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Service Manual

4000 MH / HD 4000 / B 500 Series


On-Highway Transmissions
SM2457EN
SM2457EN

Service
Manual

Allison Transmission
4000 MH
HD 4060, 4060P, 4060R, 4060PR
HD 4560, 4560P, 4560R, 4560PR
HD 4070/4076
B 500, B 500P, B 500R, B 500PR

2001 FEBRUARY

Division of General Motors Corporation


P.O. Box 894 Indianapolis, Indiana 46206-0894
www.allisontransmission.com

Printed in the U.S.A. Copyright 2001 General Motors Corp.


INTRODUCTION

ELECTRONIC CONTROL UNIT AND DIAGNOSTIC DATA READER/TOOL


DISPLAYS AND BUTTON NAMES
Shift Selector or Diagnostic Data Reader/Tool (DDR) button and display names are printed in bold capital
letters UP (), DOWN (), MODE, MONITOR, SELECT, etc.
Transmission range shifts are indicated by the letter or number on the shift selector, in bold text, followed by the
name of the range in parentheses D (Drive), N (Neutral), etc.
References to diagnostic messages displayed are printed within double quotation marks (OL, OK, etc.).

TRADEMARK USAGE
The following trademarks are the property of the companies indicated:
Pro-Link is a registered trademark of Micro Processor Systems, Inc.
DEXRON is a registered trademark of General Motors Corp.
Biobor JF is the registered trademark for a biological inhibitor manufactured by U.S. Borax
and Chemical Corporation.
Loctite is a registered trademark of the Loctite Corporation.
Teflon is a registered trademark of the DuPont Corporation.
TranSyndTM is a trademark of Castrol, Ltd.

NOTE:
This publication is revised periodically to include improvements,
new models, special tools, and procedures. A revision is indicated
by the date on the title page. Check with your Allison
Transmission service outlet for the currently applicable
publication. Additional copies of this publication may be
purchased from authorized Allison Transmission service outlets.
Look in your telephone directory under the heading of
Transmissions Truck, Tractor, etc.

ii Copyright 2001 General Motors Corp.


IMPORTANT SAFETY NOTICE

IT IS YOUR RESPONSIBILITY to be completely familiar with the Warnings and Cau-


tions described in this Service Manual. These Warnings and Cautions advise against the
use of specific service methods that can result in personal injury, damage to the equip-
ment, or cause the equipment to become unsafe. It is, however, important to understand
that these Warnings and Cautions are not exhaustive. Allison Transmission could not
possibly know, evaluate, and advise the service trade of all conceivable ways in which
service might be done or of the possible hazardous consequences of each way. Conse-
quently, Allison Transmission has not undertaken any such broad evaluation. Accord-
ingly, ANYONE WHO USES A SERVICE PROCEDURE OR TOOL WHICH IS NOT
RECOMMENDED BY ALLISON TRANSMISSION MUST first be thoroughly satisfied
that neither personal safety nor equipment safety will be jeopardized by the service
methods selected.
Proper service and repair are important to the safe, reliable operation of the equipment.
The service procedures recommended by Allison Transmission and described in this Ser-
vice Manual are effective methods for performing service operations. Some of these ser-
vice operations require the use of tools specifically designed for the purpose. The special
tools should be used when and as recommended.

WARNINGS, CAUTIONS, AND NOTES


Three types of headings are used in this manual to attract your attention:

WARNING!
is used when an operating procedure, practice,
etc., which, if not correctly followed, could result
in personal injury or loss of life.

CAUTION:
is used when an operating procedure, practice,
etc., which, if not strictly observed, could result
in damage to or destruction of equipment.

NOTE:
is used when an operating procedure, practice, etc.,
is essential to highlight.

Copyright 2001 General Motors Corp. iii


LIST OF WARNINGS
This manual contains the following Warnings

IT IS YOUR RESPONSIBILITY TO BE FAMILIAR WITH ALL OF THEM.

If you leave the vehicle and the engine is running, the vehicle can move suddenly and
you or others could be injured. If you must leave the engine running, do not leave the
vehicle until you:
Put the transmission in N (Neutral)and
Apply the parking brake and emergency brakes and make sure they are properly
engagedand
Chock the wheels and take any other steps necessary to keep the vehicle from
moving.
Avoid contact with the hot fluid or the sump when draining transmission fluid. Direct
contact with the hot fluid or the hot sump may result in bodily injury.
DO NOT conduct a converter stall test until the following actions are taken. The
parking brake and/or emergency brakes must be set and properly engaged and the
wheels must be chocked. Warn personnel to keep clear of the vehicle and its travel path.
Failure to do so can cause serious injury.
Use appropriate safety equipment such as safety glasses, safety shoes, and gloves.
Do not burn discarded Teflon seals; toxic gases are produced by burning Teflon.
Never dry bearings by spinning them with compressed air. A spinning bearing can
disintegrate, allowing balls or rollers to become lethal flying projectiles. Also, spinning
a bearing without lubrication can damage the bearing.
DO NOT disconnect the hydraulic fluid line between the accumulator and the retarder
until air and hydraulic pressure have been bled from the retarder.
PREVENT PERSONAL INJURY: Use proper tools and lifting equipment when
installing or removing a transmission from the repair stand. Transmission dry weights
are as follows:
4000 MH/HD/B 500 (Basic) 377 kg (831 lb)
With PTO Provision 405 kg (893 lb)
With Retarder 411 kg (906 lb)
With PTO and Retarder 439 kg (968 lb)
HD 4070 w/ PTO and Retarder 555 kg (1224 lb)
Get help when lifting the control module. Assistance from a hoist or another person
may be required. The control module weighs approximately 25 kg (55 lb).

iv Copyright 2001 General Motors Corp.


LIST OF WARNINGS
This manual contains the following Warnings

IT IS YOUR RESPONSIBILITY TO BE FAMILIAR WITH ALL OF THEM.

Get help when lifting the C6 adapter housing module. Assistance from a hoist or
another person may be required. The C6 adapter housing module weighs
approximately 68kg (150 lb).
Carefully release spring force. Piston springs are highly compressed. Personal injury
can occur if the spring force is not controlled.
Place the P3 planetary assembly on its side to avoid possible injury while disassembling
the planetary.
Piston springs are highly compressed. Be extremely careful during removal and
installation. Personal injury can occur if the spring force is not controlled.
Be sure that lifting equipment and the repair stand can properly support the weight of
the transmission being serviced. The dry weights are:
HD 4060/4560/B 500PR Series 440 kg (968 lb)
HD 4060/4560/B 500P Series 406 kg (893 lb)
HD 4070PR 640 kg (1411 lb)
HD 4070P 606 kg (1336 lb)

v Copyright 2001 General Motors Corp.


TABLE OF CONTENTS
Paragraph Page Paragraph Page

Section 1. GENERAL INFORMATION 110. RESTORING TRANSMISSION


TO SERVICE
11. SCOPE OF MANUAL
a. Transmission Exterior . . . . . . . . . . . . . . . 18
a. Content and Organization . . . . . . . . . . . . 11
b. Sealed Breather and Openings. . . . . . . . . 18
b. Illustrations. . . . . . . . . . . . . . . . . . . . . . . . 11
c. New Transmissions . . . . . . . . . . . . . . . . . 18
c. Maintenance Information . . . . . . . . . . . . 11 d. Stored Without Fluid . . . . . . . . . . . . . . . . 18
12. SUPPLEMENTARY INFORMATION . . . . 11 e. Stored With Fluid. . . . . . . . . . . . . . . . . . . 18
13. ORDERING PARTS 111. ELECTROMAGNETIC/RADIO
a. Transmission Nameplate . . . . . . . . . . . . . 11 FREQUENCY INTERFERENCE . . . . . . . . 19
b. Parts Catalog . . . . . . . . . . . . . . . . . . . . . . 11 112. OPERATING INSTRUCTIONS . . . . . . . . . 19
14. GENERAL DESCRIPTION 113. SPECIFICATIONS AND DATA . . . . . . . . . 19
a. Major Modules. . . . . . . . . . . . . . . . . . . . . 15
b. Unique Features. . . . . . . . . . . . . . . . . . . . 15
Section 2. PREVENTIVE MAINTENANCE
15. MAJOR COMPONENTS
21. SCOPE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
a. Input Module . . . . . . . . . . . . . . . . . . . . . . 15
b. Torque Converter . . . . . . . . . . . . . . . . . . . 15 22. PERIODIC INSPECTION AND CARE
c. Power Takeoff . . . . . . . . . . . . . . . . . . . . . 15 a. Exterior Cleaning and Inspection . . . . . . 21
d. Main Housing and Gear Module. . . . . . . 15 23. IMPORTANCE OF PROPER
e. Range Clutches . . . . . . . . . . . . . . . . . . . . 15 FLUID LEVEL
f. Control System . . . . . . . . . . . . . . . . . . . . 16 a. Transmission Fluid . . . . . . . . . . . . . . . . . 21
g. Transmission Fluid Filters . . . . . . . . . . . . 16 b. Oil Level Sensor . . . . . . . . . . . . . . . . . . . 21
h. Transmission Fluid Coolers . . . . . . . . . . . 16 c. Electronic Controls and
i. C6 Adapter Housing Module. . . . . . . . . . 16 Protection Circuits . . . . . . . . . . . . . . . . . . 21
j. Rear Cover . . . . . . . . . . . . . . . . . . . . . . . . 16 24. ELECTRONIC FLUID LEVEL CHECK
k. Output Retarder and Output Flange. . . . . 16 (WHEN AN OPTIONAL OLS IS
16. MODEL DESIGNATION CODE. . . . . . . . . 16 PRESENT FULL-FUNCTION
PUSHBUTTON OR LEVER SHIFT
17. EXPLODED (DISASSEMBLED) SELECTORS)
VIEWS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16 a. Fluid Level Check Procedure . . . . . . . . . 22
18. DIAGNOSIS 25. ELECTRONIC FLUID LEVEL CHECK
a. Before Starting . . . . . . . . . . . . . . . . . . . . . 17 (WHEN AN OPTIONAL OLS IS
b. DO NOT SHIFT or CHECK TRANS PRESENT STRIP TYPE PUSHBUTTON
Light . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17 SHIFT SELECTORS)
c. Entering Diagnostic Mode . . . . . . . . . . . 17 a. Fluid Level Check Procedure
d. Diagnostic Codes . . . . . . . . . . . . . . . . . . . 17 (WTEC II) . . . . . . . . . . . . . . . . . . . . . . . . 23
e. Displaying Diagnostic Codes . . . . . . . . . 17 b. Fluid Level Check Procedure
f. Diagnostic Code Displays . . . . . . . . . . . . 17 (WTEC III). . . . . . . . . . . . . . . . . . . . . . . . 23
g. Exiting Diagnostic Mode . . . . . . . . . . . . 17 26. MANUAL FLUID LEVEL CHECK
19. PRESERVATION AND STORAGE PROCEDURE
a. Storage (New Transmissions, a. Preparation . . . . . . . . . . . . . . . . . . . . . . . 24
Before Installation) . . . . . . . . . . . . . . . . . 17 b. Consistency of Readings . . . . . . . . . . . . . 24
b. Preservation Methods . . . . . . . . . . . . . . . 17 27. COLD CHECK
c. One Year Storage (Without Fluid). . . . . . 18 a. Purpose. . . . . . . . . . . . . . . . . . . . . . . . . . . 24
d. One Year Storage (With Fluid) . . . . . . . . 18 b. Cold Check Procedure . . . . . . . . . . . . . . . 24

Copyright 2001 General Motors Corp. vii


4000 MH/HD 4000/B 500 SERIES ON-HIGHWAY SERVICE MANUAL
Paragraph Page Paragraph Page

28. HOT CHECK d. Possible Points of Fluid Leaks and


a. Procedure. . . . . . . . . . . . . . . . . . . . . . . . . 25 Their Causes . . . . . . . . . . . . . . . . . . . . . 217
e. Repairing Leak . . . . . . . . . . . . . . . . . . . 218
29. KEEPING FLUID CLEAN
a. Foreign Material . . . . . . . . . . . . . . . . . . . 25 218. OUTPUT FLANGE/YOKE AND OIL
SEAL MAINTENANCE (All Models
210. FLUID RECOMMENDATIONS
Except HD 4070/4076)
a. Fluid Type . . . . . . . . . . . . . . . . . . . . . . . . 26
a. Disassembly . . . . . . . . . . . . . . . . . . . . . 218
211. FLUID AND FILTER b. Assembly. . . . . . . . . . . . . . . . . . . . . . . . 219
CHANGE INTERVALS
219. OUTPUT FLANGE/YOKE AND
a. Fluid and Filter Changes. . . . . . . . . . . . . 26 OIL SEAL MAINTENANCE
b. Fluid Analysis . . . . . . . . . . . . . . . . . . . . . 28 (HD 4070 Models Only)
212. FLUID CONTAMINATION a. Disassembly . . . . . . . . . . . . . . . . . . . . . 219
a. Water . . . . . . . . . . . . . . . . . . . . . . . . . . . 28 b. Assembly . . . . . . . . . . . . . . . . . . . . . . . 220
b. Engine Coolant . . . . . . . . . . . . . . . . . . . . 28 220. ON-VEHICLE MAINTENANCE . . . . . . . 220
c. Metal . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
213. FLUID AND FILTER CHANGE Section 3. GENERAL OVERHAUL
PROCEDURE INFORMATION
a. Drain Fluid . . . . . . . . . . . . . . . . . . . . . . . 28 31. SCOPE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
b. Replace Filters. . . . . . . . . . . . . . . . . . . . . 29
c. Refill Transmission . . . . . . . . . . . . . . . . . 29 32. TOOLS AND EQUIPMENT
a. Improvised Equipment . . . . . . . . . . . . . . 31
214. BREATHER b. Special Tools . . . . . . . . . . . . . . . . . . . . . . 31
a. Location and Purpose . . . . . . . . . . . . . . 210 c. Mechanics Tools and
b. Maintenance . . . . . . . . . . . . . . . . . . . . . 210 Shop Equipment . . . . . . . . . . . . . . . . . . . 31
215. TRANSMISSION STALL TEST AND 33. REPLACEMENT PARTS
NEUTRAL COOL-DOWN CHECK a. Ordering Information . . . . . . . . . . . . . . . 36
a. Purpose . . . . . . . . . . . . . . . . . . . . . . . . . 210 b. Parts Normally Replaced
b. Stall Testing Preparation. . . . . . . . . . . . 210 at Overhaul . . . . . . . . . . . . . . . . . . . . . . . 36
c. Stall Test Procedures
Without Pro-Link . . . . . . . . . . . . . . . . 211 34. CAREFUL HANDLING . . . . . . . . . . . . . . . 36
d. Stall Test Procedures 35. CLEANING AND INSPECTION
With Pro-Link . . . . . . . . . . . . . . . . . . . 211 a. Dirt Causes Malfunction . . . . . . . . . . . . . 36
e. Stall Test Procedures b. Cleaning Transmission, Parts . . . . . . . . . 36
Smoke-Controlled Engines . . . . . . . . . . 212 c. Cleaning Bearings. . . . . . . . . . . . . . . . . . 36
f. Neutral Cool-Down Check Procedure . . 212 d. Inspecting Bearings. . . . . . . . . . . . . . . . . 37
g. Stall Test Results. . . . . . . . . . . . . . . . . . 212 e. Keeping Bearings Clean . . . . . . . . . . . . . 37
f. Inspecting Cast Parts and
216. CHECKING CLUTCH PRESSURES
Machined Surfaces . . . . . . . . . . . . . . . . . 37
a. Purpose . . . . . . . . . . . . . . . . . . . . . . . . . 212
g. Inspecting Bushings and
b. Transmission and Vehicle Preparation. . 213
Thrust Washers . . . . . . . . . . . . . . . . . . . . 37
c. Recording Data . . . . . . . . . . . . . . . . . . . 213
h. Inspecting Sealrings and Gaskets . . . . . . 38
d. Comparing Recorded Data
i. Inspecting Gears . . . . . . . . . . . . . . . . . . . 38
to Specifications . . . . . . . . . . . . . . . . . . 213
j. Inspecting Splined Parts . . . . . . . . . . . . . 38
217. FLUID LEAK DIAGNOSIS k. Inspecting Threaded Parts. . . . . . . . . . . . 38
a. Finding Leak . . . . . . . . . . . . . . . . . . . . . 217 l. Inspecting Retaining Rings . . . . . . . . . . . 38
b. Powder Method . . . . . . . . . . . . . . . . . . . 217 m. Inspecting Springs. . . . . . . . . . . . . . . . . . 39
c. Black Light and Dye Method . . . . . . . . 217 n. Inspecting Clutch Plates . . . . . . . . . . . . . 39

viii Copyright 2001 General Motors Corp.


