pump cover assembly.
- Lower the converter housing/oil pump cover assembly (1) over the turbine shaft (2) and onto the transmission case (4).
- Tap the converter housing until the converter housing seats on the transmission case.
- Remove the sling.
- Remove 2 guide bolts (5) from the transmission case.
- Install 18 bolts (1).
- Install one bolt (2).
- Install one bolt (3). Tighten: Tighten bolts (1, 2, 3) to 56 N.m (42 lb ft).
- Install the short-threaded end of the transmission external oil filter adapter (6) into the converter housing by hand. Tighten: Tighten the adapter to 30 N.m (22 lb ft.)
- Install the magnet (7) onto the transmission external oil filter adapter.
- Lubricate the gasket on the transmission external oil filter (8) with transmission fluid.
- Install the transmission external oil filter by hand until the gasket on the filter touches the converter housing.
- Using J 45023 (9) or by hand, turn the filter ONE FULL TURN ONLY. See «Special Tools»(ref-246434-S09644350722006122100000) .
- Install the line pressure test hole plug O-ring (4) onto the line pressure test hole plug (5).
- Install the plug. Tighten: Tighten the plug to 12 N.m (108 lb in).
- Install the torque converter housing access hole cover (10).
- If present, install the O-rings (3) onto the transmission oil cooler pipe connectors (2).
- Install 2 transmission oil cooler pipe connectors (2). Tighten: Tighten the connectors to 25 N.m (19 lb ft).
Scheme 792
Scheme 793
- Position the transmission case so that the rear of the case is facing up.
- At dimension A, measure the distance from the rear face of the low and reverse clutch housing (1) to the rear face of output speed sensor (OSS) reluctor wheel (2).
- At dimension B, measure the distance from the rear face of the low and reverse clutch housing (3) to the rear face of the retaining ring (4).
- Calculate Dimension C by subtracting Dimension B from Dimension A.
- Select the appropriate selective spacer (1) based upon Dimension C. Refer to «Selective Components Specifications»(ref-246434-S22577166062006122100000) .
- Install the selective spacer (1) onto the output shaft (2).
Scheme 794
Scheme 795
- Position the transmission case so that the rear of the case is facing up.
- At dimension A, measure the distance from the rear face of the low and reverse clutch housing (1) to the rear face of the bearing spacer (2).
- At dimension B, measure the distance from the rear face of the low and reverse clutch housing (3) to the rear face of the retaining ring (4).
- Calculate Dimension C by subtracting Dimension B from Dimension A.
- Select the appropriate selective spacer (1) based upon Dimension C. Refer to «Selective Components Specifications»(ref-246434-S22577166062006122100000) .
- Install the selective spacer (1) onto the output shaft (2).
Torque Converter Assembly Installation
Tools Required
- J 46409 Torque Converter Lifting Handles. See «Special Tools»(ref-246434-S09644350722006122100000) .
- J 21366 Torque Converter Retaining Strap
- If not installed, install J 46409 , positioned 180 degrees apart, into 2 threaded bosses on the torque converter (1). See «Special Tools»(ref-246434-S09644350722006122100000) .
- Raise the torque converter (1) over the torque converter housing.
- Lower the torque converter (1) over the turbine shaft and the stator shaft and into the oil pump assembly.
- Make sure the torque converter is seated in the oil pump assembly.
- Remove the J 46409 . See «Special Tools»(ref-246434-S09644350722006122100000) .
- Install the J 21366 to retain the torque converter to the transmission.