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Technical Service Information ALLISON 1000/2000 SERIES PRELIMINARY INFORMATION Allison Transmission has now developed a family of two new automatic transmissions, refered to as the 1000 Series and the 2000 Series, for light duty (8600-19850 GVW) and medium duty (19850-30000 GVW) commercial trucks. These two new transmissions are scheduled to start appearing in General Motors vehicles for the 2000 model year and come in two wheel drive and four wheel drive configurations, as shown in Figure 2. Both the 1000 and 2000 Series are available with an optional PTO gear. The PTO gear is driven off of the torque converter, and thus is turbine driven. Engine driven performance can be obtained by engaging the torque converter clutch during neutral PTO operation. PTO mounting provisions are in the form of a standard SAE 6 bolt pad on each side of the transmissions main case, as shown in Figure 1 and 2. General description and operation begins on Page 3 of this bulletin.

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Figure 1

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ALLISON 1000/2000 SERIES Engine Speed Sensor

Turbine Speed Sensor

Output Speed Sensor

Allison

Neutral Start Switch TWO WHEEL DRIVE Engine Speed Sensor

Turbine Speed Sensor

Allison

Neutral Start Switch FOUR WHEEL DRIVE

Copyright © 2000 ATSG

Figure 2

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Technical Service Information GENERAL DESCRIPTION AND OPERATION Allison 1000/2000/2400 Series transmissions are torque converter driven fully automatic units. All models have neutral, reverse, and up to 5 forward speeds, with 5th gear being overdrive. Refer to Figure 4 for the different gears ratios available in the different models. The torque converter housings of these units mate directly to SAE No. 2, SAE No. 3, or direct to the engine block in some cases. Flexplate drive is used for all engine to transmission torque transfer. Several different torque converters are available to match the transmissions to a wide variety of diesel and gasoline engines. The torque converter is a single stage, three element unit, consisting of a pump, stator, and turbine, with the addition of a converter clutch to provide direct drive from the engine to the transmission. The converter clutch is applied and released electronically, and changes the direction of fluid flow in the converter as in most typical converters today. Internally these units contain 2 rotating clutches (C1 and C2), and 3 brake clutches (C3, C4 and C5), to direct the flow of torque through the unit. All clutch packs are hydraulically applied and spring released, with automatic wear compensation, and their locations in the transmission are shown in the cutaway in Figure 4. The Transmission Control Module (TCM) signals six different solenoids, located on the valve body, to apply and release clutches based on vehicle speed and power combinations, and the range selected by the operator. The planetary gear train consists of three constant mesh, helical gear planetary sets, refered to as P1, P2, and P3. By the engagement of the 5 clutch packs in various combinations, the planetary gear sets react singly or together to provide 5 forward speeds, neutral, and reverse. A common hydraulic system provides fluid for all hydraulic operations, lubrication, and cooling. The front oil pump, driven by the converter, provides the pressure needed for the hydraulic system, and comes from the common sump in the bottom pan. A suction filter, located in the bottom pan provides general protection to the entire hydraulic system, and a spin-on filter provides full time protection for the control solenoids and multipass protection for the entire system.

The spin-on filter is located externally on the converter housing at the lower left front of the transmission. Some 1000/2000/2400 Series transmissions are available with an optional extension housing that accommodates an OEM installed two shoe, expanding type, drum parking brake. The TCM calibration determines the available forward ranges for each selector position. Although specific installations vary, typical selector positions for the 1000/2000 Series are as follows: P - Park. Parking pawl or parking brake is engaged if available, and the transmission is in neutral. This position is not available on all shift selectors. R - Reverse, allows the vehicle to go backwards. N - Neutral. The TCM disables the starter switch if a range other than Neutral or Park is selected before starting the vehicle. D - Drive. The highest forward range used in normal operation. Shifts to 1st gear for launch, and then will automatically upshift through the gears, as operating conditions permit, until the highest range available is attained.