TABLE OF CONTENTS
Paragraph Page Paragraph Page

o. Inspecting Swaged and h. Removal of Retarder Module


Interference-Fit Parts . . . . . . . . . . . . . . . . 39 (All Models Except HD 4070/4076) . . . . 46
p. Inspecting Sealing Surfaces . . . . . . . . . . 39 i. Removal of Retarder and Output Shaft
36. ASSEMBLY PROCEDURES Module (HD 4070/4076 Models) . . . . . . 48
a. Parts Lubrication . . . . . . . . . . . . . . . . . . . 39 j. Removal of Rear Cover Module (All
b. Grease Used for Assembly . . . . . . . . . . . 39 Models Except HD 4070/4076) . . . . . . . . 49
c. Sealing Compounds and k. Removal of Rear Cover and Output
Nonsoluble Greases . . . . . . . . . . . . . . . . . 39 Shaft Module (HD 4070/4076 Models) . 49
d. Clutches and Pistons . . . . . . . . . . . . . . . . 39 l. Removal of C6 Adapter Housing
e. Threaded Plugs and Hydraulic Module (HD 4070/4076 Models) . . . . . 410
Fittings . . . . . . . . . . . . . . . . . . . . . . . . . . 310 m. Removal of P3 Planetary Module
f. Lip-Type Oil Seals. . . . . . . . . . . . . . . . . 310 (HD 4070 Models Only) . . . . . . . . . . . . 410
g. Butt-Joint Sealrings . . . . . . . . . . . . . . . . 310 n. Removal of Main Shaft Module . . . . . . 410
h. Bearings . . . . . . . . . . . . . . . . . . . . . . . . . 310 o. Removal of P2 Module,
i. Bushings. . . . . . . . . . . . . . . . . . . . . . . . . 310 C5 Clutch Plates, and P1 Module . . . . . 410
j. Electrical Components . . . . . . . . . . . . . 310 p. Removal of Front Support/
37. REMOVING TRANSMISSION Charging Pump Module and
FROM VEHICLE Rotating Clutch Module . . . . . . . . . . . . 411
a. Drain Fluid. . . . . . . . . . . . . . . . . . . . . . . 311 q. Removal of C3/C4 Clutch Assembly
b. Disconnecting Controls . . . . . . . . . . . . . 311 From Main Housing Module. . . . . . . . . 412
c. Uncoupling Transmission From
Vehicle and Engine Driveline . . . . . . . . 311 Section 5. MODULE REBUILD
d. Removing Transmission . . . . . . . . . . . . 312
51. SCOPE
38. WEAR LIMITS . . . . . . . . . . . . . . . . . . . . . . 312 a. Section . . . . . . . . . . . . . . . . . . . . . . . . . . . 51
39. SPRING SPECIFICATIONS . . . . . . . . . . . 312 b. Procedures . . . . . . . . . . . . . . . . . . . . . . . . 51
310. TORQUE SPECIFICATIONS . . . . . . . . . . 312 52. GENERAL INFORMATION FOR
MODULE REBUILD . . . . . . . . . . . . . . . . . . 51
Section 4. TRANSMISSION DISASSEMBLY 53. TORQUE CONVERTER MODULE
41. SCOPE a. Disassembly . . . . . . . . . . . . . . . . . . . . . . . 51
a. Section . . . . . . . . . . . . . . . . . . . . . . . . . . . 41 b. Assembly . . . . . . . . . . . . . . . . . . . . . . . . . 52
b. Procedures . . . . . . . . . . . . . . . . . . . . . . . . 41 54. TORQUE CONVERTER HOUSING
c. Illustrations. . . . . . . . . . . . . . . . . . . . . . . . 41 MODULE (Models without PTO Provision)
d. General Information. . . . . . . . . . . . . . . . . 41 a. Disassembly . . . . . . . . . . . . . . . . . . . . . . . 54
e. Foldouts . . . . . . . . . . . . . . . . . . . . . . . . . . 41 b. Assembly . . . . . . . . . . . . . . . . . . . . . . . . . 54
42. DISASSEMBLY OF TRANSMISSION
55. TORQUE CONVERTER HOUSING
a. Mounting Transmission
MODULE (Models with PTO Provision)
on Repair Stand . . . . . . . . . . . . . . . . . . . . 41
a. Disassembly . . . . . . . . . . . . . . . . . . . . . . . 54
b. Removal of Power Takeoff . . . . . . . . . . . 41
c. Removal of External Parts . . . . . . . . . . . . 41 b. Disassembly of Bearing Retainer . . . . . . 54
d. Removal of Integral Oil Cooler . . . . . . . . 43 c. Disassembly of PTO Gear Assembly . . . 54
e. Removal of Control Valve Module . . . . . 44 d. Assembly of PTO Gear Assembly . . . . . 54
f. Removal of Torque Converter Module . . 45 e. Assembly of Bearing
g. Removal of Converter Retainer Assembly. . . . . . . . . . . . . . . . . . 55
Housing Module . . . . . . . . . . . . . . . . . . . 46 f. Assembly . . . . . . . . . . . . . . . . . . . . . . . . . 55

Copyright 2001 General Motors Corp. ix


4000 MH/HD 4000/B 500 SERIES ON-HIGHWAY SERVICE MANUAL
Paragraph Page Paragraph Page

56. FRONT SUPPORT AND OIL PUMP MODULE b. Disassembly of Temperature Sensor . . 522
a. Disassembly . . . . . . . . . . . . . . . . . . . . . . 55 c. Disassembly of Retarder Housing . . . . 524
b. Assembly of Front Support . . . . . . . . . . . 57 d. Disassembly of P3 Planetary
c. Assembly of Pump Housing . . . . . . . . . 58 Carrier Assembly . . . . . . . . . . . . . . . . . 524
57. ROTATING CLUTCH MODULE e. Disassembly of Retarder
a. Disassembly . . . . . . . . . . . . . . . . . . . . . . 58 Stator Assembly . . . . . . . . . . . . . . . . . . 525
b. Assembly . . . . . . . . . . . . . . . . . . . . . . . . 510 f. Assembly of Retarder Stator . . . . . . . . . 525
58. C3/C4 AND MAIN HOUSING MODULE g. Assembly of P3 Planetary
a. Disassembly . . . . . . . . . . . . . . . . . . . . . 512 Carrier Assembly . . . . . . . . . . . . . . . . . 526
b. Assembly . . . . . . . . . . . . . . . . . . . . . . . . 513 h. Assembly of Retarder Housing
59. MAIN SHAFT MODULE Assembly. . . . . . . . . . . . . . . . . . . . . . . . 526
a. Disassembly . . . . . . . . . . . . . . . . . . . . . 514 i. Assembly of the Retarder Valve Body. . 527
b. Assembly (4000 MH, HD 4060, and j. Disassembly of Retarder Valve Body. . 528
B 500 Models Only) . . . . . . . . . . . . . . . 514 k. Disassembly of Temperature Sensor. . . 528
c. Assembly
(HD 4070/4076 Models Only) . . . . . . . 515 l. Disassembly of Retarder Housing. . . . . 528
m. Disassembly of P3 Planetary Carrier
510. P1 PLANETARY MODULE
Assembly . . . . . . . . . . . . . . . . . . . . . . . . 529
a. Disassembly . . . . . . . . . . . . . . . . . . . . . 515
n. Disassembly of Retarder Stator. . . . . . . 529
b. Assembly. . . . . . . . . . . . . . . . . . . . . . . . 515
o. Assembly of Retarder Stator . . . . . . . . . 530
511. P2 PLANETARY MODULE
a. Disassembly . . . . . . . . . . . . . . . . . . . . . 517 p. Assembly of P3 Planetary
Carrier Assembly. . . . . . . . . . . . . . . . . . 530
b. Assembly. . . . . . . . . . . . . . . . . . . . . . . . 517
q. Assembly of Retarder Housing
512. P3 PLANETARY MODULE Assembly . . . . . . . . . . . . . . . . . . . . . . . . 530
(HD 4070/4076 Models Only)
r. Assembly of the Retarder Valve Body. . 531
a. Disassembly . . . . . . . . . . . . . . . . . . . . . 518
b. Assembly . . . . . . . . . . . . . . . . . . . . . . . 518 515. RETARDER AND OUTPUT SHAFT
MODULE (HD 4070 Models Equipped
513. C6 ADAPTER HOUSING MODULE
With Retarder)
(HD 4070/4076 Models Only)
a. Disassembly of Ring Gear and Hub a. Disassembly of Retarder Valve Body. . 532
Assembly . . . . . . . . . . . . . . . . . . . . . . . 518 b. Disassembly of Temperature Sensor . . 532
b. Disassembly . . . . . . . . . . . . . . . . . . . . . 518 c. Disassembly of Retarder Housing . . . . 532
c. Disassembly of P4 Planetary Carrier
d. Disassembly of Output Shaft
Assembly . . . . . . . . . . . . . . . . . . . . . . . 519
Assembly . . . . . . . . . . . . . . . . . . . . . . . 533
d. Disassembly of Remaining C6 Parts. . . 519
e. Completion of Retarder Housing
e. Assembly . . . . . . . . . . . . . . . . . . . . . . . 520
Disassembly . . . . . . . . . . . . . . . . . . . . . 533
f. Assembly of P4 Planetary Carrier
Assembly . . . . . . . . . . . . . . . . . . . . . . . 521 f. Disassembly of Retarder Stator
g. Assembly of C6 Clutch . . . . . . . . . . . . 521 Assembly . . . . . . . . . . . . . . . . . . . . . . . 533
g. Assembly of Retarder Stator
514. RETARDER AND P3 PLANETARY
Assembly . . . . . . . . . . . . . . . . . . . . . . . 533
MODULE (4000 MH, HD 4060, HD 4560,
And B 500 Models Equipped With Retarder) h. Assembly of Retarder Housing . . . . . . 534
a. Disassembly of Retarder Valve Body . . 522 i. Assembly of Output Shaft Assembly . . 534

x Copyright 2001 General Motors Corp.


TABLE OF CONTENTS
Paragraph Page Paragraph Page

j. Completion of Retarder Housing b. Disassembly of Rotating Clutch


Assembly . . . . . . . . . . . . . . . . . . . . . . . . 534 Solenoid Body . . . . . . . . . . . . . . . . . . . . 546
k. Assembly of Retarder Valve Body . . . . 535 c. Disassembly of Stationary Clutch
l. Disassembly of Retarder Valve Body . . 536 Solenoid Body . . . . . . . . . . . . . . . . . . . . 546
m. Disassembly of Temperature Sensor . . . 536 d. Disassembly of C6 Control Valve
Body (HD 4070/4076 Models Only) . . . 546
n. Disassembly of Retarder Housing . . . . . 536
e. Disassembly of Main
o. Completion of Retarder Housing
Valve Body. . . . . . . . . . . . . . . . . . . . . . . 546
Disassembly . . . . . . . . . . . . . . . . . . . . . . 537
f. Disassembly of Channel Plate. . . . . . . . 547
p. Disassembly of Output Shaft
g. Assembly of Channel Plate . . . . . . . . . . 547
Assembly . . . . . . . . . . . . . . . . . . . . . . . . 537
h. Assembly of Main Valve Body . . . . . . . 548
q. Disassembly of Retarder Stator
i. Assembly of C6 Control Valve Body
Assembly . . . . . . . . . . . . . . . . . . . . . . . . 537
(HD 4070/4076 Models Only). . . . . . . . 548
r. Assembly of Retarder Stator . . . . . . . . . 537 j. Assembly of Stationary Clutch
s. Assembly of Retarder Housing . . . . . . . 538 Solenoid Body . . . . . . . . . . . . . . . . . . . . 549
t. Assembly of Output Shaft Assembly . . 538 k. Assembly of Rotating Clutch
u. Completion of Retarder Housing Solenoid Body . . . . . . . . . . . . . . . . . . . . 549
Assembly . . . . . . . . . . . . . . . . . . . . . . . . 538 l. Assembly of Control Valve Module . . . 549
v. Assembly of Retarder Valve Body . . . . 539
516. REAR COVER MODULE (4000 MH, Section 6. TRANSMISSION ASSEMBLY
HD 4060, HD 4560, and B 500 Models
61. SCOPE
Equipped With Rear Cover)
a. Section . . . . . . . . . . . . . . . . . . . . . . . . . . . 61
a. Disassembly . . . . . . . . . . . . . . . . . . . . . . 539
b. Procedures . . . . . . . . . . . . . . . . . . . . . . . . 61
b. Disassembly of P3 Planetary
c. Illustrations . . . . . . . . . . . . . . . . . . . . . . . 61
Carrier Assembly . . . . . . . . . . . . . . . . . . 540
d. General Information . . . . . . . . . . . . . . . . 61
c. Completion of Rear Cover
e. Foldouts . . . . . . . . . . . . . . . . . . . . . . . . . . 61
Disassembly. . . . . . . . . . . . . . . . . . . . . . 540
d. Beginning Rear Cover Assembly . . . . . 540 62. ASSEMBLY OF TRANSMISSION
e. Assembly of P3 Planetary a. Assembly of Main Housing Module. . . . 61
Carrier Assembly . . . . . . . . . . . . . . . . . . 541 b. Installation of Rotating Clutch Module . . 61
f. Completion of Rear Cover Assembly. . . 541 c. Installation of Front Support/
517. REAR COVER AND OUTPUT SHAFT Charging Pump Module. . . . . . . . . . . . . . 62
MODULE (HD 4070/4076 Models d. Installation of P1 Planetary Module . . . . 62
Equipped With Rear Cover) e. Installation of P2 Planetary Module . . . . 62
a. Disassembly . . . . . . . . . . . . . . . . . . . . . 542 f. Installation of C5 Clutch Pack . . . . . . . . . 62
b. Disassembly of Output Shaft g. Installation of Main Shaft Module
Assembly . . . . . . . . . . . . . . . . . . . . . . . . 543 (4000 MH, HD 4060, HD 4560,
c. Completion of Rear Cover and B 500 Models Only) . . . . . . . . . . . . . 62
Disassembly . . . . . . . . . . . . . . . . . . . . . 543 h. Installation of Main Shaft Module
d. Beginning Rear Cover Assembly . . . . . 543 (HD 4070/4076 Models Only) . . . . . . . . 63
e. Assembly of Output Shaft i. Main Shaft Selective Shim
Assembly . . . . . . . . . . . . . . . . . . . . . . . . 543 Measurement (Close Ratio Models) . . . . 63
f. Completion of Rear Cover Assembly . . 544 j. Main Shaft Selective Shim
518. CONTROL VALVE MODULE Measurement (Wide Ratio Models) . . . 64
a. Disassembly of Control k. Installation of P3 Planetary Module
Valve Module. . . . . . . . . . . . . . . . . . . . . 545 (HD 4070/4076 Retarder Models Only). . 65

Copyright 2001 General Motors Corp. xi


4000 MH/HD 4000/B 500 SERIES ON-HIGHWAY SERVICE MANUAL
Paragraph Page Paragraph Page

l. Installation of C6 Adapter Housing u. Installation of Converter Housing


Module (HD 4070/4076 Retarder Module. . . . . . . . . . . . . . . . . . . . . . . . . . 614
Models Only) . . . . . . . . . . . . . . . . . . . . . 65 v. Installation of Torque Converter
m. P3 Planetary Selective Shim Module. . . . . . . . . . . . . . . . . . . . . . . . . . 614
Measurement (HD 4070/4076 Models w. Installation of Control Module . . . . . . . 617
Equipped With Retarder) . . . . . . . . . . . . 66 x. Installation of Externally
n. P3 Planetary Selective Shim Mounted Parts . . . . . . . . . . . . . . . . . . . . 617
Measurement (HD 4070/4076 Models y. Installation of Power Takeoff . . . . . . . . 618
Equipped With Rear Cover) . . . . . . . . . . 67
z. Removal of Transmission
o. Installation of Remainder of P3 From Repair Stand . . . . . . . . . . . . . . . . 618
Planetary Module and C6 Adapter
Housing Module
(HD 4070/4076 Models Only) . . . . . . . . 68 Section 7. WEAR LIMITS AND
p. Installation of Tolerance Rings Module SPRING DATA
(HD 4070/4076 Models Equipped With
Retarder) . . . . . . . . . . . . . . . . . . . . . . . . . 69 71. WEAR LIMITS DATA
q. Installation of Retarder Module a. Maximum Variations . . . . . . . . . . . . . . . 71
(4000 MH, HD 4060, HD 4560, b. Cleaning and Inspection . . . . . . . . . . . . . 71
and B 500 Models Equipped With
Retarders) . . . . . . . . . . . . . . . . . . . . . . . . 69 72. SPRING DATA
r. Installation of Retarder and Output a. Spring Replacement . . . . . . . . . . . . . . . . 71
Shaft Module (HD 4070/4076 Models b. Inspection . . . . . . . . . . . . . . . . . . . . . . . . 71
Equipped With Retarders) . . . . . . . . . . 610
s. Installation of Rear Cover Module
(4000 MH, HD 4060, HD 4560, and Section 8. CUSTOMER SERVICE
B 500 Models Only) . . . . . . . . . . . . . . . 612
81. OWNER ASSISTANCE. . . . . . . . . . . . . . . . 81
t. Installation of Rear Cover Module
(HD 4070/4076 Models Only) . . . . . . . 613 82. SERVICE LITERATURE . . . . . . . . . . . . . . 82

xii Copyright 2001 General Motors Corp.


4000 MH/HD 4000/B 500 SERIES ON-HIGHWAY SERVICE MANUAL
LIST OF FOLDOUT ILLUSTRATIONS
(Back of Service Manual)

CROSS-SECTION VIEWS
Foldout

1 Model 4000 MH/HD 4060 (Close Ratio) Transmission Cross Section


2 Model HD 4560 (Wide Ratio) Transmission With PTO Provision Cross Section
3 Model 4000 MH, HD 4060, B 500 (Close Ratio) Transmission With Retarder Cross Section
3,A HD 4070/4076 Cross Section
3,B HD 4070/4076 With Retarder Cross Section
3,C HD 4070/4076 With Retarder and PTO Provision Cross Section

EXPLODED VIEWS
Foldout

4,A Flexplate and Adapter


4,B Torque Converter Module
5,A Converter Housing Module
5,B Converter Housing Module With PTO Provision
6,A Front Support and Charging Oil Pump Module
6,B Rotating Clutch Module
7 Main Housing Module
8 Main Shaft Module
9,A P1 Planetary Module
9,B P2 Planetary Module
9,C P3 Planetary Module and C6 Adapter Housing Module (HD 4070/4076 Models Only)
10,A Retarder and P3 Planetary, Retarder Valve Body Module (Units Prior to S/N 6610066447)
10,B Rear Cover and P3 Planetary Module
10,C Retarder and Output Shaft Module (HD 4070/4076 Models Prior to S/N 6610066447)
10,D Rear Cover and Output Shaft Module (HD 4070/4076 Models Only)
10,E Retarder and P3 Module (Units Starting With S/N 6610066447)
10,F Retarder and Output Shaft Module (HD 4070/4076 Models Starting With S/N 6610066447)
11,A Control Module
11,B Control Module
12,A Output Flange and Yoke
12,B Support Equipment
13 4000 MH, HD 4000, B 500 Hydraulic Schematic Neutral

Copyright 2001 General Motors Corp. xiii


Section 1 GENERAL INFORMATION
11. SCOPE OF MANUAL 3. Required tools and fixtures are available as
shown in Section 3 of this manual. Refer to
a. Content and Organization. This Service Figures 32 and 33 and Tables 31 and 32.
Manual describes overhaul procedures for the
4000 MH, HD 4000, and B 500 Series automatic 4. Reasonable and prudent maintenance practices
transmissions (Figures 11 through 16). are used.

Detailed instructions are provided for


disassembly, rebuild, and reassembly. NOTE:
Part inspection instructions are in Section 3.
Service organizations and individuals are
encouraged to contact their local ATD Distributor
Wear limits and spring data are in Section 7. for information and guidance on any task outlined
Major transmission components and their in this manual.
functions are explained in WT Series
Principles of Operation PO2454EN.
b. Illustrations 12. SUPPLEMENTARY
1. The text is supported with line drawings and INFORMATION
cross-sectional views. Overhaul procedures are
Supplementary information will be issued, as required,
illustrated by line drawings. Cross-sections
if any changes occur after publication of this manual.
show the relationship of assembled parts.
Check with your dealer or distributor to be sure you
Cross-sections, exploded views, and a
have the latest information.
hydraulic schematic (transmission in Neutral)
are on foldout pages in the back of the manual.

2. Illustrations show correct procedures for all 13. ORDERING PARTS


models including models not illustrated.
a. Transmission Nameplate. The nameplate
c. Maintenance Information. Each task described (Figure 17) is located on the right side of the
in this manual has been successfully completed by transmission. The nameplate used prior to April 14,
service organizations and individuals. Not every 1998, was imprinted with the transmission serial
service organization or individual possesses the number, part number (assembly number), and model
required special tooling, training or experience to number. Use all three numbers when ordering
perform all described tasks. However, any task may be replacement parts or requesting service information.
performed if the following conditions are met: The nameplate used beginning April 14, 1998, is
imprinted with the transmission model, serial number,
1. The organization or individual has the
date code, TransID number, and groups. Use all of
required knowledge of the task through:
these numbers when ordering replacement parts or
Formal instruction at Allison Transmission requesting service information.
Division (ATD) or a Distributor training b. Parts Catalog. Replacement parts are listed in
facility. the current HD 4000/B 500 Series Parts Catalog
On-the-job instruction by an ATD or PC2456EN. Do not order by the item numbers used on
Distributor representative. exploded views in this manual. Use the Parts Catalog
to determine the correct part number. Order all
Experience in performing the task.
replacement parts from your distributor. Check the
2. The work environment is suitable to prevent Yellow Pages for your nearest authorized service
contamination or damage to transmission parts outlet. Listings are under Transmission Truck or
or assemblies. Engines Diesel.

