ALLISON 1000/2000 SERIES INDEX
ALLISON 1000/2000 SERIESINDEXCLUTCH AND SOLENOID APPLICATION CHART . 4TRANSMISSION IDENTIFICATION TAG INFORMATION . 5GENERAL DESCRIPTION AND OPERATION . 6ELECTRICAL OPERATION . 9THROTTLE POSITION SENSOR . . 10NEUTRAL START BACK UP SWITCH . 11TRANSMISSION CONTROL MODULE CONNECTOR IDENTIFICATION . 12DIAGNOSTIC TROUBLE CODE IDENTIFICATION . 14SOLENOID IDENTIFICATION AND OPERATION . 16INTERNAL WIRING HARNESS SCHEMATIC AND RESISTANCE CHART . 18EXTERNAL WIRING HARNESS SCHEMATIC AND TERMINAL IDENTIFICATION . 19PRESSURE SWITCH ASSEMBLY IDENTIFICATION AND OPERATION . 20RETRIEVING DIAGNOSTIC TROUBLE CODES . 22LINE PRESSURE TESTS . . 23BELL HOUSING OIL PASSAGE IDENTIFICATION . 24MAIN CASE "FRONT" OIL PASSAGE IDENTIFICATION . 26MAIN CASE "REAR" OIL PASSAGE IDENTIFICATION . 27OIL PUMP COVER OIL PASSAGE IDENTIFICATION . 29SHIFT VALVE BODY OIL PASSAGE IDENTIFICATION . 31MAIN VALVE BODY "TOP VIEW" OIL PASSAGE IDENTIFICATION . 32MAIN VALVE BODY "BOTTOM VIEW" OIL PASSAGE IDENTIFICATION . 33MAIN CASE "BOTTOM VIEW" OIL PASSAGE IDENTIFICATION . 35TRANSMISSION DISASSEMBLY PROCESS . 36COMPONENT REBUILDTRANSMISSION CASE ASSEMBLY . 53OIL PUMP AND BELLHOUSING ASSEMBLY . 55FOUR DIFFERENT BELL HOUSINGS IDENTIFICATION . 66C1/C2 CLUTCH HOUSING ASSEMBLY . 68C1/C2 CLUTCH HOUSING SNAP RING IDENTIFICATION . 72VALVE BODY ASSEMBLY . 80SOLENOID AIR CHECKS . 83EXTENSION HOUSING ASSEMBLY . 91GEAR TRAIN PARTS . 96CASE CLUTCH PARTS . 100FINAL TRANSMISSION ASSEMBLY PROCESS . 102BOLT IDENTIFICATION CHART . 119TORQUE SPECIFICATION CHART . 120CAUTION: ATSG service manuals are intended for use by professional,qualified technicians. Attempting repairs or service without the propertraining, tools and equipment could cause injury to you or others and damageto the vehicle that may cause it not to operate properly.AUTOMATIC TRANSMISSION SERVICE GROUP18639 S.W. 107TH AVENUEMIAMI, FLORIDA 33157(305) 670-4161Copyright ATSG 2000May, 2000
UpdatedOctober, 2003INTRODUCTIONALLISON 1000/2000 SERIESBeginning at the start of production for the 2000 model year, General Motors introduced two new Allisonautomatic transmissions referred to as the 1000 Series and the 2000 Series, for light duty (8600-19850 GVW)and medium duty (19850-3000 GVW) commercial trucks.The 1000 and 2000 Series transmissions both have helical cut planetary gear systems to minimize noiseconcerns and come in two different gear ratio configurations. The 1000 Series uses closer steps to improve theshift quality that we now expect from an automatic transmission. The 2000 Series uses wider steps toaccommodate the greater vehicle weights associated with the 2000 Series. The gear ratios for both of the newunits are shown in this Manual.The 1000 and 2000 Series transmissions have a Park position, Reverse, Neutral and five forward speeds with5th gear being overdrive, and are completely electronic shift controlled. Notice that the standard GeneralMotors case connector has been utilized, and the Park/Neutral switch is exactly the same switch used currentlyon the THM 4L60-E transmission. Two different bottom pan configurations are also provided to make theseunits even more versitile. The 1000 and 2000 Series transmissions utilize five clutch packs (No Bands-NoFreewheels) to obtain the five forward gears and reverse. This manual will cover the dis-assembly, rebuild of allcomponents and re-assembly of both the 1000 and 2000 Series units.No part of any ATSG publication may be reproduced, stored in any retrieval system or transmitted in any form orby