Technical Service Information: Automatic Transmission Service Group

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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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AUTOMATIC TRANSMISSION SERVICE GROUP Page 1 of 22
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Engine Speed Turbine Speed Output Speed
Sensor Sensor Sensor
Allison
Neutral Start
Switch
TWO WHEEL DRIVE
Engine Speed Turbine Speed

Sensor Sensor
Allison
Neutral Start
Switch
FOUR WHEEL DRIVE Copyright © 2000 ATSG
Figure 2
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GENERAL DESCRIPTION AND OPERATION
Allison 1000/2000/2400 Series transmissions are The spin-on filter is located externally on the
torque converter driven fully automatic units. All converter housing at the lower left front of the
models have neutral, reverse, and up to 5 forward transmission.
speeds, with 5th gear being overdrive. Refer to Some 1000/2000/2400 Series transmissions are
Figure 4 for the different gears ratios available in the available with an optional extension housing that
different models. accommodates an OEM installed two shoe,
The torque converter housings of these units mate expanding type, drum parking brake.
directly to SAE No. 2, SAE No. 3, or direct to the
The TCM calibration determines the available
engine block in some cases. Flexplate drive is used
forward ranges for each selector position. Although
for all engine to transmission torque transfer.
specific installations vary, typical selector positions
Several different torque converters are available to
for the 1000/2000 Series are as follows:
match the transmissions to a wide variety of diesel
and gasoline engines. The torque converter is a single P - Park. Parking pawl or parking brake is engaged if
stage, three element unit, consisting of a pump, stator, available, and the transmission is in neutral. This
and turbine, with the addition of a converter clutch to position is not available on all shift selectors.
provide direct drive from the engine to the R - Reverse, allows the vehicle to go backwards.
transmission. The converter clutch is applied and
released electronically, and changes the direction of N - Neutral. The TCM disables the starter switch if a
fluid flow in the converter as in most typical range other than Neutral or Park is selected before
converters today. starting the vehicle.
Internally these units contain 2 rotating clutches (C1 D - Drive. The highest forward range used in normal
and C2), and 3 brake clutches (C3, C4 and C5), to operation. Shifts to 1st gear for launch, and then will
direct the flow of torque through the unit. All clutch automatically upshift through the gears, as operating
packs are hydraulically applied and spring released, conditions permit, until the highest range available is
with automatic wear compensation, and their attained.
locations in the transmission are shown in the cut-
away in Figure 4. TYPICAL MANUAL SHIFT TOWER
The Transmission Control Module (TCM) signals
six different solenoids, located on the valve body, to
apply and release clutches based on vehicle speed and DO NOT
SHIFT
power combinations, and the range selected by the
operator.
The planetary gear train consists of three constant P
mesh, helical gear planetary sets, refered to as P1, P2,
and P3. By the engagement of the 5 clutch packs in R
various combinations, the planetary gear sets react
singly or together to provide 5 forward speeds,
N
neutral, and reverse. D
A common hydraulic system provides fluid for all
hydraulic operations, lubrication, and cooling. The 4
front oil pump, driven by the converter, provides the
pressure needed for the hydraulic system, and comes 2
from the common sump in the bottom pan.
A suction filter, located in the bottom pan provides
1
general protection to the entire hydraulic system, and DO NOT
SHIFT
a spin-on filter provides full time protection for the
control solenoids and multipass protection for the
entire system.
Figure 3
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ALLISON 1000/2000 SERIES TRANSMISSION

"C2" CLUTCH "C3" CLUTCH "C4" CLUTCH
"C1" CLUTCH "C5" CLUTCH
C1 C2 C3 C4 C5 Sol Sol Sol Sol Sol Sol Ratios

Range Clut Clut Clut Clut Clut "A" "B" "C" "D" "E" "F" 1000 2000
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.
Figure 4
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ALLISON IDENTIFICATION TAG LOCATION