Copyright 2001 General Motors Corp. 11


4000 MH/HD 4000/B 500 SERIES ON-HIGHWAY SERVICE MANUAL

PTO
(TOP RIGHT POSITION)

SHIPPING BRACKET (3)

FEEDTHROUGH HARNESS
CONNECTOR

MOUNTING PAD

ENGINE-SPEED SENSOR

OUTPUT-SPEED SENSOR
TURBINE-SPEED SENSOR

FILL TUBE
COOLER PORTS
NAMEPLATE

V06829
.

Figure 11. Model 4000 MH/HD 4060P/4560P/B 500P Transmission Right-Rear View

FEEDTHROUGH
HARNESS
CONNECTOR

MOUNTING PAD
(BOTH SIDES)

PTO
(BOTTOM LEFT POSITION)

MAIN-PRESSURE TAP

COOLER PORTS

V06830

Figure 12. Model 4000 MH/HD 4060P/4560P/B 500P Transmission Left-Rear View

12 Copyright 2001 General Motors Corp.


GENERAL INFORMATION

FILL TUBE
PTO
(TOP RIGHT POSITION)
FEEDTHROUGH HARNESS
CONNECTOR

RETARDER
TEMPERATURE
CONNECTOR

"K" SOLENOID
CONNECTOR

TORQUE CONVERTER
MODULE
NAMEPLATE

TURBINE-SPEED SENSOR

ENGINE-SPEED SENSOR
MOUNTING PAD

V01732

Figure 13. Model 4000 MH/HD 4060PR/4560PR/B 500PR Transmission Right-Front View

FEEDTHROUGH HARNESS
CONNECTOR

MOUNTING PAD

OUTPUT-SPEED
PTO PAD SENSOR
(BOTTOM LEFT POSITION)

RETARDER
MAIN-PRESSURE TAP

COOLER PORTS

ACCUMULATOR PORT V06831

Figure 14. Model 4000 MH/HD 4060PR/4560PR/B 500P Transmission Left-Rear View

Copyright 2001 General Motors Corp. 13


4000 MH/HD 4000/B 500 SERIES ON-HIGHWAY SERVICE MANUAL

BREATHER
PTO PROVISION

C6 ADAPTER
HOUSING

RETARDER

OUTPUT
MOUNTING PAD FLANGE

PTO PROVISION

MOUNTING PAD
V05579

Figure 15. Model HD 4070PR/4076PR Transmission Left-Rear View

PTO PROVISION
(TOP RIGHT POSITION)

HARNESS
CONNECTOR
C6 ADAPTER
HOUSING

MOUNTING PAD

INPUT
SPEED
SENSOR

TURBINE
SPEED
SENSOR
FILL T UBE

OUTPUT SPEED SENSOR NAMEPLATE

V06832

Figure 16. Model HD 4070P/4076P Transmission Right-Rear View

14 Copyright 2001 General Motors Corp.


GENERAL INFORMATION
Integral retarder (optional)
Integral oil filters, serviceable without
World Transmission complete loss of transmission fluid
Manufactured By AN
D
AGR
ICULTURA
L
IM

Adaptive electronic closed-loop controls with

PL
E

EM
ILE AEROSPAC
UAW

ENT
WORKERS
933

OB
Division of General Motors Corporation

OM

OF
UT AM
DA ERI

self-diagnostic capabilities
UNITE CA

Indianapolis, Indiana

SERIAL NO. PART NO.

XXXXXXXXXX 29509045
MODEL
15. MAJOR COMPONENTS
NO. XX XXXX
a. Input Module. The Input Module includes:
Prior to 4/14/98 V02003.02
Engine adaptation
D
A GRI
CU LTURAL
I MP
L
Torque converter

AN

EM
E , A EROSPACE

EN
T WORKERS O
Div. of General Motors Corp.

BIL
MO

F
AM
O ER
UT

Power takeoff gearing (optional)


ICA
UNITED A

Indianapolis, Indiana, USA

01-XXX 02-XXX 05-XXX 08-XXX


10-XXX 14-XXXX 15-XXX 16-XXXX b. Torque Converter
20-XXX 21-750 24-XXX 25-XXX
31-XXX 34-XXX 38-XXX 1. The torque converter includes a lockup clutch
39-XXX and torsional damper for direct and smooth
50-XXX 70-XXX
GROUPS RESERVED FOR
MILITARY P/N transfer of engine power.
Model XX XXX XXXXXXXX
S/N XXXXXXXXXX 98XXX TIDX
2. Torque converter models available are:
Beginning 4/14/98 DATE TRANS ID
NUMBER V05116.01
Torque Converter Model
TC 521
Figure 17. Transmission Nameplate
TC 531
TC 541
14. GENERAL DESCRIPTION TC 551
The Allison 4000 MH/HD 4000/B 500 Series is a TC 561
complete transmission system that includes all
hardware needed for vehicle application. c. Power Takeoff. Direct, engine-driven PTO
gearing is available at two positions.
a. Major Modules. The 4000 MH/HD 4000/B 500
Series transmission contains the following major d. Main Housing and Gear Module. The Main
modules: Housing and Gear Module include:

Input Module Main Housing

Main Housing and Gear Module Oil pump charging system

Control Module Three planetary gear sets


(four for HD 4070/4076)
Output Module
Two rotating clutches
Adapter Module (HD 4070/4076 only)
Three stationary clutches
b. Unique Features. Features unique to the (four for HD 4070/4076)
4000 MH/HD 4000/B 500 Series transmission are:
e. Range Clutches. Range clutches are multiple-
Three, four, five, six, or seven forward speed disc, wet-type clutches. Exhaust backfill pressure is
configurations used to reduce fill time for quick response and smooth
Lockup clutch with torsional damper shifts.

Copyright 2001 General Motors Corp. 15


4000 MH/HD 4000/B 500 SERIES ON-HIGHWAY SERVICE MANUAL
f. Control System. The control system is capable of 16. MODEL DESIGNATION CODE
recognizing hydraulic and electronic conditions that
are not within the operating limits of the programmed Following is the explanation for the transmission
microchip (EEPROM). Some out-of-limit conditions model designation code stamped on some
can be corrected by the control system. All transmission nameplates:
out-of-limit condition diagnostic codes are stored for
later retrieval by a technician. 4000 MH

The Electronic Control System includes: MH Indicates motor home model

Electronic Control Unit (ECU) HD 4060/4560/4070/4076PR

Control module
Indicates planetary gear type automatic
HD
transmission
Shift selector 4 Indicates series
Sensors 0 = Indicates close ratio
0,5
5 = Indicates wide ratio
Wiring harness (customer-furnished)
6,7 Indicates number of forward ranges
The ECU is a high-speed digital computer that 6 Indicates major model change
receives information from the sensors and shift
selector. This information is processed and shift P Indicates PTO drive provision
commands are sent to the control module for range R Indicates integral retarder
selection.
B 500PR
g. Transmission Fluid Filters. Two disposable B Indicates bus or coach application
external-access filters are part of the control module. 5 Indicates series
Each filter is in a separate cavity which permits 0 Indicates close ratio
removal and replacement without complete loss of
transmission fluid. 0 Indicates major model change
P Indicates PTO drive provision
h. Transmission Fluid Coolers. The 4000 MH/ R Indicates integral retarder
HD 4000/B 500 has provision for remote or integral
transmission fluid coolers.
17. EXPLODED
i. C6 Adapter Housing Module. The C6 adapter (DISASSEMBLED) VIEWS
housing module is unique to the HD 4070/4076 Exploded views illustrate the 4000 MH/HD 4000/
models. It provides a seventh range and is located B 500 Series transmission parts in relation to each
between the main housing and rear cover/retarder. other. The parts numbering system in the exploded
views is used in all procedures described in the text.
j. Rear Cover. A rear cover is standard equipment
on the 4000 MH/HD 4000/B 500. The output shaft can
be provided with a variety of companion flanges or 18. DIAGNOSIS
yokes.
NOTE:
k. Output Retarder and Output Flange. The Refer to TS2470EN (WTEC II) or TS2973EN
optional output retarder module replaces the standard (WTEC III), Electronic Controls Troubleshooting
rear cover. An output flange or yoke is available for Manual, for in-depth troubleshooting procedures.
use with the retarder.

16 Copyright 2001 General Motors Corp.


GENERAL INFORMATION
a. Before Starting. Before attempting to repair the about one second. The displayed diagnostic code and
transmission, the faulty condition and its probable the logged position of the code will be displayed
cause should be identified. sequentially until the MODE button is pressed. When
all codes have been displayed by pressing the MODE
b. DO NOT SHIFT or CHECK TRANS Light.
button, the first code will be redisplayed. Any log
Continued illumination of the DO NOT SHIFT or
position not containing a diagnostic code will display
CHECK TRANS light during vehicle operation
at the code and sub code positions. No codes are
indicates the ECU has signaled a diagnostic code. At
logged after a display.
start-up, the DO NOT SHIFT or CHECK TRANS
light will briefly illuminate. g. Exiting Diagnostic Mode
c. Entering Diagnostic Mode 1. Press the same buttons used to enter the
diagnostic mode.
1. Pushbutton Shift Selector. Begin by pressing
the (Up) and (Down) arrow keys 2. Select any range. The transmission will enter
simultaneously. Diagnostics will be displayed the selected range if the range is not inhibited.
immediately, if no oil level sensor (OLS) is
present. Press the (Up) and (Down) arrow 3. Turn off the ignition switch.
keys simultaneously a second time to enter the
Diagnostic Mode when an OLS is present. The 4. The ECU diagnostic mode is exited
display will list the diagnostic codes logged automatically after approximately two minutes
positions (d1, d2, d3, etc.). have elapsed without an operator input.

2. Lever Shift Selector. Begin by pressing the


DISPLAY MODE button. Diagnostics will be
19. PRESERVATION AND STORAGE
displayed immediately, if no oil level sensor
(OLS) is present. Press the DISPLAY MODE a. Storage (New Transmissions, Before Installation).
button a second time to enter Diagnostic Mode New transmissions are filled with transmission fluid
when an OLS is present. The display will list and drained before shipment. The residual fluid in the
the diagnostic codes logged positions (d1, d2, transmission provides adequate protection to safely
d3, etc.). store the transmission without further treatment for
one full year if stored indoors, in conditions of normal
d. Diagnostic Codes. Diagnostic codes can be climate, and with all shipping plugs installed.
displayed on the display portion of the shift selector or
by using the Allison Transmission Diagnostic Tool CAUTION:
(ATDT) or Diagnostic Data Reader/Tool (DDR or
Pro-Link). A diagnostic code is either active or Whenever a transmission is overhauled or ex-
changed, the Electronic Control Unit (ECU)
historical. An active code is any code that is current in
must be RESET TO UNADAPTED SHIFTS.
the ECU decision-making process. Historical codes This causes the ECU to erase previous adaptive
are codes that are retained in the ECU memory and information and begin to adapt in Fast Adaptive
will not necessarily affect the ECU decision-making Mode from the base calibration. Use the Allison
process. Active codes are indicated on the shift Transmission Diagnostic Tool (ATDT) or the
selector by the MODE ON indicator. Pro-Link 9000 DDR and select RESET UN-
ADAPTED SHIFTS. Follow the instructions in
e. Displaying Diagnostic Codes. Press and release the tool Users Guide to accomplish the reset.
MODE button to sequentially display the logged
diagnostic codes.
b. Preservation Methods. When the transmission is
f. Diagnostic Code Displays. The logged position stored or inactive for an extended period (one or more
(d1, d2, d3, d4, and d5) of the following diagnostic years), specific preservation methods are required to
code is the first item of a diagnostic code display. After prevent damage from rust, corrosion, and organic
two seconds the main code and sub code are displayed growth in the transmission fluid. Preservation methods
(example: 25 11). A WTEC III shift selector displays described are for storage with or without transmission
one character at a time. Each character is displayed for fluid and on or off a vehicle.

Copyright 2001 General Motors Corp. 17


4000 MH/HD 4000/B 500 SERIES ON-HIGHWAY SERVICE MANUAL
c. One Year Storage (Without Fluid)
CAUTION:
1. Drain the transmission fluid. If the unit does not have a converter-out temper-
ature gauge, do not stall the converter.
2. Remove the breather and spray 30 ml (one
ounce) of VCI #10 (or equivalent) into the
6. If normal operating temperature is less than
transmission through the breather hole.
107C (225F), shift the transmission to
Re-install the breather. Also, spray 30 ml (one
forward range and stall the converter. Do not
ounce) through the fill tube hole.
exceed 107C (225F).

3. Seal all openings and the breather with 7. As soon as the transmission is cool enough to
moisture-proof tape. touch, seal all openings and the breather with
moisture-proof tape.
4. Coat all exposed, unpainted surfaces with
preservative grease such as petrolatum 8. Coat all exposed, unpainted surfaces with
(MIL-C-11796, Class 2). preservative grease such as petrolatum
(MIL-C-11796), Class 2.
5. If additional storage time is required, repeat
Steps (2) through (4) at yearly intervals. 9. If additional storage time is required, repeat
Steps (2) through (8) at yearly intervals,
except, it is not necessary to drain the
d. One Year Storage (With Fluid)
transmission each year. Just add VCI #10 and
1. Drain the fluid and replace the oil filter Biobor JF (or equivalents).
elements.

2. Fill the transmission to operating level with a 110. RESTORING TRANSMISSION


mixture of one part VCI #10 (or equivalent) to TO SERVICE
30 parts transmission fluid. Add 3 ml of
Biobor JF (or equivalent) for each 10 liters a. Transmission Exterior. Wash all external grease
(1 4 teaspoon for every gallon) of fluid in the from the transmission with mineral spirits.
system.
b. Sealed Breather and Openings. Remove all tape
from openings and the breather.
NOTE:
c. New Transmissions. If the transmission is new,
When calculating the amount of Biobor JF drain the residual preservative oil. Refill the
required, use the total volume of the system, not just transmission to the proper level with an Allison-
the quantity required to fill the transmission. approved transmission fluid. Refer to Paragraph 210.
Include external lines, filters, and the cooler.
d. Stored Without Fluid. If the transmission was
prepared for storage without fluid, drain the residual
3. Operate the transmission in N (Neutral) for fluid and replace the oil filter elements. Refill the
approximately five minutes at 1500 rpm. transmission to the proper level with an Allison-
approved transmission fluid. Refer to Paragraph 210.
4. Make sure the transmission shifts through all e. Stored With Fluid. If the transmission was
ranges and the lockup clutch activates. prepared for storage with fluid, it is not necessary to
drain and refill the transmission with new transmission
5. Continue operating the transmission in neutral fluid. Check for proper fluid level. Add or drain
at 1500 rpm until normal operating transmission fluid, as required, to obtain the proper
temperature is reached. level.

18 Copyright 2001 General Motors Corp.


GENERAL INFORMATION
111. ELECTROMAGNETIC/RADIO control devices, or power leads may create or be
FREQUENCY INTERFERENCE subject to electromagnetic interference (EMI) from the
transmission control system. Refer to the Electronic
All electrical and electronic systems generate Controls Troubleshooting Manual (TS2470EN for
electromagnetic fields that can interfere with other WTEC II and TS2973EN for WTEC III) for detailed
electronic systems. Allison Transmissions electronic instructions regarding EMI problems.
transmission controls comply with Federal
Communications Commission (FCC) regulations and
other guidelines concerning emitted radio frequency 112. OPERATING INSTRUCTIONS
interference for transportation electronics. Some
Detailed transmission operation information is in the
radio-telephone or two-way communications radios
MD/HD/B Series Principles of Operation PO2454EN
(land-mobile radio), or the manner in which they are
manual or in OM2995EN Operators Manual. Refer to
installed, can be affected by other vehicle components
the latest revision.
or adversely affect vehicle operation. Manufacturers
and installers of EMI/RFI emitting equipment are
responsible for adhering to FCC regulations and other
113. SPECIFICATIONS AND DATA
guidelines concerning emitted radio frequency
interference for transportation electronics. Radio or The following specifications and data provide a
other two-way communication antenna, power, or quick reference to the major characteristics of the
ground leads near the transmission wiring harness, transmission.

Table 11. Specifications and Data Chart*

GEAR DATA:
Type . . . . . . . . . . . . . . . . . . . . . . . . . . Planetary helical, constant mesh
4000 MH/HD 4060/
Range B 500 Ratios HD 4560 Ratios HD 4070/4076 Ratios
First . . . . . . . . . . . . . . . . . . . . . . . . . . 3.51:1 4.70:1 7.63
Second . . . . . . . . . . . . . . . . . . . . . . . . 1.91:1 2.21:1 3.51
Third. . . . . . . . . . . . . . . . . . . . . . . . . . 1.43:1 1.53:1 1.91
Fourth . . . . . . . . . . . . . . . . . . . . . . . . . 1.00:1 1.00:1 1.43
Fifth . . . . . . . . . . . . . . . . . . . . . . . . . . 0.74:1 0.76:1 1.00
Sixth . . . . . . . . . . . . . . . . . . . . . . . . . . 0.64:1 0.67:1 0.74
Seventh. . . . . . . . . . . . . . . . . . . . . . . . 0.64
Reverse. . . . . . . . . . . . . . . . . . . . . . . . 4.80:1 5.55:1 4.8
ENGINE-DRIVEN POWER TAKEOFF PROVISION:
Positions . . . . . . . . . . . . . . . . . . . . . . 8 oclock and 1 oclock (viewed from rear)
PTO Unit Ratings at the Transmission
PTO Drive Gear . . . . . . . . . . . . . . . . . Maximum torque through one pad: 930 Nm (685 lb ft)
Maximum torque through both pads simultaneously: 1595 Nm (1175 lb ft)
(NOTE: No more than 930 Nm (685 lb ft) allowed through any
single pad)

* All data and specifications are subject to change without notice.


Gear ratios do not include torque converter multiplication.