any means, including but not limited to electronic, mechanical, photocopying, recording or otherwise,without written permission of Automatic Transmission Service Group. This includes all text illustrations,tables and charts."Portions of materials contained herein have been reprinted underlicense from General Motors Corp, Service & Parts Operations."The information and part numbers contained in this booklet havebeen carefully compiled from industry sources known for theirreliability, but ATSG does not guarantee its accuracy.DALE ENGLANDFIELD SERVICE CONSULTANTCopyright ATSG 2000JIM DIALTECHNICAL CONSULTANTWAYNE COLONNAED KRUSETECHNICAL SUPERVISORTECHNICAL CONSULTANTPETER LUBANGREGORY LIPNICKTECHNICAL CONSULTANTTECHNICAL CONSULTANTJON GLATSTEINDAVID CHALKERTECHNICAL CONSULTANTTECHNICAL CONSULTANTJERRY GOTTMIKE SOUZATECHNICAL CONSULTANTTECHNICAL CONSULTANTGERALD CAMPBELLROLAND ALVAREZTECHNICAL CONSULTANTTECHNICAL CONSULTANTAUTOMATIC TRANSMISSION SERVICE GROUP18639 S.W. 107TH AVENUEMIAMI, FLORIDA 33157(305) 670-41611
Technical Service InformationALLISON 1000/2000 SERIESEngine SpeedSensorTurbine SpeedSensorOutput SpeedSensorAllisonNeutral StartSwitchTWO WHEEL DRIVEEngine SpeedSensorTurbine SpeedSensorAllisonNeutral StartSwitchFOUR WHEEL DRIVECopyright 2000 ATSGFigure 1AUTOMATIC TRANSMISSION SERVICE GROUP3
Technical Service InformationALLISON 1000/2000 SERIES TRANSMISSION"C2" CLUTCH"C3" CLUTCH"C4" CLUTCH"C1" NON"C5" "****Ratios1000 74X Electrical Power Applied To Solenoid* Apply Solenoid "F" To Apply Converter Clutch* * Solenoids "A" and "B" are "Trim" solenoids used to control oncoming, off-going, andholding pressure to the five clutch packs.Copyright 2000 ATSGFigure 24AUTOMATIC TRANSMISSION SERVICE GROUP
Technical Service Information98.8.9ALLISON IDENTIFICATION TAG A 393nTraR P.XXX- X XXXX XXXXXX XXXXXX XXXXXX XXXXXXX- X XXXX XXXXXX XXXXXX XXXXXX XXXXMODEL1000 SERIESDATETID99F21XXSERIAL FGENERALMOTORSCORP.INDIANAPOLIS, INDIANA98.LDETIDMOIESXXSER TE00 DA. X10NOX X1F2 IAL X99 SER X XXX X NX XX X EFCXXXXXXO898.DC9.RSTONAOM IAAL NDER , IEN LISFG PONO NAIO IAIS INDIV9.8nnisoissioAllsmXX- XXXXXX- XXXXXX- XXXXXX- XXXXXX- XXXXXX- XXXXXX- XXXXXX- XXXXXX- XXXXXX- XXXXCopyright 2000 ATSGFigure 3TRANSMISSION IDENTIFICATION TAGSeveral different transmission configurations areavailable within the 1000/2000/2400 Series. Thedifferent models are identified as follows:1000SeriesHeavy-duty automatic transmissionwith parking pawl.Maximum GVW 19850 lb.2000SeriesHeavy-duty automatic transmissionwithout parking pawl.Maximum GVW 30000 lb.2400SeriesHeavy-duty automatic transmissionwith parking pawl.Maximum GVW 26000 lb.This information must be used when discussingspecific service issues, or when parts replacement isnecessary. The transmission identification tag alsoincludes the date of manufacture, and also thetransmission identification number used with thediagnostic systems.Special Note:Allison Series 1000/2000/2400 transmissions aredesigned and manufactured to metric standards, andmetric tools are required for service.The cooler ports and the main line pressure tap arethe only non-metric fittings on the transmissioncase. The output flange/yoke retaining bolt is alsonon-metric.Each transmission is identified by a modeldesignation, group numbers, and serial number. Thisinformation is included on the transmissionidentification tag located on the right rear side of thetransmission case, as shown in Figure 3.AUTOMATIC TRANSMISSION SERVICE GROUP5
