ATSG Allison 1000 2000 Gen1 2 3 4 5 Transmission Rebuild Repair Overhaul Manual

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Publisher::Automatic Transmission Service Group (ATSG)
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Country/Region of Manufacture:United States
Non-Domestic Product:No
Make:General Motors

Allison 1000 & 2000 Series Transmission Rebuild Manual: Generations 1 – 5This manual will cover the dis-assembly, rebuild of all components, and finally the re-assembly of both the 1000 and 2000 Series units. This manual is the most current, revised edition. Beginning at the start of production for the 2000 model year, General Motors introduced two new Allison Automatic Transmissions referred to as the 1000 Series and the 2000 Series, for Light-Duty (8600-19850 GVW) and Medium-Duty (19850-3000 GVW) Commerical Trucks. The 1000 and 2000 Series Transmissions both have helical cut planetary gear systems to minimize noise concerns and come in two different gear ratio configurations. The 1000 Series uses closer steps to improve the 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 show in this Manual. The 1000 and 2000 Series Transmissions have a Park position, Reverse, Neutral and FIVE forward speeds with 5th gear being overdrive, and are completely electronic shift controlled. Notice that the standard GM case connector has been utilized, and the Park/Neutral switch is exactly the same switch used currently on the THM 4L60E Transmission. Two different bottom pan configurations are also provided to make these units more versatile. The 1000 and 2000 Series Transmissions utilize five clutch packs (No Bands, No Freewheels) to obtain the five forward gears and reverse. Contents:Clutch and Solenoid Application ChartTransmission Identification Tag InformationGeneral Description and OperationElectrical OperationThrottle Posistion SensorNeutral Start Backup SwitchTransmission Control Module Connector IdentificationDiagnostic Trouble Code IdentificationSolenoid Idenitifcation and OperationInternal Wiring Harness Schematic and REsistance ChartExternal Wiring Harness Schematic and Terminal IdentificationPressure Switch Assembly Identification and OperationRetrieving Diagnostic Trouble CodesLine Pressure TestsBell Housing Oil Passage IdentificationMain Case “Front” Oil Passage IdentificationMain Case “Rear” Oil Passage IdentificationOil Pump Cover Oil Passage IdentificationShaft Valve Body Oil Passage IdentificationMain Valve Body “Top View” Oil Passage IdentificationMain Valve Body “Bottom View” Oil Passage IdentificationMain Case “Bottom View” Oil Passage IdentificationTransmission Disassembly ProcessComponent RebuildFinal Transmission Assembly ProcessBolt Identification ChartTorque Specification ChartAllison 6 SpeedElectronic Modulated Line Pressure ControlGear Ratio InformationFifth Generation Electronic ControlsRotating Module Changes Publisher: ATSG (Automatic Transmission Service Group)Softcover: 160 PagesDimensions: 8.5 x 11.0 x 0.6 inches

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