Copyright 2001 General Motors Corp. 19


4000 MH/HD 4000/B 500 SERIES ON-HIGHWAY SERVICE MANUAL
Table 11. Specifications and Data Chart* (contd)

HYDRAULIC SYSTEM:
Fluid type . . . . . . . . . . . . . . . . . . . . . . TranSyndTM, MIL-PRF-2104, MIL-PRF-46167, MIL-PRF-21260,
DEXRON-III, C-4 (Refer to Paragraph 210.)
Filters, main and cooler . . . . . . . . . . . Dual integral, replaceable cartridge type
SIZE:
4000 MH/HD 4060/ 4000 MH/HD 4060/
4560/B 500 4560/B 500
with PTO drive without PTO drive
Length (transmission mounting face to rear of output shaft)
without retarder. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 844.7 mm (33.26 in.) 771.7 mm (30.38 in.)
with retarder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 845.6 mm (33.29 in.) 772.6 mm (30.42 in.)
Length (transmission mounting flange to output flange
798.7 mm (31.45 in.) 725.7 mm (28.57 in.)
mounting face on P3 carrier). . . . . . . . . . . . . . . . . . . . . . . . . . . .
Depth (standard sump, centerline to lowest point) . . . . . . . . . . . 375.8 mm (14.80 in.) 373.2 mm (14.69 in.)
Dry weight (add 16.0 kg (35.0 lb) if integral cooler is used)
with retarder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 439 kg (968 lb) 411 kg (906 lb)
without retarder. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 405 kg (893 lb) 377 kg (831 lb)

HD 4070/4076 HD 4070/4076
with PTO drive without PTO drive
Length (transmission mounting face to rear of output shaft)
with retarder or rear cover . . . . . . . . . . . . . . . . . . . . . . . . . . . 1104.1 mm (43.47 in.) 1031.1 mm (40.59 in.)
Length (transmission mounting flange to output flange mounting
face on output shaft)
with retarder or rear cover . . . . . . . . . . . . . . . . . . . . . . . . . . . 798.7 mm (31.45 in.) 725.7 mm (28.57 in.)
Depth (standard sump, centerline to lowest point) . . . . . . . . . . . 375.8 mm (14.80 in.) 375.8 mm (14.80 in.)
Dry weight (add 16.0 kg (35.0 lb) if integral cooler is used)
with retarder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 640 kg (1441 lb) 612 kg (1349 lb)
without retarder. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 606 kg (1336 lb) 578 kg (1274 lb)

* All data and specifications are subject to change without notice.

110 Copyright 2001 General Motors Corp.


SECTION 2 PREVENTIVE MAINTENANCE
21. SCOPE level is too high, the fluid aerates causing the
transmission to shift erratically and overheat.
Proper care and regular maintenance ensures that the
transmission meets its duty requirements. Perform the b. Oil Level Sensor. The optional oil level sensor
maintenance procedures described in this section on a (OLS) allows the operator to check the fluid level from
regular basis to prevent premature transmission or either a full-function pushbutton or a lever shift
support equipment failure. Allison transmissions are selector. Although strip type pushbutton selectors are
manufactured to provide long-term, efficient service in rarely used, the OLS can give fluid level information
their designed applications. on a WTEC II version. There is no fluid level reading
capability for a WTEC III strip type pushbutton
selector; use the ATDT or Pro-Link 9000 to obtain
22. PERIODIC INSPECTION fluid level data from the OLS.
AND CARE
a. Exterior Cleaning and Inspection NOTE:
The oil level sensor compensates for transmission
fluid temperatures from 60104C (140220F).
CAUTION: Any temperature below 60C (140F) or above
DO NOT pressure-wash the transmission 104C (220F) will result in an Invalid for
electrical connectors. Water and detergent cause Display condition.
the electrical contacts to corrode and become To accurately check the transmission fluid
faulty.
level with the dipstick, the transmission fluid
must be at normal operating temperature
1. Clean and inspect the exterior of the (7193C; 160200F).
transmission at regular intervals. Severity of
service and operating conditions determine the c. Electronic Controls and Protection Circuits.
frequency of inspections. The 4000 MH/HD 4000/B 500 transmission electronic
2. Inspect the transmission for: controls and protection circuits alert the operator to a
transmission malfunction or the need for service. The
Loose bolts transmission and mounting electronic controls and protection circuits do not
components replace regular, manual, fluid level checks. Check the
Fluid leaks repair immediately fluid level at the intervals specified in vehicle service
instructions.
Loose, dirty, or improperly adjusted throttle
sensor linkage
Damaged or loose fluid hoses 24. ELECTRONIC FLUID LEVEL
Worn, frayed, or improperly routed CHECK (WHEN AN OPTIONAL
electrical harnesses OLS IS PRESENT FULL-
Worn or out-of-phase driveline U-joints and FUNCTION PUSHBUTTON OR
slip fittings LEVER SHIFT SELECTORS)

23. IMPORTANCE OF NOTE:


PROPER FLUID LEVEL The WTEC II full-function pushbutton and lever
shift selectors can display two characters at one
a. Transmission Fluid. Transmission fluid cools, time. One character is displayed under the
lubricates, and transmits hydraulic power. Always SELECT label and one under the MONITOR label.
maintain the correct fluid level. If the level is too low, The WTEC III full-function pushbutton and lever
the torque converter and clutches do not receive selectors display one character at a time.
enough fluid and the transmission overheats. If the

Copyright 2001 General Motors Corp. 21


4000 MH/HD 4000/B 500 SERIES ON-HIGHWAY SERVICE MANUAL
a. Fluid Level Check Procedure 6. High fluid level is reported when O L is
displayed, followed by H I and a number.
1. Park the vehicle on a level surface and shift to H I indicates high fluid level and the
N (Neutral). Apply the parking brake. number indicates the number of quarts the
transmission is overfilled. Example:
2. On the full-function pushbutton shift selector, O L H I 0 1 indicates 1 quart of fluid
simultaneously press the (Up) and (Down) above the full level.
arrow buttons once.

3. On the Lever shift selector, press the CAUTION:


DISPLAY MODE pushbutton once. A low or high fluid level causes overheating and
irregular shift patterns and if not corrected, can
damage the transmission.
NOTE:
The ECU may delay the fluid level check until the 7. An Invalid for Display condition is reported
following conditions are met: when O L is displayed, followed by
and a number display. The displayed number is
The fluid temperature is above 60C (140F) a fault code, and indicates improper conditions
or below 104C (220F). or a system malfunction. Example: O L
The transmission is in neutral. 70 indicates an Invalid for Display
condition and fault code 70.
The vehicle has been stationary for approxi-
mately two minutes to allow the fluid to settle. 8. Invalid for Display is activated when
conditions do not allow the fluid level to be
The engine is at idle. checked. Review the following codes and
The delayed fluid level display signal for a WTEC II conditions, and correct as necessary. If these
selector is a flashing indicator under the SELECT conditions cannot be corrected, contact the
display and a countdown from 8 to 1 under the nearest distributor or dealer in your area.
MONITOR display. For a WTEC III selector, the (Check the telephone directory for the Allison
delayed fluid level display is a countdown from 8 to Transmission service outlet nearest you.)
1 in the display window.
Code Cause of Code
OL 50 Engine speed (rpm) too low
4. Correct fluid level is reported when O L is
displayed (O L indicates the Oil Level OL 59 Engine speed (rpm) too high
Check Mode), followed by O K O K. The
O K display indicates the fluid level is within OL 65 N (Neutral) must be selected
the O K zone. The sensor display and the OL 70 Sump oil temperature too low
transmission dipstick may not agree exactly
because the oil level sensor compensates for OL 79 Sump oil temperature too high
fluid temperature. Example: O L O K O K
indicates correct fluid level. OL 89 Output shaft rotation
OL 95 Sensor failure
5. Low fluid level is reported when O L is
displayed, followed by L O and a number.
L O indicates a low fluid level and the
number indicates the number of quarts of fluid NOTE:
the transmission requires. Confirm a low fluid Report sensor failure to a distributor or dealer
level condition by making a manual fluid level in your area. (Check the telephone directory for
check. Example: O L L O 0 2 indicates an Allison Transmission distributor or dealer
2 additional quarts of fluid will bring the fluid nearest you.)
level within the middle of the O K zone.

22 Copyright 2001 General Motors Corp.


PREVENTIVE MAINTENANCE
9. To exit the oil level display mode: 3. Correct fluid level is indicated by a flashing red
LED on the N (Neutral) pushbutton. When this
Pushbutton shift selector press any
occurs, the fluid level is within the O K zone.
pushbutton on the shift selector.
The selector display and the transmission
Lever shift selector press the DISPLAY dipstick may not agree exactly because the oil
MODE button twice. level sensor compensates for fluid temperature.

4. Low fluid level is indicated by a flashing red


25. ELECTRONIC FLUID LEVEL LED on the R (Reverse) pushbutton and a
CHECK (WHEN AN OPTIONAL tone. The number of times the tone sounds is
OLS IS PRESENT STRIP TYPE the number of quarts of fluid which need to be
PUSHBUTTON SHIFT added to produce an OK level. The
N (Neutral) pushbutton red LED will remain
SELECTORS)
on during this display.

NOTE: 5. High fluid level is indicated by a flashing red


LED on the D (Drive) pushbutton and a tone.
The WTEC II strip type pushbutton shift selectors
The number of times the tone sounds is the
can give fluid level information. The WTEC III
number of quarts of fluid which need to be
strip type pushbutton selector can only give fluid
drained to produce an OK level. The
level data by using the ATDT or Pro-Link 9000.
N (Neutral) pushbutton red LED will remain
on during this display.
a. Fluid Level Check Procedure (WTEC II)

1. Park the vehicle on a level surface and shift to CAUTION:


N (Neutral). Apply the parking brake. Low or high fluid level can cause overheating and
irregular shift patterns. These conditions can
2. Activate switch provided by the vehicle damage the transmission if not corrected.
manufacturer to initiate display of fluid level
information.
6. An Invalid for Display condition is indicated
by flashing red LEDs in a repeated sequence
NOTE: from R (Reverse) down through the lowest
The ECU may delay the fluid level check until the D (Drive) range while the N (Neutral) red
following conditions are met: LED remains constantly illuminated. A
constant tone sounds until the fluid level
The fluid temperature is above 60C (140F)
mode is exited. (Reasons for Invalid For
or below 104C (220F).
Display are the same as those in the chart in
The transmission is in neutral. Paragraph 24 above.)
The vehicle has been stationary for approxi-
mately two minutes to allow the fluid to settle. 7. To exit the fluid level display mode, press any
pushbutton or deactivate the switch provided
The engine is at idle. by the vehicle manufacturer that was used to
The delayed fluid level display signal for a WTEC II enter the fluid level display mode in Step 2.
selector is a flashing indicator under the SELECT
display and a countdown from 8 to 1 under the b. Fluid Level Check Procedure (WTEC III)
MONITOR display. For a WTEC III selector, the
delayed fluid level display is a countdown from 8 to 1. Connect the Allison Transmission Diagnostic
1 in the display window. Tool (ATDT) or DDR (Pro-Link 9000) to the
DDR connector on the wiring harness.

Copyright 2001 General Motors Corp. 23


4000 MH/HD 4000/B 500 SERIES ON-HIGHWAY SERVICE MANUAL
2. Scroll (down) the Diagnostic Data List to OIL 27. COLD CHECK (Figure 21)
LVL display.

3. Read the fluid level. Repeat to confirm the first CAUTION:


reading. DO NOT start the engine until the presence of
sufficient transmission fluid has been confirmed.
An Invalid for Display condition is indicated by a Remove the transmission fluid dipstick and be
message on the DDR. (Reasons for Invalid For sure the static fluid level is near the HOT FULL
Display are the same as those in the chart in Paragraph mark.
24 above under Cause Of Code.)

a. Purpose. The purpose of the cold check is to


26. MANUAL FLUID LEVEL determine if the transmission has enough fluid to be
operated safely until a hot check can be made.
CHECK PROCEDURE
b. Cold Check Procedure
WARNING! 1. Park the vehicle on a level surface, chock the
If you leave the vehicle and the engine is running, wheels, and apply the parking brake.
the vehicle can move suddenly and you or others
could be injured. If you must leave the engine 2. Run the engine at idle for at least one minute
running, do not leave the vehicle until you: with the transmission in N (Neutral). Shift to
Put the transmission in N (Neutral)and D (Drive), then shift to R (Reverse) to clear
Apply the parking brake and emergency the hydraulic system of air. Then, shift to
brakes and make sure they are properly en- N (Neutral) and allow the engine to idle
gagedand (500800 rpm).
Chock the wheels and take any other steps
necessary to keep the vehicle from moving. 3. With the engine running, remove the dipstick
from the tube and wipe clean.

a. Preparation. Clean all dirt from around the end 4. Insert the dipstick into the tube and remove.
of the fluid fill tube before removing the dipstick. Do Check the fluid level. Repeat the check
not allow dirt or foreign matter to enter the procedure to verify the reading.
transmission. Dirt or foreign matter in the hydraulic
system may clog passages and cause undue
5. If the fluid level is within the COLD RUN
transmission part wear or sticking valves.
band, the transmission can be operated until
the fluid is hot enough to perform a HOT
b. Consistency of Readings. Always check the fluid RUN check. If the fluid level is not within the
level reading at least twice using the following COLD RUN band, add or drain as necessary
procedure. Consistency (repeatable readings) is to bring the fluid level to the middle of the
important to maintaining proper fluid level. If COLD RUN band.
inconsistent readings persist, check the transmission
breather to be sure it is not clogged. If readings are 6. Perform a hot check at the first opportunity
still inconsistent, contact your nearest Allison after normal operating temperature is reached
distributor or dealer. 7193C (160200F).

24 Copyright 2001 General Motors Corp.


PREVENTIVE MAINTENANCE
a. Procedure
Calibration level marking
locations with respect to FILL 1. Operate the transmission in D (Drive) range
transmission control module TUBE until normal operating temperature is reached:
split line and fill tube
SCALE NONE Sump temperature

FULL
HOT
7193C (160200F)
Converter-out temperature
DIMENSION A
SEE CHART 82104C (180220F)

ADD
HOT
BELOW 132.6 mm
(5.22 in.) If a transmission temperature gauge is not
DIMENSION B

COLD
FULL
present, check fluid level when the engine
DIMENSION C water temperature gauge has stabilized and the

COLD
ADD
transmission has been operated under load for
at least one hour.
13.8 mm (0.54 in.) REFERENCE DIMENSION D
TRANSMISSION DETERMINED BY 2. Park the vehicle on a level surface and shift to
CONTROL MODULE INSTALLATION
N (Neutral). Apply the parking brake and
SPLIT LINE
chock the wheels. Allow the engine to idle
DIMENSION DIMENSION DIMENSION (500800 rpm).
A B C
106.7 mm 76.2 mm 66.0 mm
(4.20 in.) (3.00 in.) (2.60 in.)
V02511 3. With the engine running, remove the dipstick
from the tube and wipe clean.

Figure 21. Fluid Dipstick Markings 4. Insert the dipstick into the tube and remove.
Check fluid level. Repeat the check procedure
to verify the reading.
28. HOT CHECK (Figure 21) 5. If the fluid level is not within the HOT RUN
band, add or drain as necessary to bring the
fluid level within the band. Safe operating level
WARNING!
is within the HOT RUN band on the dipstick
If you leave the vehicle and the engine is running, (refer to Figure 21).
the vehicle can move suddenly and you or others
could be injured. If you must leave the engine
running, do not leave the vehicle until you:
29. KEEPING FLUID CLEAN
Put the transmission in N (Neutral)and
Apply the parking brake and emergency
brakes and make sure they are properly en- CAUTION:
gagedand Containers or fillers that have been used for
Chock the wheels and take any other steps antifreeze or engine coolant solution must
necessary to keep the vehicle from moving. NEVER be used for transmission fluid.
Antifreeze and coolant solutions contain ethylene
glycol which, if put into the transmission, can
cause clutch plate failure.
CAUTION:
An accurate fluid level check cannot be made
unless the engine is idling (500800 rpm) in a. Foreign Material. Prevent foreign material from
N (Neutral), the transmission fluid is at the entering the transmission by using clean containers,
proper temperature, and the vehicle is on a level fillers, etc. Lay the dipstick in a clean place while
surface. filling the transmission.

Copyright 2001 General Motors Corp. 25


4000 MH/HD 4000/B 500 SERIES ON-HIGHWAY SERVICE MANUAL
210. FLUID RECOMMENDATIONS Table 21. Transmission Fluid Preheating
Requirements
a. Fluid Type
(Ambient Temperature Below
1. The hydraulic fluids (oils) used in Allison Which Preheat Is Required)
transmissions directly affect transmission Viscosity Grade
performance, reliability, and durability. Celsius Fahrenheit
Recommended fluids for HD/B 500 applications
SAE 0W-20* or 37 35
are TranSyndTM and DEXRON-III. Type C-4
TranSyndTM
fluids are also approved.
DEXRON-III 32 25
2. Some DEXRON-III fluids are also qualified as
Type C-4 fluids. To ensure the fluid is qualified SAE 10W 20 4
for use in Allison transmissions, check for a
DEXRON-III or Type C-4 fluid license, or SAE 15W-40W 15 5
approval numbers on the fluid container, or SAE 30W 0 32
consult the lubricant manufacturer. Fluid types
such as Type F, and universal farm fluids may SAE 40W 10 50
or may not be properly qualified to use in your
Allison transmission. Consult your Allison * Arctic as defined by MIL-PRF-46167B
(was MIL-L-46167)
Transmission dealer or distributor before using
any fluid types except those fluids qualified for
use in Allison transmissions.
211. FLUID AND FILTER
CAUTION: CHANGE INTERVALS
Disregarding minimum fluid temperature limits
can result in transmission malfunction or
reduced transmission life. CAUTION:
Transmission fluid and filter change frequency is
3. When choosing the optimum viscosity grade of determined by the severity of transmission
fluid to use, duty cycle, preheat capabilities, service. More frequent changes may be necessary
and/or geographical location must be taken than recommended in the general guidelines
into consideration. Table 21 lists the when operating conditions create high levels of
contamination or overheating.
minimum fluid temperatures at which the
transmission may be safely operated. Preheat
with auxiliary heating equipment or by running
the equipment or vehicle with the transmission a. Fluid and Filter Changes. Table 22 is given
in N (Neutral) for a minimum of 20 minutes only as a general guide for fluid and filter change
before attempting range operation. interval.

26 Copyright 2001 General Motors Corp.


Table 22. Transmission Fluid and Filter Change
Schedule 1. Recommended Fluid and Filter Change Intervals (Non-TranSynd/Non-TES 295 Fluid)
SEVERE VOCATION GENERAL VOCATION
Filters Filters
Fluid Main Internal Lube/Auxiliary Fluid Main Internal Lube/Auxiliary
19300 km 19300 km Overhaul 19300 km 40200 km 40200 km Overhaul 40200 km
(12,000 Miles) (12,000 Miles) (12,000 Miles) (25,000 Miles) (25,000 Miles) (25,000 Miles)
6 Months 6 Months 6 Months 12 Months 12 Months 12 Months
500 Hours 500 Hours 500 Hours 1000 Hours 1000 Hours 1000 Hours
NOTE: The following recommendations in Schedule 2 are based upon the transmission containing 100% of TranSynd
fluid. For transmissions that contain a mixture of TranSynd and non-TranSynd fluids, refer to Schedule 3.
WT Filter change intervals in Schedule 2 are only valid with the use of Allison Transmission supplied filters.
Flushing Machines are not recommended or recognized due to variation and inconsistencies with ensuring removal of
100% of the used fluid. Recommendations in Schedule 2 are based upon standard Allison fluid change procedures.
Schedule 2. Recommended Fluid and Filter Change Intervals (TranSynd/TES 295 Fluid)
80400 km 80400 km Overhaul 80400 km 160900 km 80400 km Overhaul 80400 km
(50,000 Miles) (50,000 Miles) (50,000 Miles) (100,000 Miles) (50,000 Miles) (50,000 Miles)
24 Months 24 Months 24 Months 48 Months 24 Months 24 Months
2000 Hours 2000 Hours 2000 Hours 4000 Hours 2000 Hours 2000 Hours
NOTE: WT Filter change intervals in Schedule 3 are only valid with the use of Allison Transmission supplied filters.
Schedule 3. Modified Fluid and Filter Change Intervals With a Mixture* of TranSynd and Non-TranSynd Fluids
40200 km 40200 km Overhaul 40200 km 80400 km 40200 km Overhaul 80400 km

Copyright 2001 General Motors Corp.