Technical Service InformationGENERAL DESCRIPTION AND OPERATIONAllison 1000/2000/2400 Series transmissions aretorque converter driven fully automatic units. Allmodels have neutral, reverse, and up to 5 forwardspeeds, with 5th gear being overdrive. Refer toFigure 2 for the different gears ratios available in thedifferent models.The torque converter housings of these units matedirectly to SAE No. 2, SAE No. 3, or direct to theengine block in some cases. Flexplate drive is usedfor all engine to transmission torque transfer.Several different torque converters are available tomatch the transmissions to a wide variety of dieseland gasoline engines. The torque converter is a singlestage, three element unit, consisting of a pump, stator,and turbine, with the addition of a converter clutch toprovide direct drive from the engine to thetransmission. The converter clutch is applied andreleased electronically, and changes the direction offluid flow in the converter as in most typicalconverters today.Internally these units contain 2 rotating clutches (C1and C2), and 3 brake clutches (C3, C4 and C5), todirect the flow of torque through the unit. All clutchpacks are hydraulically applied and spring released,with automatic wear compensation, and theirlocations in the transmission are shown in the cutaway in Figure 2.The Transmission Control Module (TCM) signalssix different solenoids, located on the valve body, toapply and release clutches based on vehicle speed andpower combinations, and the range selected by theoperator.The planetary gear train consists of three constantmesh, helical gear planetary sets, refered to as P1, P2,and P3. By the engagement of the 5 clutch packs invarious combinations, the planetary gear sets reactsingly or together to provide 5 forward speeds,neutral, and reverse.A common hydraulic system provides fluid for allhydraulic operations, lubrication, and cooling. Thefront oil pump, driven by the converter, provides thepressure needed for the hydraulic system, and comesfrom the common sump in the bottom pan.A suction filter, located in the bottom pan providesgeneral protection to the entire hydraulic system, anda spin-on filter provides full time protection for thecontrol solenoids and multipass protection for theentire system.The spin-on filter is located externally on theconverter housing at the lower left front of thetransmission.Some 1000/2000/2400 Series transmissions areavailable with an optional extension housing thataccommodates an OEM installed two shoe,expanding type, drum parking brake.The 1000/2000/2400 Series transmissions use levertype shift selectors, as shown in Figure 4. The vehiclemay be equipped with one or two shift selectors,depending on the number of operator stations fordriving the vehicle and/or operating a variety ofchassis mounted equipment. The shift positions onthe shift selector can vary according to the shiftselector installed in the vehicle.NOTE: Refer to Figure 5 for the various ShiftSelector positions, and corresponding ranges thatcan be attained for all 1000/2000/2400 Seriesmodels.TYPICAL MANUAL SHIFT TOWERDO NOTSHIFTPRND421DO NOTSHIFTCopyright 2000 ATSGFigure 46AUTOMATIC TRANSMISSION SERVICE GROUP