TYPICAL MANUAL SHIFT TOWER DO NOT SHIFT

P R N D 4 2 1 DO NOT SHIFT

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Figure 3

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Technical Service Information ALLISON 1000/2000 SERIES TRANSMISSION "C2" CLUTCH

"C3" CLUTCH

"C1" CLUTCH

"C4" CLUTCH

"C5" CLUTCH

C1 C2 C3 C4 C5 Sol Sol Sol Sol Sol Sol Ratios "A" "B" "C" "D" "E" "F" 1000 2000 Range Clut Clut Clut Clut Clut Park ON X X X ** ** Reverse ON ON X X 4.49 5.09 ** ** Neutral ON X X X ** ** OD-1st ON ON X 3.10 3.51 ** ** OD-2nd ON ON 1.81 1.90 ** ** * OD-3rd ON ON X 1.41 1.44 ** ** * OD-4th ON ON X X 1.00 1.00 ** ** * OD-5th ON ON X 0.71 0.74 ** ** * X = Electrical Power Applied To Shift Solenoids. * = Apply Solenoid "F" To Apply Converter Clutch. * * = Solenoids "A" and "B" are "Trim" solenoids used to control oncoming, off-going, and holding pressure to the five clutch packs. Copyright © 2000 ATSG

Figure 4

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Technical Service Information

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ALLISON IDENTIFICATION TAG LOCATION

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MODEL 1000 SERIES DATE TID 99F21 XX SERIAL NO. XXXXXXXXXX EFCN XXXXXXXXX

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UAW 933

DIVISIONOFGENERALMOTORSCORP. INDIANAPOLIS, INDIANA

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Figure 5

TRANSMISSION IDENTIFICATION TAG Several different transmission configurations are available within the 1000/2000/2400 Series. The different models are identified as follows: 1000 Series

Heavy-duty automatic transmission with parking pawl. Maximum GVW = 19850 lb.

2000 Series

Heavy-duty automatic transmission without parking pawl. Maximum GVW = 30000 lb.

2400 Series

Heavy-duty automatic transmission with parking pawl. Maximum GVW = 26000 lb.

This information must be used when discussing specific service issues, or when parts replacement is necessary. The transmission identification tag also includes the date of manufacture, and also the transmission identification number used with the diagnostic systems. Special Note: Allison Series 1000/2000/2400 transmissions are designed and manufactured to metric standards, and metric tools are required for service. The cooler ports and the main line pressure tap are the only non-metric fittings on the transmission case. The output flange/yoke retaining bolt is also non-metric.

Each transmission is identified by a model designation, group numbers, and serial number. This information is included on the transmission identification tag located on the right rear side of the transmission case, as shown in Figure 5.

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Notice in Figure 6 that the standard General Motors case connector has been utilized, and the Park/Neutral switch is exactly the same switch used currently on the THM 4L60-E transmission. Two different bottom pan configurations are also provided to make these units even more versitile, and the dimensions have been provided in Figure 7. The 1000 and 2000 Series transmissions utilize five clutch packs (No Bands-No Freewheels) to obtain the five forward gears and reverse. We have provided you with a cut-away illustration to identify the clutch packs and their location in the unit, and a clutch application and solenoid chart to assist you in diagnosis as shown in Figure 4.

GEAR First Second Third Fourth Fifth Reverse

1000 Series Ratios

2000 Series Ratios

3.10 1.81 1.41 1.00 0.71 4.49

3.51 1.90 1.44 1.00 0.74 5.09

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Figure 6

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Technical Service Information DEEP BOTTOM PAN

SHALLOW BOTTOM PAN

27.35"

27.35"

Standard Oil Pan 11.18"

Shallow Oil Pan 10.67"

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Figure 7

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Technical Service Information

The illustration in Figure 8 identifies the six solenoids on the valve body that are used to control the shifting from gear to gear, shift feel as it is clutch to clutch, and the converter clutch apply and release. A solenoid resistance chart and terminal identification has been provided in Figure 9, and a wiring schematic of the internal wire harness and colors is shown in Figure 10.