( 25,000 Miles) (25,000 Miles) (25,000 Miles) (50,000 Miles) (25,000 Miles) (50,000 Miles)
12 Months 12 Months 12 Months 24 Months 12 Months 24 Months
PREVENTIVE MAINTENANCE

1000 Hours 1000 Hours 1000 Hours 2000 Hours 1000 Hours 2000 Hours
* Mixture is defined as the quantity of oil remaining in the transmission after a standard fluid change combined with the quantity of TranSynd that is
required to fill the transmission to the proper level. A mixture of TranSynd or TES 295 equivalent vs. non-TranSynd other than as defined in this
paragraph does not meet the requirements that permit the eligibility for the recommendations given in Schedule 3.
NOTE: Change fluid/filters after recommended mileage, months, or hours have elapsed, whichever occurs first.
Severe Vocation: All Retarders, On/Off Highway, Refuse, Transit, and Intercity Coach with duty cycle greater than one (1) stop per mile.
General Vocation: Intercity Coach with duty cycle less than or equal to one (1) stop per mile and all other vocations.
Local conditions, severity of operation or duty cycle may require more or less frequent fluid change intervals that differ from the
published recommended fluid change intervals of Allison Transmission. Transmission protection and fluid change intervals can be optimized
by the use of fluid analysis.

27
4000 MH/HD 4000/B 500 SERIES ON-HIGHWAY SERVICE MANUAL
b. Fluid Analysis. Transmission protection and fluid serious damage. The transmission must be completely
change intervals can be optimized by monitor- disassembled, inspected, and cleaned. Remove all
ing fluid oxidation according to the tests and traces of the coolant and varnish deposits resulting
limits shown in Table 23. Consult your local from engine coolant contamination. Replace friction
telephone directory for fluid analysis firms. To clutch plates contaminated with engine coolant.
ensure consistent and accurate fluid analysis,
c. Metal
use only one fluid analysis firm. Refer to the
Technicians Guide for Automatic Transmission
Fluid, GN2055, for additional information. CAUTION:
Table 23. Fluid Oxidation Measurement Limits If excessive metal contamination has occurred,
replace the oil cooler and visually inspect all
Test Limit bearings in the transmission.
Viscosity 25% change from new fluid
Total Acid Number +3.0* change from new fluid Metal particles in the fluid (except for the minute
particles normally trapped in the oil filter) may
Solids 2% by volume maximum
indicate internal transmission damage. When these
* mg of KOH to neutralize a g of fluid. particles are found in the sump, the transmission must
be disassembled and closely inspected to find the
source. Metal contamination requires complete
CAUTION: transmission disassembly. Clean all internal and
Contaminated fluid can leave the oil cooler external hydraulic circuits, cooler, and all other areas
contaminated. The cleanliness of the oil cooler where the particles could lodge.
affects the cleanliness of the transmission fluid. If
there is any doubt about the cleanliness of the 213. FLUID AND FILTER
cooler, replace the cooler. CHANGE PROCEDURE

212. FLUID CONTAMINATION NOTE:


If only filters are being replaced, do not drain the
a. Water fluid.
1. At each fluid change, examine the drained fluid
for evidence of dirt or water. A normal amount a. Drain Fluid
of condensation will appear in the fluid during
operation.
WARNING!
2. Obvious water contamination of the Avoid contact with the hot fluid or the sump
transmission fluid requires inspecting and when draining transmission fluid. Direct contact
pressure testing the cooler (heat exchanger) for with the hot fluid or the hot sump may result in
leaks between the water and fluid areas. bodily injury.
Transmission fluid in the water side of the
cooler (heat exchanger) is another sign of a leak.
1. Drain the transmission when the fluid is at
operating temperature 7193C (160200F).
NOTE: Hot fluid flows quicker and drains more
Cooler water can also be contaminated by engine completely.
oil, be sure to locate the correct source of cooler
water contamination. 2. Remove the drain plug from the control
module and allow the fluid to drain into a
suitable container.
b. Engine Coolant. Engine coolant (ethylene
glycol) in the transmission hydraulic system requires 3. Examine the fluid as described in
immediate action to prevent malfunction and possible Paragraph 212.

28 Copyright 2001 General Motors Corp.


PREVENTIVE MAINTENANCE
b. Replace Filters (Figure 22) 4. When reinstalling parts on units beginning
with S/N 6610009730, lubricate and install
new O-rings 6 and 7 on each cover 4. Lubricate
CAUTION: O-ring inside filter 1 and push filter onto each
Do not interchange filters for the deep and cover 4. Install new gasket 8 on each cover 4
shallow sump. Installation of the wrong filter can and align holes in gasket with holes in cover.
cause damage to the transmission.

CAUTION:
1. To replace the oil filters on units prior to
Do not use the bolts to draw filter covers to the
S/N 6610009730, remove twelve bolts 5, two sump. This can damage the covers, seals, or sump.
filter covers 4, two O-rings 2, two square cut
seals 3, and two filters 1 from the bottom of the
control module. 5. Install filter 1 and cover 4 assemblies into the
2. To replace the oil filters on units beginning filter compartment. Index each filter/cover
with S/N 6610009730, remove twelve bolts 5, assembly to the holes in the channel plate/
two filter covers 4, two gaskets 8, two sump. Push the filter/cover assemblies in by
O-rings 7, two O-rings 6, and two filters 1 from hand to seat the seals.
the bottom of the control module.
6. Install six bolts 5 into each cover 4 and tighten
3. When reinstalling parts on units prior to them to 5161 Nm (3845 lb ft).
S/N 6610009730, lubricate and install an
O-ring 2 on each cover 4. Install a square cut c. Refill Transmission
seal 3 on each cover 4. Lubricate filter O-ring
and install filters 1 onto covers 4.
NOTE:
For units prior to S/N 6610027897, when the drain
plug cannot be properly tightened due to channel
plate thread damage, take the following corrective
action:

LUBE
MAIN Rotate the original plug until all remaining
threads in the channel plate are removed.
Remove the drain plug and any residual alu-
minum particles. Use caution to prevent any
loose particles from entering the channel
plate.
Install a new longer drain plug (see Parts
Catalog PC2456EN) using a mechanical
ratchet, ensuring the plug is straight in the
9 11 bore.
1 10
2 Remove the plug and clean any aluminum
PRIOR TO 6
S/N 6610009730 3 7 particles from the plug and the bore. Reinstall
8 the new plug and O-ring. Tighten the plug to
4 STARTING WITH
5 LUBE S/N 6610009730 2532 Nm (1824 lb ft).
MAIN
V06833 If the longer drain plug will not tighten, see
Paragraph 518f for channel plate rework
procedure.
Figure 22. Filter Change

Copyright 2001 General Motors Corp. 29


4000 MH/HD 4000/B 500 SERIES ON-HIGHWAY SERVICE MANUAL
1. If removed, inspect the drain plug. Replace the stem and produce metal chips which could
O-ring. Install the drain plug and tighten it to enter the transmission.
2532 Nm (1824 lb ft).

2. After refill, check the fluid level (refer to 215. TRANSMISSION STALL TEST
Paragraphs 26 through 28). The quantity of AND NEUTRAL COOL-DOWN
refill fluid will be less than the initial fill due to
fluid remaining in the external circuits and
CHECK
transmission cavities. Table 24 shows typical
initial fill quantities. a. Purpose
1. Use the stall test to determine if poor vehicle
Table 24. Transmission Fluid Capacity performance is due to the engine or the
transmission.
Item Being Filled Initial Fill*
4000 MH/ 4.00 inch Sump 48.0 liters 2. Determine the maximum engine speed attained
HD 4000/B 500 PTO Provision 51.0 quarts with the engine at full throttle and the torque
4000 MH/ 4.00 inch Sump 45.0 liters converter turbine not moving or stalled.
HD 4000/B 500 No PTO Provision 48.0 quarts
4000 MH/ 2.00 inch Sump 41.0 liters 3. Compare the engine speed from the stall test to
HD 4000/B 500 PTO Provision 43.0 quarts the value established from engine
4000 MH/ 2.00 inch Sump 38.0 liters manufacturers specifications.
HD 4000/B 500 No PTO Provision 40.0 quarts
Additional Fill For Cooler* NOTE:
Direct-mount Non-retarder 1.0 liter Engine stall point data can be obtained from the
1.1 quart engine manufacturer or from the equipment dealer
Additional Fill For Retarder Accumulator* or distributor.
Remote Accumulator 0.6 liter
0.6 quart 4. Use stall checks for troubleshooting only. Do
* Does not include hoses or fittings. not use stall checks as part of routine or
preventive maintenance.

214. BREATHER 5. Use the neutral cool-down check for


troubleshooting the cooling circuit
a. Location and Purpose. The breather is located performance following the stall test.
on top of the transmission converter housing. It serves
to prevent air pressure buildup within the transmission
b. Stall Testing Preparation
and must be kept clean and open.
1. Make sure the fuel control linkage goes to full
b. Maintenance throttle and does not stick when released.
1. The amount of dust and dirt encountered will
determine the frequency of breather cleaning. 2. Check the air induction system for restrictions.
Use care when cleaning the transmission
exterior. Spraying steam, water, or cleaning 3. Perform a cold check of the transmission fluid
solution directly at the breather can force the level and adjust as necessary.
water or cleaning solution into the
transmission. 4. Install an accurate tachometer (do not rely on
the vehicle tachometer).
2. Always use a wrench of the proper size to
remove or replace the breather. Pliers or a pipe 5. Install a temperature gauge with the probe in
wrench can crush or damage the breathers the transmission converter-out (to cooler) line.

210 Copyright 2001 General Motors Corp.


PREVENTIVE MAINTENANCE
2. Shift to D (Drive).
WARNING!
DO NOT conduct a converter stall test until the 3. Slowly accelerate to full throttle.
following actions are taken. The parking brake
and/or emergency brakes must be set and 4. When the tachometer levels off, record the
properly engaged and the wheels must be maximum engine rpm attained.
chocked. Warn personnel to keep clear of the
vehicle and its travel path. Failure to do so can 5. Slowly release the throttle.
cause serious injury.
6. Shift to N (Neutral).
6. Start the engine and let the transmission sump
7. Skip Paragraph d and e and proceed
warm to normal operating temperature (7193C;
immediately with Paragraph f, Neutral Cool-
160200F).
Down Check Procedure.
7. Perform a hot check of the transmission fluid
level and adjust as necessary. d. Stall Test Procedures With Pro-Link

8. Turn all engine accessories off.


NOTE:
The Pro-Link can be used to select a specific
CAUTION: range while the vehicle is not moving. This al-
Fluid temperature rises rapidly during a stall lows a higher range to be used for stall testing,
test. Never maintain the stall condition for more lowering the possibility of damage due to ex-
than 30 seconds at any one time. Do not let the cessive output torque.
converter-out fluid temperature exceed 149C The Pro-Link can also be used to monitor
(300F). Use a converter-out fluid temperature
sump temperature and engine rpm.
gauge to limit the length of the stall condition. If
the stall test is repeated, do not let the engine
overheat. 1. Plug the Pro-Link into the DDR connector.

2. Scroll through the Pro-Link menus to Action


Requests and select Clutch Test.
NOTE:
For vehicles with engines equipped with 3. Apply the vehicle parking and service brakes,
smoke controls, skip to Paragraph e. and chock the wheels. Warn all personnel to
For vehicles with engines not equipped with keep clear of the vehicle.
smoke controls, go to the next note.
4. Place the shift selector in fourth range.

5. Once fourth range is attained, slowly


NOTE: accelerate to full throttle. Use the Pro-Link to
If Pro-Link (J 38538) diagnostic tool is not monitor engine rpm.
available, proceed with Paragraph c.
6. When the Pro-Link tachometer levels off,
If Pro-Link (J 38538) diagnostic tool is avail- record maximum rpm attained.
able, skip Paragraph c, and proceed with
Paragraph d. 7. Slowly release the throttle.

8. Place the shift selector in N (Neutral).


c. Stall Test Procedures Without Pro-Link
1. Apply the vehicle parking and service brakes, 9. Skip Paragraph e and proceed immediately
and chock the wheels. Warn all personnel to with Paragraph f, Neutral Cool-Down Check
keep clear of the vehicle. Procedure.

Copyright 2001 General Motors Corp. 211


4000 MH/HD 4000/B 500 SERIES ON-HIGHWAY SERVICE MANUAL
e. Stall Test Procedures Smoke-Controlled g. Stall Test Results
Engines

NOTE:
NOTE:
Environmental conditions, such as ambient
Because smoke controls and throttle-delay temperature, altitude, and engine accessory loss
mechanisms inhibit engine acceleration, the stall variations, affect the power input to the converter.
testing will need to be started while the vehicle is Under such conditions, stall speed can vary from
moving. specification by 150 rpm and still be accepted as
within normal range.

1. Locate an isolated area to perform the driving


stall test. 1. An engine stall speed of 150 rpm or more
below the stall speed specification, indicates an
2. Select a hold range that will limit road speed, engine problem. An engine stall speed of 150
usually second or third range. Do not use first rpm or more above stall speed specification
range where output torque is higher. indicates a transmission problem. Possible
transmission problems include slipping
3. Operate the engine at full throttle, maximum clutches, improper fluid level causing
governed rpm in the chosen range. cavitation, or torque converter failure.

4. Slowly depress the vehicle service brakes 2. An extremely low stall speed (such as 33
while staying at full throttle. percent of the specified engine stall rpm),
during which the engine does not smoke, may
5. When the vehicle comes to a stop, record the indicate a freewheeling torque converter stator.
engine rpm this is stall speed.
3. If the fluid does not cool during the two minute
6. Proceed immediately with Paragraph f, Neutral cool-down check, a stuck stator may be the
Cool-Down Check Procedure. source of the problem.

f. Neutral Cool-Down Check Procedure 4. If the engine stall speed meets the specification
and the cool-down check shows that
1. The neutral cool-down check determines if the transmission fluid cools properly, refer to the
transmission fluid cools properly following an Allison Transmission Electronic Control
engine load condition. Perform this check Troubleshooting Manual (TS2470EN for
immediately after the engine speed has been WTEC II or TS2973EN for WTEC III).
recorded in the stall test.

2. Record the converter-out fluid temperature.


216. CHECKING CLUTCH
3. With the transmission remaining in PRESSURES
N (Neutral), run the engine at 12001500 rpm
for two minutes to cool the fluid. a. Purpose. Checking individual clutch pressures
helps to determine if a transmission malfunction is due
4. At the end of two minutes, record the converter- to a mechanical or an electrical problem. Properly
out fluid temperature. Converter-out fluid making these pressure checks requires transmission
temperature should return to within the normal and vehicle (or test stand) preparation, recording of
operating temperature range (82104C or data, and comparing recorded data against
180220F). specifications provided.

212 Copyright 2001 General Motors Corp.


PREVENTIVE MAINTENANCE
3. Be sure that transmission sump fluid
NOTE: temperature can be measured. (Pro-Link 9000
Check to see if there are diagnostic codes set that diagnostic tool may be used for this purpose.)
are related to the transmission difficulty you are 4. Be sure that the transmission has enough fluid
evaluating. Proceed to make mechanical for cold operation until an operating
preparations for checking clutch pressures only temperature fluid level can be set.
after codes have first been evaluated.
5. Bring the transmission to normal operating
temperature of 7193C (160200F). Check
b. Transmission and Vehicle Preparation for fluid leaks in the circuits being checked.
Repair leaks as needed. Be sure that fluid level
is correct.
CAUTION:
Be sure that the hydraulic fittings have the same c. Recording Data
thread as the plugs removed (716-20 UNF-2A). 1. Use the Pro-Link 9000 diagnostic tool, which
Also please note that these fittings must be allows checking of individual range clutch
straight thread, O-ring style. Failure to do this
pressures, with the vehicle stationary. Consult
will result in damage to the control module.
the Pro-Link 9000 operating instructions for
Action Requests and select Clutch Test. Follow
1. Remove the plug from the pressure tap and instructions to check clutch pressures in
install a hydraulic fitting and a pressure gauge individual ranges.
or transducer at each location where
measurement is desired (refer to Figure 23 or NOTE:
Figure 24). Pressure gauge set J 26417-A is
Check lockup clutch pressure by driving the vehicle
available for this purpose. See Table 25 for
in a range where lockup can be obtained. Record the
pressure levels expected.
pressure values at the engine speed and sump fluid
temperature values shown in Table 25. The lockup
2. Provide for engine speed to be monitored. clutch is functioning correctly when engine speed
(Pro-Link 9000 diagnostic tool may be used and turbine speed values are equal as recorded
for this purpose.) from the Pro-Link 9000.

HD/B 500 2. Operate the transmission at the conditions


C3 shown in Table 25 and record engine speed,
C5 transmission sump fluid temperature, main
pressure, and clutch pressures in the ranges
where a problem is suspected.

d. Comparing Recorded Data to Specifications


1. Be sure that engine speed and transmission
sump fluid temperatures were within the values
specified in Table 25.

2. Compare the main pressure and clutch pressure


MAIN
LU
C2
data, recorded in Step B, with the
C4 specifications in Table 25.
C1
3. If clutch pressures are within specifications,
V01752
return the transmission and vehicle to their
original configuration and proceed with
Figure 23. Clutch Pressure Check Points electrical troubleshooting.

Copyright 2001 General Motors Corp. 213


4000 MH/HD 4000/B 500 SERIES ON-HIGHWAY SERVICE MANUAL

LOCKUP
PRESSURE TAP
C6 PRESSURE TAP
(On left side of
adapter housing,
near the bottom)
MAIN
C5
C4
C3

C1 C2
MAIN

LUBE

DRAIN PLUG

OIL FILTER
COVERS LUBE PRESSURE CLUTCH PRESSURE
TAP TAPS
V05596

Figure 24. HD 4070 Clutch Pressure Check Points

4. If clutch pressures are not within specification, 6. Return the transmission to its original
take corrective action to replace the internal configuration. (Remove instrumentation and
parts of the transmission necessary to correct
reinstall any components removed for the
the problem.
pressure testing.)
5. Recheck pressure values after the transmission
has been repaired.