Technical Service InformationALL 1000 AND 2400 ctorPositionGearsAvailableP (Park)R (Reverse)N (Neutral)D (Drive)4 (Fourth)3 (Third)1 (First)Neutral*ReverseNeutral1-51-41-31stP (Park)R (Reverse)N (Neutral)D (Drive)4 (Fourth)2 (Second)1 ctorPositionGearsAvailableP (Park)Neutral*R (Reverse)ReverseN (Neutral)NeutralD (Drive)1-5 (1-4)**3 (Third)1-32 (Second)1-21 (First)1st* With Park Pawl Engaged** 4 Speed Calibration or Trailering ModeALL 2000 SERIES "WITH" AUTO-APPLY PARKING BRAKEShiftSelectorPositionPB (Park)R (Reverse)N (Neutral)D (Drive)4 (Fourth)3 (Third)1 ilableNeutral*ReverseNeutral1-51-41-31stPB (Park)R (Reverse)N (Neutral)D (Drive)4 (Fourth)2 (Second)1 ctorPositionGearsAvailablePB (Park) Neutral*R (Reverse)ReverseN (Neutral)NeutralD (Drive)1-5 (1-4)**3 (Third)1-32 (Second)1-21 (First)1st* With Auto-Apply Parking Brake Engaged** 4 Speed Calibration or Trailering ModePB Auto-Apply Parking BrakeALL 2000 SERIES "WITHOUT" AUTO-APPLY PARKING BRAKEShiftSelectorPositionR (Reverse)N (Neutral)D (Drive)4 (Fourth)3 (Third)1 ftSelectorPositionR (Reverse)N (Neutral)D (Drive)4 (Fourth)2 (Second)1 ftSelectorGearsPositionAvailableR (Reverse)ReverseN (Neutral)NeutralD (Drive)1-5 (1-4)**3 (Third)1-32 (Second)1-21 (First)1st** 4 Speed Calibration or Trailering ModeCopyright 2000 ATSGFigure 5AUTOMATIC TRANSMISSION SERVICE GROUP7
Technical Service InformationTYPICAL TRANSMISSION CONTROL MODULEAND VEHICLE HARNESSTRANSMISSION CONTROLMODULE (TCM)VEHICLE (J1)HARNESSTRANSMISSION (J2)HARNESSJ ECTOR(RED)VIW "X"CONNECTORVIW "Y"CONNECTORGP 19CONNECTOR7 PIN4 PINNSBU SWITCHCONNECTORSOUTPUTSPEED SENSORCONNECTORTPSCONNECTORTHROTTLEPOSITIONSENSOR (TPS)TURBINESPEED SENSORCONNECTORENGINESPEED SENSORCONNECTORActual harness configuration may differ from this illustration.Copyright 2000 ATSGFigure 68AUTOMATIC TRANSMISSION SERVICE GROUP
Technical Service InformationELECTRICAL OPERATIONThe electronic control of the transmission isperformed by the Transmission Control Module(TCM). Transmissin Control Modules are availablein both 12V and 24V configurations, to match theconfiguration of the vehicle electrical system.The TCM, shown in Figure 6, recieves and processessignals from various switches and sensors. The TCMdetermines shift sequences, shift timing, and clutchapply and release pressures. The TCM uses thisinformation to control solenoids and valves, supplysystem status, and provide diagnostic information forservice technicians.EXTERNAL COMPONENTSSPEED SENSORSThe speed sensors are variable reluctance deviceswhich convert mechanical motion to an AC voltage.Each sensor consists of a wire coil wrapped around apole piece that is adjacent to a permanent magnet.These elements are contained in a housing which ismounted adjacent to a rotating ferrous member, suchas a gear tooth. Two signal wires extend from one endof the housing and an exposed end of the pole piece isat the opposite end of the housing. As a ferrous object,such as a gear tooth approaches and passes throughthe gap at the end of the pole piece, an AC voltagepulse is induced in the wire coil. The TCM calculatesthe frequency of these AC pulses and converts it to aspeed value. The AC voltage generated varies from150mV at low speed to 15V at high speed. The signalwires from the sensor are formed as twisted pairs tocancel magnetically induced fields. The cable is alsoshielded to protect from voltage-related fields. Thetypical speed sensor is shown in Figure 7. Noise fromother sources is eliminated by using two-wiredifferential inputs at the TCM.ENGINE SPEED SENSORThe Engine Speed Sensor is externally mounted inthe torque converter housing, and directed at the ribsprotruding from the torque converter as shown inFigure 1.TURBINE SPEED SENSORThe Turbine Speed Sensor is externally mounted inthe main transmission case, and directed at the tonewheel or PTO drive gear attached to the C1/C2 clutchhousing as shown in Figure 1.OUTPUT SPEED SENSORThe Output Speed Sensor is externally mounted inthe extension housing and directed at the teeth of atone wheel splined to and rotating with the outputshaft as shown in Figure 1.TYPICAL SPEED SENSORCopyright 2000 ATSGFigure 7AUTOMATIC TRANSMISSION SERVICE GROUP9