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Figure 5
TRANSMISSION IDENTIFICATION TAG

Several different transmission configurations are This information must be used when discussing
available within the 1000/2000/2400 Series. The specific service issues, or when parts replacement is
different models are identified as follows: necessary. The transmission identification tag also
includes the date of manufacture, and also the
1000 Heavy-duty automatic transmission transmission identification number used with the
Series with parking pawl. diagnostic systems.
Maximum GVW = 19850 lb.
Special Note:
2000 Heavy-duty automatic transmission
Allison Series 1000/2000/2400 transmissions are
Series without parking pawl.
designed and manufactured to metric standards, and
Maximum GVW = 30000 lb.
metric tools are required for service.
2400 Heavy-duty automatic transmission The cooler ports and the main line pressure tap are
Series with parking pawl. the only non-metric fittings on the transmission
Maximum GVW = 26000 lb. 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.
1000 Series 2000 Series

GEAR Ratios Ratios
First 3.10 3.51
Second 1.81 1.90
Third 1.41 1.44
Fourth 1.00 1.00
Fifth 0.71 0.74
Reverse 4.49 5.09

Figure 6
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DEEP BOTTOM PAN SHALLOW BOTTOM PAN
27.35" 27.35"
Shallow Oil
Standard Oil
Pan 10.67"
Pan 11.18"

Figure 7
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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 SHIFT LOCK-UP

SOLENOID SOLENOID SOLENOID
"C" "D" "F"
(N/C) TRIM (N/O) TRIM

SOLENOID "A" 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

Figure 8
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SOLENOID AND TEMP. SENSOR RESISTANCE CHART
A B C D
E F G H J K
L M N P R S
T U V W
PED 4
CONNECTOR FACE VIEW AS IN THE VEHICLE
Solenoid Terminals Resistance

In Ohms
A L and M 6W
B N and P 6W
C C and W 22 W
D C and B 22 W
E C and A 22 W
F J and S 11 W
TEMP H and G 2.8K W
SENSOR @ 72° F
All Ohms readings are actual at room temperature.

Figure 9
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INTERNAL WIRE SCHEMATIC
A B C D
E F G H J K
L M N P R S
T U V W
PED 4
CONNECTOR FACE VIEW
Dark Green
A
Orange/Black
B
Pink
C
Light Green
D
Red SHIFT SHIFT SHIFT LOCK-UP
E SOLENOID SOLENOID SOLENOID SOLENOID
Blue "C" "D" "E" "F"
F
Orange
G
Black To Pressure
H Switch Assembly
Brown A
J B
Tan C
K D
E
Red/Black F
L
Light Blue
M
Grey
N (N/C) TRIM (N/O) TRIM
SOLENOID SOLENOID
Purple "A" "B"
P
N/A
R
Black
S
Tan
T
Green
U
Green
V
Black/Tan
W

Figure 10
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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.

PRESSURE SWITCH ASSEMBLY
PIN FUNCTION AND IDENTIFICATION
A
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")

Figure 11
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PRESSURE SWITCH ASSEMBLY

SWITCH OPERATION AND FUNCTION
N/O
N/O
LO
PRND4 DR
REV
N/O N/O
N/O D21
REL
TEMPERATURE
SENSOR
N/C
NOT USED
"E" SHIFT
NOT USED "D" SHIFT
"C" SHIFT
REVERSE
THERMISTER

Figure 12
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BACK
TYPICAL MANUAL SHIFT TOWER
ALLISON SERIES 1000/2000 COMPLETE VALVE BODY
Retainer Assembly
Accumulator
Valve Springs
Accumulator
Valves
PRESSURE SWITCH
ASSEMBLY

Figure 13
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BACK
"Shift" Valve body

(See Figure 16)
Spacer Plate
"Main" Valve body

(See Figure 15)
1
5
1. PRESSURE SWITCH ASSEMBLY.