214 Copyright 2001 General Motors Corp.


Table 25. Main Pressure and Clutch Pressure Specifications
(Sump Fluid Temperature 7193C; 160200F)

Main Press. Range Clutch Conv. Out Lube LU Clutch


Transmission Clutches Spec Press. Spec* Press. Spec Press. Spec Press. Spec*
Model/Test Type Engine rpm Range Applied kPa [psi] kPa [psi] kPa [psi] kPa [psi] kPa [psi]
HD Idle 580620 Neutral C5 15002200 040 (C5)
[218319] [05.8]
Reverse C3 C5 15002200 040 (C3 And C5) 3.5 min.
[218319] [05.8] [0.5 min.]

PREVENTIVE MAINTENANCE
1C C1 C5 13001800 070 [010] (C1) 3.5 min.
[189261] 040 [05.8] (C5) [0.5 min.]
Copyright 2001 General Motors Corp.

2C C1 C4 13001800 070 [010] (C1) 3.5 min.


[189261] 040 [05.8] (C4) [0.5 min.]
HD High Speed 17801820 Neutral C5 18002200 040 (C5) 75300 50190
[261319] [05.8] [1144] [728]
Reverse C3 C5 18002200 040 (C3 And C5) 170300 120190
[261319] [05.8] [2544] [1728]
LowC** C1 C6 15501800 070 [010] (C1) 170300 120190
[225261] 040 [05.8] (C6) [2544] [1728]
1C C1 C5 15501800 070 (C1) [010] 170300 120190
[225261] 040 (C5) [05.8] [2544] [1728]
2C C1 C4 15501800 070 [010] (C1) 170300 120190
[225261] 040 [05.8] (C4) [2544] [1728]
2L C1 C4 LU 10501400 070 [010] (C1) 200350 140190 570
[152203] 040 [05.8] (C4) [2951] [2028] [0.710]
3C C1 C3 15501800 070 [010] (C1) 310410 150190
[225261] 040 [05.8] (C3) [4560] [2228]
* Subtract clutch pressure from main pressure; the difference must fall within the specifications given
** HD 4070 Only.
215
Table 25. Main Pressure and Clutch Pressure Specifications
216

(Sump Fluid Temperature 7193C; 160200F) (contd)

4000 MH/HD 4000/B 500 SERIES ON-HIGHWAY SERVICE MANUAL


Main Press. Range Clutch Conv. Out Lube LU Clutch
Transmission Clutches Spec Press. Spec* Press. Spec Press. Spec Press. Spec*
Model/Test Type Engine rpm Range Applied kPa [psi] kPa [psi] kPa [psi] kPa [psi] kPa [psi]
HD High Speed 17801820 3L C1 C3 LU 10501400 070 [010] (C1) 200350 140190 570
(contd) [152203] 040 [05.8] (C3) [2951] [2028] [0.710]
4C C1 C2 15501800 070 [010] (C1) 310410 150190
[225261] 070 [010] (C2) [4560] [2228]
4L C1 C2 LU 10501400 070 [010] (C1) 160300 110150 570
[152203] 070 [010] (C2) [2344] [1622] [0.710]
Copyright 2001 General Motors Corp.

HD High Speed 17801820 5C C2 C3 15501690 070 [010] (C2) 310410 150190


[225245] 040 [05.8] (C3) [4560] [2228]
5L C2 C3 LU 9001250 070 [010] (C2) 160300 110150 570
[131181] 040 [05.8] (C3) [2344] [1622] [0.710]
6C C2 C4 15501690 070 [010] (C2) 310410 150190
[225245] 040 [05.8] (C4) [4560] [2228]
6L C2 C4 LU 9001250 070 [010] (C2) 160300 110150 570
[131181] 040 [05.8] (C4) [2344] [1622] [0.710]
* Subtract clutch pressure from main pressure; the difference must fall within the specifications given
PREVENTIVE MAINTENANCE
217. FLUID LEAK DIAGNOSIS 1. Pour the specified amount of dye into the
transmission fill tube.
Most fluid leaks can be located and repaired by
visually finding the leak and replacing or repairing the 2. Operate the vehicle under normal operating
necessary parts. On some occasions, a fluid leak may conditions as directed in the kit.
be difficult to locate or repair. The following procedure
may help in locating and repairing most leaks. 3. Direct the black light toward the suspected
area. The dyed fluid will appear as a brightly
a. Finding the Leak colored path leading to the source.
1. Identify the fluid. Determine whether it is
d. Possible Points of Fluid Leaks
engine oil, automatic transmission fluid, or
and Their Causes
hydraulic fluid from a specific vehicle system.

2. Operate the vehicle to reach normal operating 1. Transmission mating surfaces:


temperature and park the vehicle. After a few
Bolts improperly tightened
minutes, look for dripping fluid to identify the
approximate location of the leak. Improperly installed or damaged gasket

3. Visually check around the suspected area. Mounting face damaged


Inspect all gasket mating surfaces for leaks. A
mirror is useful for finding leaks in areas that 2. Housing:
are hard to reach. Filler pipe seal damaged or missing
4. If the leak still cannot be found, clean the Filler pipe bracket dislocated
suspected area with a degreaser, steam, or
Oil cooler connector fittings loose or
spray solvent. Completely clean and dry the
damaged
area. Operate the vehicle for several miles at
normal operating temperature and varying Output shaft seals worn or damaged
speeds. After operating, visually check the
Pressure port plugs loose
suspected leak area. If the leak is not located,
use the powder or black light and dye methods. Porous casting

b. Powder Method 3. Converter end:


1. Clean the suspected area.
Converter seal damaged
2. Apply an aerosol-type white powder, such as Seal lip cut (check converter hub for
foot powder, to the suspected area. damage)
3. Operate the vehicle under normal operating Garter spring missing from seal
conditions.
Converter leak in weld area or O-ring seal
4. Visually inspect the suspected area and trace Porous casting
the leak path over the white powder surface to
the source. 4. Breather or fill tube:
c. Black Light and Dye Method Overfilled incorrect dipstick
Plugged breather
NOTE:
A dye and black light kit is available for finding Water or coolant in fluid fluid will
leaks. Refer to the manufacturers directions when appear milky
using the kit. See kit directions for the color of the Incorrect electronic fluid level indication
fluid and dye mix.
Drain-back holes plugged

Copyright 2001 General Motors Corp. 217


4000 MH/HD 4000/B 500 SERIES ON-HIGHWAY SERVICE MANUAL
5. Gaskets: e. Repairing the Leak. Once the leak has been
Fluid level/pressure is too high
located and traced to its source, repair the leaking
components. If a gasket is replaced, but the sealing
Plugged vent or drain-back holes flange is bent, the new gasket will not repair the leak.
Improperly tightened fasteners or dirty/ The bent flange must also be repaired.
damaged threads
Warped flanges or sealing surface 218. OUTPUT FLANGE/YOKE AND
Scratches, burrs, or other damage to a OIL SEAL MAINTENANCE (All
sealing surface Models Except HD 4070/4076)
Damaged or worn gasket
a. Disassembly (Figure 25)
Cracked or porous casting
Improper sealant used (where applicable)
1. Bend down tabs of locktab 9, if present, and
loosen two bolts 10, two bolts 11, or one bolt 8.
6. Seals:
2. Remove two bolts 10 and locktab 9 or two
Fluid level/pressure is too high bolts 11 and two belleville washers 12 or one
Plugged vent or drain-back holes bolt 8. Discard locktab 9 and bolts 10, bolts 11
and washers 12, or bolt 8.
Damaged seal bore
Damaged or worn seal 3. Remove flange 2 or yoke 3. Remove two
O-rings 5, retainer plug 6, and O-ring 4 or one
Improper installation
O-ring 5, retainer plug 7, and O-ring 4.
Cracks in component
Output shaft surface scratched, nicked or
4. Inspect journal sealing area. Minimum journal
damaged area diameter is 85 mm (3.346 inch).

Loose or worn bearing causing excess seal 5. Remove oil seal 1 using tool J 24171-A or
wear equivalent.

1 7
8
4
3
5
6
9
10

12
11

V06834

Figure 25. Output Flange and Oil Seal

218 Copyright 2001 General Motors Corp.


PREVENTIVE MAINTENANCE
b. Assembly (Figure 25)
BELLEVILLE
1. Install oil seal 1 using installer J 37031 and WASHER
J 8092 or equivalent.
2. Install flange 2 or yoke 3.
3. Install O-ring 4 on plug 6 or 7. Lubricate the
O-ring. BOLT

NOTE:
V05151.02
Bolts 11 and washers 12 are available in Service
Bolt Kit P/N 29535910 as described in Figure 26. Installing Redesigned Two-Bolt
SIL 15-WT-98. The convex end of belleville washer Flange Retention Kit
12 MUST contact the head of bolt 11 as shown in
Figure 26. DO NOT use locktab 9 with washer 12 219. OUTPUT FLANGE/YOKE AND
and bolt 11. OIL SEAL MAINTENANCE
(HD 4070/4076 Models Only)
4. Insert two bolts 11 through belleville a. Disassembly (Figure 27)
washers 12 and retainer plug 6 or one bolt 8
through plug 7. 1. Remove one bolt 6, O-ring 4, retainer plug 5,
and O-ring 3.
5. Install an O-ring 5 over the threaded end of
each bolt 11 or 8 so that the O-ring seats 2. Remove flange 2 or yoke 7. Inspect journal
against the retainer plug. sealing area. Minimum journal area diameter is
6. Install retainer plug 6 or 7 into the yoke or flange. 85 mm (3.346 inch).
Tighten bolts 11 to 3035 Nm (2226 lb ft). 3. Remove oil seal 1 using tool J 24171-A or
Tighten bolt 8 to 7080 Nm (5160 lb ft). equivalent.

;;;;;;;;;;;
;;;;;;;;;;;
;;;;;;;;;;;
;;;;;;;;;;;
;;;;;;;;;;;
;;;;;;;;;;; 2

;;;;;;;;;;;
;;;;;;;;;;;
1

;;;;;;;;;;;
;;;;;;;;;;;
7

3
4 5
6

V05578

Figure 27. Output Flange and Oil Seal (HD 4070/4076 Models)

Copyright 2001 General Motors Corp. 219


4000 MH/HD 4000/B 500 SERIES ON-HIGHWAY SERVICE MANUAL
b. Assembly (Figure 27) 220. ON-VEHICLE MAINTENANCE
1. Install oil seal 1 using installer J 37031 and
The following may be serviced or removed with the
J 8092 or equivalent.
transmission mounted in the vehicle. Refer to the
2. Install flange 2 or yoke 7. indicated paragraph for removal instructions:

3. Install O-ring 3 on plug 5.


Item Paragraph
4. Insert bolt 6 through retainer plug 5. PTO(s) 42b

5. Install an O-ring 4 over the threaded end of Oil Fill Tube 42c(2)
bolt 6 so that the O-ring seats against the Remote Mount Manifold 42c(3)
retainer plug. Input, Turbine, and
Output Speed Sensor 42c(8)
6. Install retainer plug 5 into the yoke or flange.
Tighten bolt 6 to 7080 Nm (5160 lb ft). Control Module 42e

220 Copyright 2001 General Motors Corp.


Section 3 GENERAL OVERHAUL INFORMATION
31. SCOPE Snapring (retaining ring) pliers
This section provides general information for Micrometer (metric preferred)
transmission overhaul. The information provided Depth micrometer (metric preferred)
includes: Dial indicator set (metric preferred)
Metric headless guide bolts set
Tools and equipment required for overhaul
M16 eye bolt
Replacement parts information
M10 eye bolt
Cleanliness and careful handling
Suitable hoist 900 kg (2000 lb) capacity
Cleaning and inspection
A 20 Nm (150 in. lb) torque wrench
Assembly procedures
A 500 Nm (350 lb ft) torque wrench
Transmission removal and installation
Clean, lint-free shop cloths (do not use waste
Locating wear data cloths)
Locating spring specifications A press for disassembly and assembly of
Locating torque specifications for plugs, bolts, spring-loaded clutches and interference-fit parts
and nuts Containers for parts
32. TOOLS AND EQUIPMENT Supply of wood blocks
a. Improvised Equipment. A work table 700 kg Petrolatum
(1500 pound) capacity (Figure 31) may be improvised. Container of mineral spirits for cleaning parts
b. Special Tools. Special tools are illustrated in
Figure 32 and Figure 33 and are identified in WARNING!
Table 31 and Table 32. Use appropriate safety equipment such as safety
glasses, safety shoes, and gloves.
c. Mechanics Tools and Shop Equipment. The
following tools, in addition to the common tools
ordinarily required, should be available. CAUTION;
Common hand tools, metric where required Caustic cleaning compounds will damage some
Metric wrench set (sockets, box-end wrenches, transmission parts. Use only mineral spirits to
and Allen wrenches) clean transmission parts.

120 cm
(48 INCHES)
200 cm
(78 INCHES) OIL DRAIN STEEL TOP

TROUGH
60 cm 16-GAUGE SHEET STEEL
(24 INCHES) 35 mm (1-1 2 INCH) DEEP
35 mm (1-1 2 INCH) WIDE
OIL DRAIN
(BOTH SIDES) 5x15 cm
(2x6 INCH BOARD)
FOR TOP FRAME
10x10 cm AND LEG BRACKETS
(4x4 INCH LEGS)
V00660

Figure 31. Work Table

Copyright 2001 General Motors Corp. 31


4000 MH/HD 4000/B 500 SERIES ON-HIGHWAY SERVICE MANUAL

1 5
2 3 4

11
7 9 10
8

14
12 13 15 16

17
18
19
20
23

24
26
21 22 25 27

28
29

NOTE: Objects are not shown to scale V06922

Figure 32. Special Tools

32 Copyright 2001 General Motors Corp.


GENERAL OVERHAUL INFORMATION
Table 31. 4000 MH/HD 4000/B 500 Special Tools*

Kent-Moore Figure 32 Reference


Tool No.** Item No. Description Paragraph
J 3940 1 Bearing Race Remover 514c,e,n; 516a,c
J 8092 2 Drive Handle 218b; 219b; 53b; 55e;
56b,c; 57b; 510b;
511b; 514g,p; 516e
J 24171-A 3 Seal Remover 218a; 55b; 56a;
514c,l; 516a
J 26417-A 29 Pressure Gauge Set 216b
J 29109 4 Overhaul Stand 42a; 62a
J 33163 5 Valve Body Parts Tray Set (includes 518a
J 33163-1 and J 33163-2)
J 33884 NA Pressure Switch Test Block 518b
J 35923-2 19 C1 Spring Compressor (use with J 37030-3) 57a,b; 513e
J 35924 7 Main-Pressure Spring Remover/Installer 518e,h
J 35926 24 Transmission Holding Bracket 42a; 62a
J 37030-1 17 C2 Spring Compressor (use with J 37030-3) 57a,b
J 37030-2 18 C5 Spring Compressor (use with J 37030-3) 514e,f; 516c,d
J 37030-3 20 C1, C2, and C5 Spring Compressor Tool Base 57a,b; 514e,f,n,o; 516c,d
J 37031 22 Output Seal Installer 218b; 219b; 62q,s
J 37032 9 Input Seal Installer 55e; 56c
J 37033 10 Output Bearing Cup Installer (use with J 37034) 514f,h,o,q; 516d
J 37034 15 Output Bearing Installer/Drive Sleeve 55e; 56b,c; 511d;
514f,g,h,o,p,q; 516d,e,f
J 37035 11 Spanner Nut Torque Tool Set 514c,h,l,q; 516a,f; 62q
J 37036 12 Turbine Shaft Bushing/Output Bushing/P2 57b; 511b; 514g,p;
Carrier Bushing Installer 516e
J 37038 21 P1 Carrier Bushing and Ground Sleeve Bearing, Pump 55e; 56b, c; 510b
Body Bushing, and Bearing Retainer Bushing Installer
J 37040 13 Rotating Clutch Bushing Installer 57b
J 37041 14 Front Support Sleeve and PTO Bearing Installer 55d; 56b
J 38548 27 Torque Converter End Play Gauge 53b; 62v
J 38564 25 Torque Converter Bolt Tool 42f; 62v
J 39534 26 Wear Plate Rivet Installer 58b
J 39949 8 Torque Converter Cover Bushing Installer 53b
J 39954 16 Charging Pump Bushing Installer 56c
J 41445 23 Transmission Holding Bracket 42a; 62a
J 41462 6 Main-Pressure Relief Spring Compressor 56a,b
J 42048 28 Retarder Flow Valve Spring Compressor 514c,h,l,q
* We believe this source and its tools to be reliable. These tools may be available from other manufacturers. General
Motors does not endorse, indicate any preference for, or assume any responsibility for the products or tools from these
firms, or for any such items that may be available from other sources.
** Kent-Moore Tool Division, 29784 Little Mack, Roseville, Michigan 48066

Copyright 2001 General Motors Corp. 33


4000 MH/HD 4000/B 500 SERIES ON-HIGHWAY SERVICE MANUAL

1
2 3 4

5 6
7 8

10
9 23

11

14

16 17
15
12

13

18 19
20

22
21

NOTE: Objects are not shown to scale V06923

Figure 33. HD 4070/4076 Special Tools

34 Copyright 2001 General Motors Corp.


GENERAL OVERHAUL INFORMATION
Table 32. HD 4070/4076 Special Tools*

Figure 33
Kent-Moore Item Reference
Tool No.** Number Description Paragraph
J 3940 1 Bearing Race Remover 515e,f,o,q; 517c
J 8092 2 Drive Handle 515i,t; 517e
J 24171-A 3 Seal Remover 219a; 515c,n; 517a
J 35923-4 11 Spring Compressor Tool Base 513d,e; 517d
J 35926-A 13 Transmission Lifting Bracket (Modified to lift 42a; 62a
HD 4070 models)
J 35926-UPD NA Modification Template (Used To Modify J 35926 to NA
become J 35926-A)
J 37030-2 10 C5 Spring Compressor 515f,q,r; 517c
J 37030-3 11 C1, C2, and C5 Spring Compressor Tool Base 515f,q,r; 517c
J 37032 4 Input Seal Installer 515g
J 37033 5 Output Bearing Cup Installer 515g,h,r,s; 517d
J 37034 9 Output Bearing Installer/Drive Sleeve 513d,e,f,r,s,t,u; 515g,h,i,j;
517d,e,f; 62r,t
J 37035 6 Spanner Nut Torque Tool Set 515c,j,n,u; 517a,f; 62r,s,t
J 37036 8 Turbine Shaft Bushing/Output Bushing/P2 Carrier 515i,t; 517e
Bushing Installer
J 41445 12 Transmission Holding Bracket 42a; 62a
J 42048 23 Retarder Flow Valve Spring Compressor 515c,j,n,u
J 43020 15 P3 Planetary Lifting Ring 42m
J 43023 16 P4 Planetary Bushing Installer 513f
J 43024 17 Output Shaft Seal Installer 62r,t
J 43025 18 C5 Return Spring 513d,e; 517d
J 43046 19 Torque Wrench Adapter 42l; 62l
J 43047 20 Bearing Installer/Remover 513d,e
J 43202 21 Output Shaft Bearing Installer 515i,t; 517e
J 43278 7 Output Shaft Holding Tool 515c,j,u; 517a,f; 62r,t
J 43922 22 Measuring Blocks And Straight Edge 62m,n
J 43975 14 HD 4070 Tool Kit (Includes the following special NA
tools: J 43020, J 43023, J 43024, J 43025, J 43046,
J 43047, J 43202, J 43278, and J 43922)
* We believe this source and its tools to be reliable. These tools may be available from other manufacturers. General
Motors does not endorse, indicate any preference for, or assume any responsibility for the products or tools from these
firms, or for any such items that may be available from other sources.
** Kent-Moore Tool Division, 29784 Little Mack, Roseville, Michigan 48066

Copyright 2001 General Motors Corp. 35


4000 MH/HD 4000/B 500 SERIES ON-HIGHWAY SERVICE MANUAL
33. REPLACEMENT PARTS b. Cleaning Transmission, Parts

a. Ordering Information. Refer to the current issue CAUTION:


of HD/B 500 Series Parts Catalog PC2456EN for parts Seal all openings and the breather prior to steam
information. Do not order replacement parts using the cleaning the transmission. The material on the
reference numbers in this service manual. friction-faced clutch plates and its bonding agent
can be damaged by water, steam cleaning, or
b. Parts Normally Replaced at Overhaul. The unapproved solvents. Use only mineral spirits for
following parts are normally replaced at each cleaning friction-faced clutch plates.
transmission overhaul:
1. Clean all metallic transmission parts, except
Gaskets
bearings and friction-faced clutch plates, by
Lockstrips steam cleaning or with mineral spirits. Do not
use caustic soda solution for steam cleaning. If
Washers or retaining rings damaged by steam cleaning method is used, do not allow
removal or abnormal wear steam or water to enter the transmission. Clean
Oil seals and piston sealrings friction-faced clutch plates and bearings with
mineral spirits only.
Spiral retaining ring 4 (Foldout 8)
2. Dry all parts, except bearing assemblies, with
Suction filter 3 (Foldout 11,A)
compressed air. To prevent rust, lubricate
steam-cleaned parts as soon as they are dry.
WARNING! 3. Clean fluid passages by working a piece of soft
Do not burn discarded Teflon seals; toxic gases wire through the passages and flushing them
are produced by burning Teflon. with mineral spirits. Dry the passages with
compressed air.