Technical Service InformationTHROTTLE POSITION SENSORABCCopyright 2000 ATSGFigure 8THROTTLE POSITION SENSORThe Throttle Position Sensor (TPS) can be mounted tothe engine, chassis, or transmission. The TPScontains a pull actuation cable and a potentiometer.One end of the cable is attached to the throttle leverand the other end, inside a protective housing, to thepotentiometer. Output voltage from the TPS isdirected to the Transmission Control Module (TCM)through the external harness. The voltage signal willvary and indicates the throttle position and incombination with other input data will determine shifttiming. Refer to the chart provided in Figure 10 forapproximate voltages at various throttle openings. Itis basically the same as most current GM models with0.5 volts at idle, to 5.0 volts at wide open ansmissionControl Module(TCM)Green, GroundA20Blue, Signal Ret.B9Pink, 5V SupplyC19TCM "J2" (RED)ConnectorFigure 910(TPS) Distance of Travel Versus 42.852.963.073.183.293.403.513.623.733.843.954.06
shift quality that we now expect from an automatic transmission. The 2000 Series uses wider steps to accommodate the greater vehicle weights associated with the 2000 Series. The gear ratios for both of the new units are shown in this Manual. The 1000 and 2000 Series transmissions have a Park position, Reverse, Neutral and five forward speeds with
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Allen, Willie Lewis 1908 Allen, George W. Clayton, Claudia Allison, Effie Pearl 1912 Allison, David Vester Allen, Essie Allison, Lewis J. 1881 Allison, Marion Lashley, Mary Allison, Lillie Mae 1912 Allison, Joseph Coleman Compton, Emma Allison, Marion Watson 1901 Allison, Will Forbes, Lou Dor Allred, Alvin 1906 Allred, Frank Capps, Daisy
411532 Sensor, 1000/2000 Allison Input / Turbine Shft Speed 00-ON 29536408 411531B Sensor, 1000/2000 Allison Output Speed 00-ON 29536408 411521A Solenoid, 1000/2000 Allison (PCS) TCC (Red Connector) 06-ON 29541898 411551 Solenoid, 1000/2000 Allison
Cable Pack Sony Cable Pack P/Oly Cable Fuji. CAPTUR Compatibility Part No. 1000 710.0 1000 710.1 1000 710.4 1000 710.3 1000 710.2 1000 708.1 1000 708.3 1000 710.5 1000 710.6 1000 710.7 1000 711.0 1000 710.8 Range Up to 100m Up to 100m Up to 100m Up to 100m Up to 100m Up to 100m Up to 100m Up to 100m
Allison 1000, 2000, 2400 series (1280510) Installation Guide. DEEP Trans Pan 1 . The Seller shall not be responsible for the products proper use and service and the Buyer . The PPE Transmission Pan is designed to fit the factory Allison 1000 transmission (supplied as original equipment). However, in some .
Allison 1000, 2000, 2400 series (1280520) Installation Guide. Standard Profile 1 . The Seller shall not be responsible for the products proper use and service and the Buyer . The PPE Transmission Pan is designed to fit the factory Allison 1000 transmission (supplied as original equipment). However, in some .
KEEPING THAT ALLISON ADVANTAGE Allison 1000/2000/2400 Series transmissions provide many advantages for the driver who must “stop and go” or change speeds frequently. Driving is easier, safer, and more efficient. The 1000/2000/2400 Series transmissions are rugged and designed to provide long, trouble-free service.
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