2. REVERSE SIGNAL PIPE ASSEMBLY.
3. VALVE BODY TO VALVE BODY BOLT, M6 X 1.0 X 65 (1 REQUIRED).
4. VALVE BODY TO VALVE BODY BOLT, M6 X 1.0 X 50 (23 REQUIRED).
5. VALVE BODY TO CASE BOLTS, M6 X 1.0 X 50 (15 REQUIRED).
Figure 14
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"MAIN" VALVE BODY EXPLODED VIEW
1. MAIN VALVE BODY CASTING. 14. SOLENOID "F" L ARGE "O" RING.
2. ALIGNMENT DOWELS (5 REQUI RED). 15. SOLENOID "F" (LOCK-UP PWM).
3. MAIN CONTROL RELIEF VALVE. 16. SOLENOID "F" RETAINING CLIP.
4. MAIN CONTROL RELIEF VALVE SPRING. 17. SHIFT SOLENOID "D" SMALL "O" RING.
5. MAIN CONTROL RELIEF VALVE SPRING RETAINER. 18. SHIFT SOLENOID "D” LARGE "O" RING.
6. EXHAUST BACKFILL VALVE SPRING RETAINER. 19. SHIFT SOLENOID "D".
7. EXHAUST BACKFILL VALVE SPRING. 20. SHIFT SOLENOID "D" RETAINING CLIP.
8. EXHAUST BACKFILL VALVE. 21. SHIFT SOLENOID "E” SMALL "O" RING.
9. BOLT, M6 X 1.0 X 50 (23 REQUIRED) 22. SHIFT SOLENOID "E" L ARGE "O" RING.
10. SOLENOID "F" TRIM VALVE SPRING. 23. SHIFT SOLENOID "E".
11. SOLENOID "F" TRIM VALVE. 24. TRIM PRESSURE ACCUMULATORS.
12. SOLENOID "F" TRIM VALVE SLEEVE. 25. TRIM PRESSURE ACCUMULATOR SPRINGS.
13. SOLENOID "F" SMALL "O" RING. 26. TRIM SOLENOID "A" AND "B" RETAINING BRACKET.
27. TRIM "B" VALVE SPRING.
5 Free Length = 1.690" 28. TRIM "B" VALVE.
Number Coils = 13 29. TRIM GAIN VALVE.
4 Spring Diameter = .550" 30. TRIM SOLENOID "B" "O" RING (BLACK).
Wire Diameter = .058"
6 31. TRIM SOLENOID "B" (NORMALLY OPEN PWM).
3 32. TRIM SOLENOID "A" (NORMALLY CLOSED PWM).
2 33. TRIM SOLENOID "A" "O" RING (GREEN).
34. TRIM GAIN VALVE.
35. TRIM "A" VALVE (Note I.D. Ring Between Lands).
8 36. TRIM "A" VALVE SPRING.
7
1
Free Length = .875"
Number Coils = 11
Spring Diameter = .490"
Free Length = .845"
Number Coils = 7
36
35
34
27 33
32
28
29
30
21 31
22
23
24
2
Free Length = 1.275"

17 Number Coils = 16
18
19 25 Wire Diameter = .043"
9 10
20
11
Free Length = .838"
Number Coils = 7
Spring Diameter = .382" 12
13 26
14
15
16 9 Copyright © 2000 ATSG
Figure 15 00-12
"SHIFT" VALVE BODY EXPLODED VIEW
1. SHIFT VALVE BODY CASTING. 11. SOLENOID "E” SHIFT VALVE.
2. SOLENOID SCREEN. 12. SOLENOID "E" SHIFT VALVE SPRING.
3. SHIFT SOLENOID "C". 13. SOLENOID "E" SHIFT VALVE BORE PLUG.
4. SHIFT SOLENOID "C ” RETAINING CLIP. 14. SOLENOID "E" SHIFT VALVE LINE-UP RETAINER.
5. MANUAL SELECTOR VALVE. 15. SOLENOID "C" SHIFT VALVE.
6. MANUAL SELECTOR VALVE PIN. 16. SOLENOID "C" SHIFT VALVE SPRING.
7. SOLENOID "D" SHIFT VALVE. 17. SOLENOID "C" SHIFT VALVE LINE-UP RETAINER.
8. SOLENOID "D" SHIFT VALVE SPRING. 18. MAIN CONTROL VALVE.
9. SOLENOID "D" SHIFT VALVE BORE PLUG. 19. MAIN CONTROL VALVE SPRING.
10. SOLENOID "D" SHIFT VALVE LINE-UP RETAINER. 20. MAIN CONTROL VALVE LINE-UP RETAINER.
3
5
4
2