4. Examine parts, especially fluid passages, after


34. CAREFUL HANDLING cleaning to make certain they are entirely
clean. Re-clean parts if necessary.
Handle parts and subassemblies carefully to prevent
nicking, scratching, and denting. Parts that fit together 5. Removal of minor defects with such items as
closely and have a specific operating clearance can crocus cloth, honing stones, and scrapers
bind if damaged. Parts that depend upon smooth produces debris and residue. Cover adjacent
surfaces for sealing may leak if scratched. Control parts, ports, and cavities before removing
valve body assembly parts are especially susceptible to defects. Thoroughly reclean the affected areas
leaking if scratched (valves, when dry, must move after rework.
freely by their own weight). Handle these parts
carefully and protect them during removal, cleaning, c. Cleaning Bearings
inspection, and installation. Keep control valve body
assembly parts in clean containers until installation.
WARNING!
Never dry bearings by spinning them with
35. CLEANING AND INSPECTION compressed air. A spinning bearing can
disintegrate, allowing balls or rollers to become
lethal flying projectiles. Also, spinning a bearing
a. Dirt Causes Malfunction. All parts must be without lubrication can damage the bearing.
clean to permit effective inspection. Do not allow dirt
or foreign material to enter the transmission during
assembly. Even minute particles can cause close-fit 1. Bearings that have been in service should be
parts, such as valves, to malfunction. thoroughly cleaned in mineral spirits.

36 Copyright 2001 General Motors Corp.


GENERAL OVERHAUL INFORMATION
2. Soak particularly dirty bearings or ones filled If a bearing is not installed immediately, wrap
with hardened grease in mineral spirits before or cover the lubricated bearing with clean
trying to clean them. paper or lint-free cloth to keep out dust.

3. Before inspection, lubricate bearings with f. Inspecting Cast Parts and Machined Surfaces
transmission fluid.
1. Inspect bores for wear, scratches, grooves, and
d. Inspecting Bearings dirt. Remove scratches and burrs with crocus
cloth. Clean the part. Replace parts that are
deeply scratched or grooved.
CAUTION:
2. Inspect all fluid passages for obstructions. If an
If excessive metal contamination has occurred, obstruction is found, remove it with
replacement of all bearings is recommended.
compressed air, or by working a soft wire back
and forth through the passage and flushing it
1. Inspect bearings for rough rotation. Replace a with mineral spirits.
bearing if its rotation is still rough after
3. Inspect mounting faces for nicks, burrs,
cleaning and lubrication.
scratches, and foreign matter. Remove any
2. Inspect bearings for scored, pitted, scratched, defects with crocus cloth or a soft stone. Clean
cracked, or chipped races, and for excessive the part. If scratches are deep, replace the
roller or ball wear. Replace the bearing if any defective part.
of these defects are found.
4. Inspect threaded openings for damaged
3. Inspect a defective bearings bore and mating threads. Chase damaged threads with the
shaft for grooved, burred, or galled conditions correct size tap.
that indicate the bearing has been turning in the
5. Inspect the ribs inside the main housing for
bore or on the shaft. If shaft or bore damage
reaction plate wear grooves in the side of the
cannot be repaired with crocus cloth, replace
ribs. Replace housings that have wear grooves
the defective part.
beyond wear limits. (Refer to Wear Limits,
4. When removing a bearing, do not apply Table 71 in Section 7.)
pressure across the balls. This can cause
6. Replace housings or other cast parts that are
brinelling and bearing failure.
cracked.
5. If a bearing must be removed or installed
without the proper tool, press only on the 7. Inspect all machined surfaces for damage that
race which is adjacent to the mounting could cause fluid leakage or other malfunction.
surface. Rework or replace defective parts.

e. Keeping Bearings Clean. Ball or roller bearing 8. Inspect the oil tracks of the control module and
failures are usually caused by dirt or grit in the main housing for porosity, broken lands,
bearing. Keep bearings clean during removal and cracks, dirt, and land surface imperfections.
installation. Observe the following rules to ensure These imperfections will cause severe fluid
maximum bearing life: leakage leading to transmission failure.
Do not unwrap new bearings until they are to g. Inspecting Bushings and Thrust Washers
be installed.
1. Inspect bushings for scores, burrs, sharp edges,
Do not remove the grease in which new and evidence of overheating. Remove scores
bearings are packed until they are to be with crocus cloth. Remove burrs and sharp
installed. edges with a scraper or knife blade. Before
Do not lay bearings on a dirty bench. Place re-installing, carefully check bushings for
bearings on clean paper, or lint-free cloth. signs of distress.

Copyright 2001 General Motors Corp. 37


4000 MH/HD 4000/B 500 SERIES ON-HIGHWAY SERVICE MANUAL
i. Inspecting Gears
CAUTION:
1. Inspect gears for scuffed, nicked, burred, or
When removing a defective bushing, do not
damage the bushing bore. broken teeth. If a defect cannot be removed
with a soft stone, replace the gear.

2. Replace bushings that are out-of-round, deeply 2. Inspect gear teeth for wear that has changed
scored, or excessively worn. Inspect parts the original tooth shape. If this condition is
mated to bushings to ensure they are not found, replace the gear.
damaged or worn beyond use.
3. Inspect the thrust face of gears for scores,
3. Inspect thrust washers for distortion, scores, scratches, and burrs. Remove such defects with
burrs, and wear. Replace a thrust washer if a soft stone. If scratches and scores cannot be
defective or worn. removed with a soft stone, replace the gear.
4. Inspect gears for load pattern and signs of
h. Inspecting Sealrings and Gaskets distress. Any sign of distress indicates that a
1. Inspect piston sealrings and lip-type seals for gear failure during operation is possible.
nicks, cuts, tears, splits, and pattern damage. A Reusing distressed gears is an individual
damaged seal can indicate rough or sharp customer decision based upon experience.
edges in piston grooves or on a mating surface Backlash cannot be used to establish critical
that could damage a new seal. gear wear. Backlash tolerances are of such
nature that a gear usually pits, scuffs, scores, or
2. Inspect piston sealring grooves for nicks, burrs, galls long before gear wear becomes critical.
dents, or displaced metal that could damage
j. Inspecting Splined Parts
the new seal. Remove raised metal, sharp
edges, burrs, or nicks with a soft stone and 1. Inspect splined parts for stripped, twisted,
crocus cloth. Thoroughly clean all residue chipped, or burred splines. Remove burrs with
from the piston before assembly. a soft stone. Replace the part if other defects
are found. Spline wear is not considered
3. Replace all composition gaskets. harmful except where it affects the fit of the
splined parts.
4. Inspect hook-type sealrings for wear, broken
hooks, and distortion. Install a new hook-type 2. Spline wear is determined by measuring and
sealring if the old ring shows any wear on its comparing the unworn and worn areas of the
outside diameter, or if there is excessive side spline. This can also be checked by comparing
wear. Install a new sealring if there is wear on feeler gauge thickness to the depth of the worn
the sealring outside diameter mating surface. area. Replace parts having excessive spline
wear. (Refer to Wear Limits, Section 7.)
5. Inspect clutch housing sealing surfaces for 3. Backlash cannot be used to establish critical
nicks, burrs, dents, or displaced metal that spline wear. Accurate backlash measurement
could interfere with mating parts or damage requires the mating parts to be concentrically
the piston seal. Remove raised metal, sharp located.
edges, burrs, or nicks with a soft stone and
crocus cloth. Thoroughly clean all residue k. Inspecting Threaded Parts. Inspect threaded
from the housing before assembly. parts for burred or damaged threads. Remove burrs
with a soft stone or fine file. Replace damaged parts.
6. Measure butt-joint sealring end gap by
inserting the sealring into its respective sealing l. Inspecting Retaining Rings. Inspect all retaining
bore. Use a feeler gauge to measure end gap. rings for nicks, distortion, or excessive wear. Replace
Discard sealrings that do not meet the retaining ring if any of these defects are found. The
specifications. (Refer to Wear Limits, retaining ring must snap tightly into its groove to
Section 7.) function properly.

38 Copyright 2001 General Motors Corp.


GENERAL OVERHAUL INFORMATION
m. Inspecting Springs. Inspect springs for signs of p. Inspecting Sealing Surfaces
cracking, overheating, permanent set, or wear due to
1. Inspect surfaces in contact with hook-type and
rubbing adjacent parts. Replace the spring if any of
butt-joint sealrings for step wear, nicks,
these defects are found. (Refer to Spring Data, Table
scratches, and scoring. Use a soft stone or
72 in Section 7.)
crocus cloth to remove only the raised metal
n. Inspecting Clutch Plates (Figure 34) portion of these defects. Polishing the area to
remove a defect is neither necessary nor
1. Inspect friction-faced clutch plates for burrs, desirable. If the defects are too severe to
embedded metal particles, severely pitted correct, replace the defective part.
faces, loose faces, excessive wear, cone,
2. Inspect surfaces in contact with spring-loaded,
cracks, distortion, shallow oil groove depth, or
lip-type oil seals for nicks, scratches,
damaged spline teeth. Remove burrs using a
roughness, or other surface irregularities.
soft stone. Replace plates which have any
Inspect for embedded particles, step wear, and
defects.
dirt on flanges or other components exposed to
2. Inspect steel plates for burrs, scoring, external contamination. Remove the defects
excessive wear, excessive cone, distortion, and restore the finish. Replace the part if scores
embedded metal, galling, cracks, breaks, or or scratches permit fluid leakage.
damaged tangs. Remove burrs and minor
surface irregularities using a soft stone.
Replace plates which have any non-repairable 36. ASSEMBLY PROCEDURES
defects.
a. Parts Lubrication. During final assembly,
3. The amount of clutch plate cone is determined lubricate all moving parts with transmission fluid. The
by measuring the distance between the inside fluid will help protect friction surfaces and ferrous
diameter of the plate and a level surface metals until the unit is in service.
(Figure 34). Discard plates having excessive
cone. (Refer to Wear Limits, Section 7.) b. Grease Used for Assembly. During assembly use
oil-soluble grease with a low melting point
4. Determine oil groove depth with a depth (petrolatum) to temporarily retain parts, butt-joint
micrometer or by measuring the smooth sealrings, scarf-cut sealrings, and hook-type sealrings.
surface (total) thickness of the plate, measuring
the thickness of the steel part of the plate at the c. Sealing Compounds and Nonsoluble Greases.
oil groove, and subtracting this measurement Do not use gasket-type sealing compounds, fibrous
from the total thickness. Replace plates not greases, or nonsoluble vegetable-base cooking
having the minimum oil groove depth. (Refer compounds inside the transmission or where they
to Wear Limits, Section 7.) could be flushed into the transmission hydraulic
system.
o. Inspecting Swaged and Interference-Fit Parts.
If there is evidence of looseness, replace the assembly. d. Clutches and Pistons
1. Soak each friction-faced clutch plate (two-
CLUTCH PLATE minute minimum) in transmission fluid before
LEVEL SURFACE
final assembly.

2. Apply a generous amount of transmission fluid


to the piston cavity before final assembly.
MEASURE HERE FOR CONE
V00493.01
3. Assemble clutch plates so that the cone of each
Figure 34. Method of Measuring Clutch Plate Cone plate faces the same direction.

Copyright 2001 General Motors Corp. 39


4000 MH/HD 4000/B 500 SERIES ON-HIGHWAY SERVICE MANUAL
e. Threaded Plugs and Hydraulic Fittings atmosphere causing the sealring to expand.
Check sealring end clearance before
installation to ensure the sealring has not
CAUTION: expanded.
Do not use Teflon tape on threaded parts
where slivers can enter the transmission and 2. Remove the sealring from its package and
cause a malfunction. place the sealring in its operational position
Improperly installed plugs or fittings can inside the bore that it will be sealing.
cause leakage and cracked housings.
3. Use a feeler gauge to check the end clearance
of the sealring. The end clearance must not be
Threaded plugs in the HD 4000/B 500 transmissions are less than the specifications. Refer to the
the straight-thread, O-ring type. Be sure that the O-ring respective assembly Steps in Section 5.
is in like-new condition and tighten all plugs to the
torque value specified in the assembly procedure or in 4. If the end clearance is less than specifications,
the exploded views. bake the sealring in an oven at 93149C
(200300F) for 24 hours or get a new
f. Lip-Type Oil Seals sealring. Repeat Steps (2) and (3).

1. When replacing lip-type seals, make sure the 5. Pack the sealring and its groove with a liberal
spring-loaded lip is toward the fluid to be amount of oil-soluble grease.
sealed (toward the inside of the unit). Coat the
inside of the seal with high temperature grease 6. Roll the sealring to about half its free diameter
(MIL-G-3545A or equivalent) to protect the and hold it for about 10 seconds. Being careful
seal during shaft installation and to provide not to spread the sealring more than necessary,
lubrication during initial operation. slide it onto the hub. Place one end of the
sealring into the groove and gradually work the
2. The circumference of some seals is precoated seal into the groove.
with a dry sealant. The sealant is usually
colored for easy identification. Precoated seals h. Bearings
do not require any additional sealant before
1. When removing a bearing, do not apply
installation.
pressure across the balls. This can cause
3. Before installation, apply a non-hardening brinelling and bearing failure.
sealant to the circumference of seals not
2. If a bearing must be removed or installed
precoated with a dry sealant.
without an installation sleeve, drive or press
g. Butt-Joint Sealrings only on the race which is adjacent to the
mounting surface. If a press is not available,
carefully seat the bearing with a drift and a
CAUTION: hammer, driving against the supported race.
If humidity is allowed to penetrate and expand a
i. Bushings. Whenever a new bushing is being
butt-joint sealring, the sealring can be damaged
during installation. A damaged sealring will installed, NEVER allow the pressing tool to bottom
permit transmission fluid to leak from the clutch against a needle thrust bearing. ALWAYS make sure
piston cavity and cause clutch slippage. Do not that the pressing tool bottoms against the part that the
open the sealed package until you are ready to bushing is being pressed into.
install the sealring.
j. Electrical Components. For inspection and
repair of electrical components, refer to the MD/HD/
1. Butt-joint sealrings require special handling B Series Troubleshooting Manual TS2470EN
during assembly. The sealrings contain (WTEC II Controls) or TS2973EN (WTEC III
materials that absorb moisture from the Controls).

310 Copyright 2001 General Motors Corp.


GENERAL OVERHAUL INFORMATION
37. REMOVING TRANSMISSION interfere with transmission removal. Plug all
FROM VEHICLE (Figure 35) openings to keep dirt from entering the cooling
system.
a. Drain Fluid
b. Disconnecting Controls
WARNING! 1. Disconnect or completely remove controls. If
Avoid contact with the hot fluid or the sump controls are not removed from the
when draining transmission fluid. Direct contact transmission, position them so that they do not
with the hot fluid or the hot sump may result in interfere with transmission removal.
bodily injury.
2. Disconnect the transmission external harness
1. Drain the transmission fluid before removing from the transmission feedthrough harness
the transmission from the vehicle. The connector or older style feedthrough connector.
transmission fluid should be warm to promote Also disconnect the external harness from the
complete drainage. engine, output, and turbine speed sensors
(Figure 35). Place a cover on the transmission
2. Remove the drain plug from the control electrical connector to keep out dirt. Also be
module. Examine the drained fluid for evidence sure to disconnect the transmission
of contamination (see Paragraph 212). feedthrough harness from the harness bracket.
Re-install the drain plug. If the drain plug
threads are damaged, see Paragraph 213 for 3. If PTO(s) are used, disconnect the PTO(s)
corrective action. harness.
3. Remove transmission fill tube if it interferes
4. Disconnect the transmission external harness
with transmission removal.
from the retarder temperature sensor and the
retarder control valve body.
WARNING!
c. Uncoupling Transmission From Vehicle and
DO NOT disconnect the hydraulic fluid line
between the accumulator and the retarder until Engine Driveline
air and hydraulic pressure have been bled from
1. Disconnect the vehicle drive shaft from the
the retarder.
transmission output flange or yoke. Position
the disconnected shaft to avoid interference
with removing the transmission.
NOTE
A significant amount of fluid may drain from a 2. Transmissions with PTOs require uncoupling
hydraulic hose when it is disconnected from the one of the following:
transmission.
PTO from transmission

4. Disconnect all hydraulic hoses from the PTO drive shaft from the PTO
transmission. If a retarder is installed, 3. If the transmission supports the rear of the
disconnect the accumulator line from the engine, place a jack or other support under the
retarder housing. Remove the hoses from the engine.
vehicle if they interfere with the transmission
removal. Plug all openings to keep dirt from 4. Securely support the transmission with a hoist,
entering the hydraulic system. jack, or other suitable removal equipment.

5. If an integral cooler is used, drain coolant from 5. Remove all bolts, nuts, washers, spacers, and
the cooler and disconnect coolant hoses. supports that attach the transmission to the
Remove the hoses from the vehicle if they vehicle and the engine.