SOLENOID I.D. SHIFT SOLENOID "C" (N/C) TRIM SOLENOID "A"

SHIFT SOLENOID "D"

LOCK-UP SOLENOID "F"

(N/O) TRIM SOLENOID "B"

SHIFT SOLENOID "E" Solenoids "A" (N/C) and "B" (N/O) are "Trim" solenoids used to control oncoming, off-going, and holding pressure to the five clutch packs. Solenoid's "C", "D" and "E" are shift solenoids and are "Normally vented" Solenoid "F" is the TCC pwm solenoid

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Figure 8

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Technical Service Information SOLENOID AND TEMP. SENSOR RESISTANCE CHART

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PED 4 CONNECTOR FACE VIEW AS IN THE VEHICLE

Solenoid

Terminals

A B C D E F TEMP SENSOR

L and M N and P C and W C and B C and A J and S H and G

Resistance In Ohms 6W 6W 22 W 22 W 22 W 11 W 2.8K W @ 72° F

All Ohms readings are actual at room temperature.

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Figure 9

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Technical Service Information INTERNAL WIRE SCHEMATIC

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Dark Green Orange/Black Pink Light Green Red

SHIFT SOLENOID "C"

Blue

SHIFT SOLENOID "D"

SHIFT SOLENOID "E"

LOCK-UP SOLENOID "F"

Orange Black

To Pressure Switch Assembly

Brown

A B C D E F

Tan Red/Black Light Blue Grey Purple

(N/C) TRIM (N/O) TRIM SOLENOID SOLENOID "A" "B"

N/A Black Tan Green Green Black/Tan

Copyright © 2000 ATSG

Figure 10

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Technical Service Information

Both of the new units also utilize the familiar GM Pressure Switch Assembly with the normally open and normally closed switches, and temperature sensor. We have provided you with terminal identification and function in Figure 11. Figure 12 illustrates the bottom side showing switch location and whether they are "Normally Open" or "Normally Closed". The Pressure Switch Assembly bolts to the main valve body as shown in Figure 13. Figures 14, 15, and 16 are exploded views of the valve body.

ALLISON 1000/2000 SERIES PRESSURE SWITCH ASSEMBLY PIN FUNCTION AND IDENTIFICATION

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B C D E F

(A) SHIFT "C" SIGNAL TO PCM (CASE CONNECTOR TERMINAL "D") (B) SHIFT "D" SIGNAL TO PCM (CASE CONNECTOR TERMINAL "F") (C) SHIFT "E" SIGNAL TO PCM (CASE CONNECTOR TERMINAL "E")

(F) TEMP SENSOR (CASE CONNECTOR TERMINAL "H") (E) TEMP SENSOR (CASE CONNECTOR TERMINAL "G") (D) REVERSE SWITCH TO PCM (CASE CONNECTOR TERMINAL "K") Copyright © 2000 ATSG

Figure 11

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Technical Service Information PRESSURE SWITCH ASSEMBLY SWITCH OPERATION AND FUNCTION

N/O

N/O

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TEMPERATURE SENSOR N/C

NOT USED

"E" SHIFT

"D" SHIFT

NOT USED

"C" SHIFT

REVERSE THERMISTER

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Figure 12

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Technical Service Information TYPICAL MANUAL SHIFT TOWER ALLISON SERIES 1000/2000 COMPLETE VALVE BODY

Retainer Assembly Accumulator Valve Springs

Accumulator Valves

PRESSURE SWITCH ASSEMBLY

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Figure 13

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Technical Service Information

"Shift" Valve body (See Figure 16)

Spacer Plate

"Main" Valve body (See Figure 15)

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PRESSURE SWITCH ASSEMBLY. REVERSE SIGNAL PIPE ASSEMBLY. VALVE BODY TO VALVE BODY BOLT, M6 X 1.0 X 65 (1 REQUIRED). VALVE BODY TO VALVE BODY BOLT, M6 X 1.0 X 50 (23 REQUIRED). VALVE BODY TO CASE BOLTS, M6 X 1.0 X 50 (15 REQUIRED).

Copyright © 2000 ATSG

Figure 14

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Technical Service Information "MAIN" VALVE BODY EXPLODED VIEW 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13.