Number Coils = 11
Wire Diameter = .037" 7
11
15
8 18
9
12 16 19
10 13 17 20
14
Free Length = 1.155" Free Length = 1.170" Free Length = 1.705"

Number Coils = 11 Number Coils = 11 Number Coils = 13
Spring Diameter = .435" Spring Diameter = .435" Spring Diameter = .550"
Wire Diameter = .037" Wire Diameter = .037" Wire Diameter = .057"

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

Figure 17
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AIR PRESSURE TEST PORTS
"C2" Clutch "C1" Clutch
29536808
"C4" Clutch "C3" Clutch "C5" Clutch

Figure 18
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BACK
There are four different Bell Housings

as shown in Figures 21 and 22.
9
.8

Figure 19
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OIL PUMP COVER EXPLODED VIEW
1 2 3
4

Number Coils = 7

Number Coils = 11
5 6 7
Free Length = 1.068" 8

Number Coils = 8
9 10 11
Free Length = 1.980" Free Length = 1.400"

Number Coils = 12 Number Coils = 7
Spring Diameter = .535" Spring Diameter = .635"
Wire Diameter = .055" Wire Diameter = .055"
12 13 14 15 16 17 18
19
1. CONVERTER FLOW VALVE. 11. CLUTCH BACKFILL VALVE RETAINER.

2. CONVERTER FLOW VALVE SPRING. 12. CONVERTER RELIEF VALVE.
3. CONVERTER FLOW VALVE STOP. 13. CONVERTER RELIEF VALVE SPRING.
4. CONVERTER FLOW VALVE STOP RETAINING PIN. 14. CONVERTER RELIEF VALVE SPRING RETAINER.
5. MAIN PRESSURE REGUL ATOR VALVE. 15. LUBE REGULATOR VALVE.
6. MAIN PRESSURE REGUL ATOR VALVE SPRING. 16. LUBE REGULATOR VALVE SPRING.
7. PRESSURE REGUL ATOR VALVE STOP. 17. LUBE REGULATOR VALVE SPRING STOP.
8. PRESSURE REGUL ATOR VALVE STOP RETAINING PIN. 18. LUBE REGULATOR VALVE STOP "O" RING.
9. CLUTCH BACKFILL VALVE. 19. LUBE REGULATOR VALVE STOP RETAINING PIN.
10. CLUTCH BACKFILL VALVE SPRING. Copyright © 2000 ATSG
Figure 20
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BACK
SAE NUMBER 3 BELL HOUSING SAE NUMBER 3 BELL HOUSING

WITH INTEGRAL FILTER AND WITH MANIFOLD FOR FILTER
COOLER PORTS AND COOLER PORTS
7 8
6
3
5
2 4
10
1. MAIN CONTROL FILTER ASSEMBLY. 9