MAIN VALVE BODY CASTING. ALIGNMENT DOWELS (5 REQUI RED). MAIN CONTROL RELIEF VALVE. MAIN CONTROL RELIEF VALVE SPRING. MAIN CONTROL RELIEF VALVE SPRING RETAINER. EXHAUST BACKFILL VALVE SPRING RETAINER. EXHAUST BACKFILL VALVE SPRING. EXHAUST BACKFILL VALVE. BOLT, M6 X 1.0 X 50 (23 REQUIRED) SOLENOID "F" TRIM VALVE SPRING. SOLENOID "F" TRIM VALVE. SOLENOID "F" TRIM VALVE SLEEVE. SOLENOID "F" SMALL "O" RING.

14. 15. 16. 17. 18. 19. 20. 21. 22. 23. 24. 25. 26. 27. 28. 29. 30. 31. 32. 33. 34. 35. 36.

Free Length = 1.690" Number Coils = 13 Spring Diameter = .550" Wire Diameter = .058"

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SOLENOID "F" L ARGE "O" RING. SOLENOID "F" (LOCK-UP PWM). SOLENOID "F" RETAINING CLIP. SHIFT SOLENOID "D" SMALL "O" RING. SHIFT SOLENOID "D" L ARGE "O" RING. SHIFT SOLENOID "D". SHIFT SOLENOID "D" RETAINING CLIP. SHIFT SOLENOID "C" SMALL "O" RING. SHIFT SOLENOID "C" L ARGE "O" RING. SHIFT SOLENOID "C". TRIM PRESSURE ACCUMULATORS. TRIM PRESSURE ACCUMULATOR SPRINGS. TRIM SOLENOID "A" AND "B" RETAINING BRACKET. TRIM "B" VALVE SPRING. TRIM "B" VALVE. TRIM GAIN VALVE. TRIM SOLENOID "B" "O" RING (BLACK). TRIM SOLENOID "B" (NORMALLY OPEN PWM). TRIM SOLENOID "A" (NORMALLY CLOSED PWM). TRIM SOLENOID "A" "O" RING (GREEN). TRIM GAIN VALVE. TRIM "A" VALVE (Note I.D. Ring Between Lands). TRIM "A" VALVE SPRING.

7 1 Free Length = .875" Number Coils = 11 Spring Diameter = .490" Wire Diameter = .034"

Free Length = .845" Number Coils = 7 Spring Diameter = .384" Wire Diameter = .028"

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Free Length = 1.275" Number Coils = 16 Spring Diameter = .306" Wire Diameter = .043"

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Figure 15

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Technical Service Information "SHIFT" VALVE BODY EXPLODED VIEW 1. SHIFT VALVE BODY CASTING. 2. SOLENOID SCREEN. 3. SHIFT SOLENOID "E". 4. SHIFT SOLENOID "E" RETAINING CLIP. 5. MANUAL SELECTOR VALVE. 6. MANUAL SELECTOR VALVE PIN. 7. SOLENOID "D" SHIFT VALVE. 8. SOLENOID "D" SHIFT VALVE SPRING. 9. SOLENOID "D" SHIFT VALVE BORE PLUG. 10. SOLENOID "D" SHIFT VALVE LINE-UP RETAINER.

11. 12. 13. 14. 15. 16. 17. 18. 19. 20.

SOLENOID "E" SHIFT VALVE. SOLENOID "E" SHIFT VALVE SPRING. SOLENOID "E" SHIFT VALVE BORE PLUG. SOLENOID "E" SHIFT VALVE LINE-UP RETAINER. SOLENOID "C" SHIFT VALVE. SOLENOID "C" SHIFT VALVE SPRING. SOLENOID "C" SHIFT VALVE LINE-UP RETAINER. MAIN CONTROL VALVE. MAIN CONTROL VALVE SPRING. MAIN CONTROL VALVE LINE-UP RETAINER.

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Free Length = 1.155" Number Coils = 11 Spring Diameter = .435" Wire Diameter = .037"

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Free Length = 1.155" Number Coils = 11 Spring Diameter = .435" Wire Diameter = .037"

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Free Length = 1.170" Number Coils = 11 Spring Diameter = .435" Wire Diameter = .037"

Free Length = 1.705" Number Coils = 13 Spring Diameter = .550" Wire Diameter = .057"

Copyright © 2000 ATSG

Figure 16

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Figure 17 will show you retainer locations, and the only screen in the valve body. Notice that there are not any checkballs to worry about. Figure 18 illustrates air pressure check locations for the five clutch packs. RETAINER AND SCREEN LOCATIONS

Screen Assembly

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Figure 17

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Technical Service Information AIR PRESSURE TEST PORTS "C1" Clutch

29536808

"C2" Clutch

"C4" Clutch

"C3" Clutch

"C5" Clutch

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Figure 18

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There are four different Bell Housings as shown in Figures 21 and 22.

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Figure 19

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Technical Service Information OIL PUMP COVER EXPLODED VIEW 1

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Free Length = 1.388" Number Coils = 7 Spring Diameter = .635" Wire Diameter = .055" Free Length = 2.825" Number Coils = 11 Spring Diameter = .890" Wire Diameter = .108"

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Free Length = 1.068" Number Coils = 8 Spring Diameter = .380" Wire Diameter = .025"

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Free Length = 1.980" Number Coils = 12 Spring Diameter = .535" Wire Diameter = .055"

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CONVERTER FLOW VALVE. CONVERTER FLOW VALVE SPRING. CONVERTER FLOW VALVE STOP. CONVERTER FLOW VALVE STOP RETAINING PIN. MAIN PRESSURE REGUL ATOR VALVE. MAIN PRESSURE REGUL ATOR VALVE SPRING. PRESSURE REGUL ATOR VALVE STOP. PRESSURE REGUL ATOR VALVE STOP RETAINING PIN. CLUTCH BACKFILL VALVE. CLUTCH BACKFILL VALVE SPRING.

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Free Length = 1.400" Number Coils = 7 Spring Diameter = .635" Wire Diameter = .055"

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CLUTCH BACKFILL VALVE RETAINER. CONVERTER RELIEF VALVE. CONVERTER RELIEF VALVE SPRING. CONVERTER RELIEF VALVE SPRING RETAINER. LUBE REGULATOR VALVE. LUBE REGULATOR VALVE SPRING. LUBE REGULATOR VALVE SPRING STOP. LUBE REGULATOR VALVE STOP "O" RING. LUBE REGULATOR VALVE STOP RETAINING PIN.

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Figure 20

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Technical Service Information SAE NUMBER 3 BELL HOUSING WITH INTEGRAL FILTER AND COOLER PORTS

SAE NUMBER 3 BELL HOUSING WITH MANIFOLD FOR FILTER AND COOLER PORTS

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MAIN CONTROL FILTER ASSEMBLY. MAIN CONTROL FILTER MAGNET. MAIN CONTROL FILTER ADAPTER TUBE. MAIN LINE PRESSURE TAP PLUG. MAIN LINE PRESSURE PLUG "O" RING. TO COOLER SHIPPING PLUG. TO COOLER SHIPPING PLUG "O" RING. FROM COOLER SHIPPING PLUG. FROM COOLER SHIPPING PLUG "O" RING. COOLER MANIFOLD RETAINING BOLT, M8 x 1.25 x 30 (8 REQ). COOLER MANIFOLD RETAINING BOLT, M8 x 1.25 x 40 (4 REQ).

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Figure 21

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Technical Service Information SAE NUMBER 2 BELL HOUSING WITH MANIFOLD FOR FILTER AND COOLER PORTS

SAE NUMBER 8 BELL HOUSING WITH INTEGRAL FILTER AND COOLER PORTS

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MAIN CONTROL FILTER ASSEMBLY. MAIN CONTROL FILTER MAGNET. MAIN CONTROL FILTER ADAPTER TUBE. MAIN LINE PRESSURE TAP PLUG. MAIN LINE PRESSURE PLUG "O" RING. TO COOLER SHIPPING PLUG. TO COOLER SHIPPING PLUG "O" RING. FROM COOLER SHIPPING PLUG. FROM COOLER SHIPPING PLUG "O" RING. COOLER MANIFOLD RETAINING BOLT, M8 x 1.25 x 30 (8 REQ). COOLER MANIFOLD RETAINING BOLT, M8 x 1.25 x 40 (4 REQ). TO COOLER CONNECTOR FITTING ASSEMBLY. FROM COOLER CONNECTOR FITTING ASSEMBLY.

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Figure 22

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