2. MAIN CONTROL FILTER MAGNET.
3. MAIN CONTROL FILTER ADAPTER TUBE. 7 8
4. MAIN LINE PRESSURE TAP PLUG.
5. MAIN LINE PRESSURE PLUG "O" RING. 11 6
6. TO COOLER SHIPPING PLUG.
3 5
7. TO COOLER SHIPPING PLUG "O" RING.
8. FROM COOLER SHIPPING PLUG. 2 4
9. FROM COOLER SHIPPING PLUG "O" RING.
10. COOLER MANIFOLD RETAINING BOLT, M8 x 1.25 x 30 (8 REQ).
1
Figure 21
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SAE NUMBER 2 BELL HOUSING SAE NUMBER 8 BELL HOUSING

WITH MANIFOLD FOR FILTER WITH INTEGRAL FILTER AND
AND COOLER PORTS COOLER PORTS
13
3 12
5
2 4
1. MAIN CONTROL FILTER ASSEMBLY.

10
2. MAIN CONTROL FILTER MAGNET.
9 3. MAIN CONTROL FILTER ADAPTER TUBE.
4. MAIN LINE PRESSURE TAP PLUG.
7 8 5. MAIN LINE PRESSURE PLUG "O" RING.
6. TO COOLER SHIPPING PLUG.
11 6 7. TO COOLER SHIPPING PLUG "O" RING.
8. FROM COOLER SHIPPING PLUG.
3 5 9. FROM COOLER SHIPPING PLUG "O" RING.
2 4 10. COOLER MANIFOLD RETAINING BOLT, M8 x 1.25 x 30 (8 REQ).
12. TO COOLER CONNECTOR FITTING ASSEMBLY.
13. FROM COOLER CONNECTOR FITTING ASSEMBLY.
1
Figure 22
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Technical Service Information

Copyright © 2000 ATSG

ALLISON 1000/2000 SERIES

TWO WHEEL DRIVE

Engine Speed Turbine Speed

ALLISON 1000/2000 SERIES TRANSMISSION

"C1" CLUTCH "C5" CLUTCH

C1 C2 C3 C4 C5 Sol Sol Sol Sol Sol Sol Ratios

ALLISON IDENTIFICATION TAG LOCATION

MODEL XX- XXXX XX- XXXX

XXXXXXXXXX XX- XXXX XX- XXXX

Copyright © 2000 ATSG

TRANSMISSION IDENTIFICATION TAG

1000 Series 2000 Series

Copyright © 2000 ATSG

DEEP BOTTOM PAN SHALLOW BOTTOM PAN

Copyright © 2000 ATSG

SHIFT SHIFT LOCK-UP

(N/C) TRIM (N/O) TRIM

Solenoid "F" is the TCC pwm solenoid

Copyright © 2000 ATSG

SOLENOID AND TEMP. SENSOR RESISTANCE CHART

Solenoid Terminals Resistance

All Ohms readings are actual at room temperature.

Copyright © 2000 ATSG

INTERNAL WIRE SCHEMATIC

Copyright © 2000 ATSG

ALLISON 1000/2000 SERIES

(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")

(D) REVERSE SWITCH TO PCM (CASE CONNECTOR TERMINAL "K")

Copyright © 2000 ATSG

PRESSURE SWITCH ASSEMBLY

Copyright © 2000 ATSG

Copyright © 2000 ATSG

"Shift" Valve body

"Main" Valve body

1. PRESSURE SWITCH ASSEMBLY.

Free Length = 1.275"

16 9 Copyright © 2000 ATSG

Free Length = 1.155"

Free Length = 1.155" Free Length = 1.170" Free Length = 1.705"

Copyright © 2000 ATSG

RETAINER AND SCREEN LOCATIONS

Copyright © 2000 ATSG

AIR PRESSURE TEST PORTS

"C2" Clutch "C1" Clutch

"C4" Clutch "C3" Clutch "C5" Clutch

Copyright © 2000 ATSG

There are four different Bell Housings

Copyright © 2000 ATSG

OIL PUMP COVER EXPLODED VIEW

Free Length = 1.388"

Free Length = 2.825"

Free Length = 1.068" 8

Free Length = 1.980" Free Length = 1.400"