Copyright 2001 General Motors Corp. 311


4000 MH/HD 4000/B 500 SERIES ON-HIGHWAY SERVICE MANUAL

REAR OUTPUT
FRONT COOLER COOLER SPEED
PORTS (OPTIONAL) PORTS SENSOR

FRONT REAR (WITHOUT RETARDER)

PTO CONTROLS
OUTPUT SPEED SENSOR AND LINES

RETARDER
TEMPERATURE
ACCUMULATOR LINE SENSOR
(RETARDER ONLY)
FEEDTHROUGH
HARNESS
CONNECTOR

REAR COOLER PORTS TURBINE


RETARDER K SOLENOID CONNECTOR SPEED SENSOR ENGINE SPEED SENSOR

REAR (WITH RETARDER) RIGHT SIDE V01483.03

Figure 35. Disconnection Locations

d. Removing the Transmission 39. SPRING SPECIFICATIONS


1. Move the transmission away from the engine Refer to Spring Data, Table 72, for spring
approximately 106 mm (4.17 inch) until it is identification and specifications.
completely clear of the engine. Remove the
adapter ring and/or gasket (if used).
2. Raise or lower the transmission as necessary to
310. TORQUE SPECIFICATIONS
remove it from the vehicle. Assembly procedures in Sections 5 and 6 specify
the torque requirements for all plugs, bolts, and
nuts. Torque values are also presented with the
38. WEAR LIMITS foldout illustrations in the back of this manual.
Torque values specified are for dry assembly, except
Refer to Wear Limits Data, Table 71, for information when otherwise noted. Wash and dry bolts and
covering part fits, clearances, and wear limits. washers before assembly.

312 Copyright 2001 General Motors Corp.


Section 4 TRANSMISSION DISASSEMBLY
41. SCOPE 2. Attach a hoist, making sure lifting attachments
are placed so that the transmission is balanced,
a. Section. This section covers disassembly of the and raise the transmission to the mounting face
4000 MH, HD 4060, HD 4560, HD 4070, and B 500 of the overhaul stand.
transmissions. The disassembly sequence is continu-
ous and includes all models. 3. Secure the transmission holding fixture to
overhaul stand J 29109.
b. Procedures. When a procedure does not apply to
your specific model, go to the next applicable b. Removal of Power Takeoff (Figure 41)
procedure.
NOTE:
c. Illustrations. Illustrations will not always show
Each PTO has eight mounting bolts, two studs, and
your model, but when an operation is identical for all
a gasket. Removal instructions are for a
models, the correct procedure is shown.
transmission with a single left-side or top mounted
d. General Information. Refer to Sections 3 and 7 PTO. If your transmission has more than one PTO
for general information as follows: or the PTO is mounted in a different location, use
the same procedure to remove the PTO(s).
Paragraph Title
32 Tools and Equipment
1. Remove eight PTO mounting bolts 1.
33 Replacement Parts
Carefully remove PTO assembly 2, and
34 Careful Handling
gasket 3.
35 Cleaning and Inspection
37 Removing Transmission From Vehicle 2. Inspect two PTO studs 4 for damage and
71 Wear Limits Data remove if necessary.
72 Spring Data
c. Removal of External Parts
e. Foldouts. Refer to Foldouts 4 through 12 for (Figures 42 and 43)
exploded views. 1. Inspect transmission breather 25 for damage or
an obstruction. Remove if necessary for
42. DISASSEMBLY OF replacement or cleaning.
TRANSMISSION
NOTE:
WARNING! If your transmission is PTO equipped and you have
PREVENT PERSONAL INJURY not removed the PTO(s), return to Paragraph 42b.
Use proper tools and lifting equipment when
installing or removing a transmission from the 2. Remove screw 5 retaining oil fill tube bracket 6
repair stand. to the main housing module. Remove
Transmission dry weights are as follows: bracket 6, fill tube 8, seal 9, and dipstick 7.
4000 MH/HD/B 500 (Basic) 377 kg (831 lb) 3. Remove six bolts 12 retaining remote cooler
With PTO Provision 405 kg (893 lb) manifold 11 to the main housing module.
With Retarder 411 kg (906 lb) Remove remote cooler manifold 11 and
With PTO and Retarder 439 kg (968 lb) gasket 10.
HD 4070 w/ PTO and Retarder 555 kg (1224 lb) 4. Bend down tabs of locktab 21, if present, and
loosen two bolts 22 or loosen two bolts 23 or
a. Mounting Transmission on Repair Stand one bolt 19.

1. Mount holding bracket J 35926 or J 35926-A 5. Remove two bolts 22 and locktab 21 or two
(HD 4070 models), with holding bracket bolts 23 and two belleville washers 24 or one
J 41445 attached, onto the main housing bolt 19. Discard locktab 21 and bolts 22,
module. bolts 23 and washers 24, or bolt 19.

Copyright 2001 General Motors Corp. 41


4000 MH/HD 4000/B 500 SERIES ON-HIGHWAY SERVICE MANUAL

1 2
4
3

3
1

4
V06836

Figure 41. PTO Removal

25 ENGINE
SPEED 1 2 7
SENSOR
TURBINE 4
SPEED 3 5
SENSOR 6

13
9

OUTPUT
SPEED
SENSOR 13

18
19
16
14
17
20
21
22

24
10 23
11 12

V06837

Figure 42. Removal of Externally Mounted Parts

42 Copyright 2001 General Motors Corp.


TRANSMISSION DISASSEMBLY
6. Remove flange 13 or yoke 14. Remove two 7. Inspect journal sealing area for minimum
O-rings 17, retainer plug 20, and O-ring 16 or allowed diameter of 85.0 mm (3.346 inch).
one O-ring 17, retainer plug 18, and O-ring 16.
8. Remove bolt 4, retainer 3, speed sensor 2, and
O-ring 1 from the converter housing module
(engine speed sensor), main housing module
(turbine speed sensor), and rear cover or
retarder (output speed sensor).

d. Removal of Integral Oil Cooler (Figure 44)

NOTE:
The integral oil cooler is only available on non-
retarder transmissions in the HD/B 500 Series.
ENGINE
SPEED SENSOR 1. Remove two bolts 11 and seventeen bolts 12.
Remove cover 13, gasket 14, and two
O-rings 10.
TURBINE
OUTPUT SPEED SENSOR 2. Remove plate assembly 9 and four O-rings 8.
SPEED SENSOR V06838
3. Remove nine bolts 7 and nine washers 6.
Figure 43. Speed Sensors Remove cooler housing 3 and gasket 1.

5
4
3
1
11
8
4 2 9
5
6 7 10
8
19
18 17
11 19
18 17 10

16 11
15

12

14
13 11 V06843

Figure 44. Integral Oil Cooler

Copyright 2001 General Motors Corp. 43


4000 MH/HD 4000/B 500 SERIES ON-HIGHWAY SERVICE MANUAL
e. Removal of Control Valve Module 2. Loosen control module 2 by applying pressure
(Figure 45) at the reinforced tabs or use jack bolts, inserted
into the control module bolt holes that bottom
against the main housing module.
WARNING!
3. Remove covers and filters if a handhold is
Get help when lifting the control module.
Assistance from a hoist or another person may be needed to remove the control module.
required. The control module weighs 4. Remove control module assembly 2 and
approximately 25 kg (55 lb).
gasket 1.

CAUTION:
The control module or filters may contain re-
sidual transmission fluid.
Be sure the external part of feedthrough harness
connector 3 (clip and/or bracket nut) has been
disconnected from external brackets before re-
moving the control module.

NOTE:
1
Transmissions between S/N 6610009662 and
6610009762 may contain control module to main
housing bolts that are too short. See Figure 46 for 3
the correct and incorrect bolt descriptions. Replace
the incorrect bolts and inspect the main housing
threads. 2
2

5
1. Remove forty-three bolts 4 and 5 retaining 4
V06839
control module 2 to the main housing module,
including the bolts retaining the filter covers. Figure 45. Control Module Removal

10.9 9.8
M 50 mm M
55 mm (1.969 in.)
(2.165 in.)

BOLT HEAD BOLT HEAD


10.9 9.8

CORRECT BOLT INCORRECT BOLT


V03022

Figure 46. Correct and Incorrect Control Module Bolt Length

44 Copyright 2001 General Motors Corp.


TRANSMISSION DISASSEMBLY
f. Removal of Torque Converter Module 2. Using snapring pliers, remove retaining ring 1
(Figure 47) (Figure 47, View A).
1. Remove any brackets installed to prevent 3. Thread an M6 x 30-1 bolt into converter end
torque converter movement. plug 2 and remove plug 2 and O-ring 3.
Proceed to Step (6).
NOTE:
4. Keep the torque converter cover from turning
For units prior to S/N 6610032772, proceed to
by using a heel bar, two bolts and a screwdriver
Step (2).
(Figure 47, View C).
For units beginning with S/N 6610032772, skip
Steps (2) and (3) and proceed to Step (4). 5. Remove threaded plug 7 and O-ring 8 using a
34 inch Allen socket.

Cupped end down Restrict movement


6 Use hoist and sling
2 3
4 5

7 8

J 38564

VIEW A

VIEW B

LOCKUP
PRESSURE
TAP

VIEW C VIEW D E06840.01

Figure 47. Torque Converter Module Removal

Copyright 2001 General Motors Corp. 45


4000 MH/HD 4000/B 500 SERIES ON-HIGHWAY SERVICE MANUAL
6. Attempting to loosen bolt 4 may cause the
turbine and turbine shaft to rotate. Hold the
turbine and turbine shaft stationary by using
one of the methods listed below:

If the control module is removed, insert a


screwdriver into the vanes on the rotating
clutch module (Figure 47, View B). 1
If the control module is in place, apply the 3
lockup clutch by applying restricted air
pressure through the lockup pressure tap
located on the main housing (Figure 47,
2
View D). Insert a heel bar into a torque 4
converter housing bolt hole. Insert two bolts
into the flexplate adapter bolt holes. Then
V06841
place a screwdriver at an angle to prevent
converter rotation (Figure 47, View C).
7. Using converter bolt tool J 38564, remove Figure 48. Converter Housing Module Removal
bolt 4.
3. Remove main housing gasket 2 from converter
8. Remove selective shim 5 located under bolt 4 housing 1 or from main housing module 4.
(Figure 47, View A).

9. Attach a sling to the flexplate adapter by NOTE:


positioning the adapter connections an equal
distance from each other. Using a chain hoist, Proceed to Paragraph 42 sub-paragraph shown
carefully lift torque converter module 6 out of below by output module configuration and model.
the converter housing (Figure 47, View A). h Retarder (All Models Except
HD 4070/4076)
10. Place two wooden blocks on the workbench,
spaced to support the torque converter module i Retarder (4070/4076 Models)
and high enough for the converter hub to clear j Rear Cover (All Models Except
the workbench. Lower the converter module, HD 4070/4076)
converter hub down, onto the blocks.
k Rear Cover (4070/4076 Models)
g. Removal of Converter Housing Module
(Figure 48)
h. Removal of Retarder Module
(All Models Except HD 4070/4076)
NOTE:
Seven converter housing retaining bolts 3 are NOTE:
removed from inside converter housing 1. Use
For units prior to S/N 6610066447, proceed to
mechanical fingers or a similar tool to remove these
Step (1).
bolts.
For units beginning with S/N 6610066447, skip
Steps (1) through (3) and proceed to Step (4).
1. Remove twenty-five bolts 3 that retain
converter housing 1 to main housing module 4.
1. Remove twelve bolts 3 (Figure 49), seven
2. Using the same sling used for removing the bolts 6, two bolts 5, and four bolts 4 that secure
converter module, lift straight up on converter retarder module 2 to main housing module 7. If
housing module 1 to remove it. used, remove the rear support bracket.

46 Copyright 2001 General Motors Corp.


TRANSMISSION DISASSEMBLY
5. Thread an M14 eye bolt into the retarder
WARNING! output shaft and lift retarder module 1 from
Get help when lifting the retarder module. main housing module 8.
Assistance from a hoist or another person may be
required. The retarder module weighs 6. Remove retarder gasket 7 from main housing
approximately 34 kg (75 lb). module 8 or from retarder module 1.
2. Thread an M10 or M14 eye bolt into the
retarder output shaft and lift retarder module 2
from main housing module 7.

3. Remove retarder gasket 1 from main housing


module 7 or from retarder module 2.
2
4. Remove twelve bolts 2 (Figure 410), three
bolts 3, two bolts 4, four bolts 5, and four bolts 3
6 that secure retarder module 1 to main
housing module 8. If used, remove the rear 7
support bracket.
1 4

WARNING! 5
6
V06842
Get help when lifting the retarder module.
Assistance from a hoist or another person may be
required. The retarder module weighs Figure 49. Removal of Retarder Module
approximately 34 kg (75 lb). (Units Prior to S/N 6610066447)

2 2
2 2
2 2

2 2
1
2 2 2

8 4 2
4 2
5
7 6 5 5 5
3
3 OR
4 6 6 6
6 5 3 3
V06844

Figure 410. Removal of Retarder Module (Units Beginning With S/N 6610066447)

Copyright 2001 General Motors Corp. 47


4000 MH/HD 4000/B 500 SERIES ON-HIGHWAY SERVICE MANUAL
i. Removal of Retarder And Output Shaft Module
(HD 4070/4076 Models)
1
NOTE:
For units prior to S/N 6610066447, proceed to 2
Step (1).
For units beginning with S/N 6610066447, skip 3 4
Steps (1) through (3) and proceed to Step (4).
5
1. Remove twelve bolts 4 (Figure 411 and 412),
seven bolts 8, two bolts 7, and four bolts 6 that
secure the retarder module to the main housing
module. If used, remove the rear support 6
bracket.

9 8 7
WARNING!
V05373
Get help when lifting the retarder module.
Assistance from a hoist or another person may be
required. The retarder module weighs
approximately 34 kg (75 lb). Figure 411. Removal of Retarder and Output
Shaft Module (Units Prior to S/N 6610066447)
2. Thread an M14 eye bolt into the end of the
output shaft and lift the retarder and output
shaft module 5 from the transmission.
3. Remove and discard retarder housing gasket 3
from the retarder and output shaft module. 4 4
BOLT, M12 x 1.75 x 55 4 4
(12) MARKED 4
4. Remove twelve bolts 4 (Figure 413), three 4 4
bolts 6, two bolts 7, four bolts 8, and four
bolts 9 that secure retarder module 5 to main 4 4

housing module 1. If used, remove the rear


4 4
support bracket.
7 4
WARNING! 4
BOLT, M12 x 1.75 x 105 7
Get help when lifting the retarder module. 6 6
(2) MARKED 7 6 6 8
Assistance from a hoist or another person may be 8
required. The retarder module weighs 8
BOLT, M10 x 1.5 x 345
approximately 34 kg (75 lb). 8 8 8 8
(7) MARKED 8
BOLT, M12 x 1.75 x 350
5. Thread an M14 eye bolt into the retarder (4) MARKED 6 V01739.01
output shaft and lift retarder module 5 from
main housing module 1.

6. Remove retarder gasket 3 from main housing Figure 412. Retarder and Output Shaft Module Bolts
module 1 or from retarder module 5. (Units Prior to S/N 6610066447)

48 Copyright 2001 General Motors Corp.


TRANSMISSION DISASSEMBLY

1
4 4
4 4
2 4 4

4 4
3 4

4 4
5
7 4
7 4
8
9 8 8 8
6 6 OR
9 9 9 6 6
7 8
9
V06845

Figure 413. Removal of Retarder Module (Units Beginning With S/N 6610066447)

j. Removal of Rear Cover Module k. Removal of Rear Cover And Output Shaft
(All Models Except HD 4070/4076) Module (HD 4070/4076 Models)
1. If used, remove the rear support bracket.
1. If used, remove the rear support bracket.
2. Remove fourteen bolts 4 (Figure 415 and 416).
2. Remove nineteen bolts 5 (Figure 414) and
Remove five bolts 5.
washer 4, if present.
3. Thread an M14 eye bolt into output shaft 7 and
3. Thread an M10 or M14 eye bolt into the output lift upward to remove rear cover module 6.
shaft and lift upward to remove rear cover
4. Remove rear cover gasket 3 from C6 adapter
module 3.
housing module 2 or from rear cover module 6.
4. Remove rear cover gasket 2 from main housing
module 1 or from rear cover module 3. 1

3 4

1 5
2
4
5
3 V05580
V06846

Figure 415. Removal of Rear Cover and Output


Figure 414. Rear Cover Module Removal Shaft Module

Copyright 2001 General Motors Corp. 49


4000 MH/HD 4000/B 500 SERIES ON-HIGHWAY SERVICE MANUAL

BOLT, M12 x 1.75 x 45 1


(14) MARKED 4
4 4
4 4 J 43046
2
4 4
3
4 4
4
4 4

4 4

BOLT, 4 5 5 4
METRIC HEAVY 5 5
(5) MARKED 5 5

5
V05374
V05576

Figure 417. Removal of C6 Adapter Housing Module


Figure 416. Rear Cover and Output Shaft Module Bolts

l. Removal of C6 Adapter Housing Module


1
(HD 4070/4076 Models) (Figure 417)
1. Remove fourteen bolts 3 that secure the C6
adapter housing module 4 to main housing
module 1 using special tool J 43046. 2

3
4
WARNING!
Get help when lifting the C6 adapter housing 5
module. Assistance from a hoist or another
person may be required. The C6 adapter housing J 43020
module weighs approximately 68kg (150 lb).
V05375

2. Attach a sling to the C6 adapter housing


module 4 with the legs of the sling equally Figure 418. Removal of P3 Planetary Module
spaced on the module. Using a chain hoist,
3. Remove P4 shaft flange 3.
carefully lift the C6 adapter housing module 4
from the transmission.
4. Attach special tool J 43020 to P3 planetary 2.
Attach chain hoist and lift from transmission.
3. Remove and discard C6 adapter housing
gasket 2.
n. Removal of Main Shaft Module (Figure 419).
Remove main shaft module assembly 1 from the
4. Remove and discard eleven tolerance rings 5.
transmission.
m. Removal of P3 Planetary Module
(HD 4070 Models Only) (Figure 418) o. Removal of P2 Module, C5 Clutch Plates,
and P1 Module
1. Remove selective shim 5.
1. Lift P2 planetary module 1 from the main
2. Remove shim locating ring 4. housing module (Figure 420).

410 Copyright 2001 General Motors Corp.


TRANSMISSION DISASSEMBLY
2. Lift C5 clutch pack from the main housing p. Removal of Front Support/Charging Pump
module eight friction plates 3 and nine steel Module and Rotating Clutch Module
reaction plates 2.
1. Remove seven bolts 1 and seven bolts 2 that
3. Measure the thickness and cone of each retain front support and charging pump
friction plate 3. Minimum thickness is module 3 to the main housing module
3.48 mm (0.137 inch). Maximum allowable (Figure 422).
cone is 0.25 mm (0.010 inch).
2. Lift front support and charging pump module 3
4. Measure thickness and cone of each steel over the turbine shaft and away from the main
reaction plate 2. Minimum thickness is housing module.
2.41 mm (0.095 inch). Maximum allowable
cone is 0.25 mm (0.010 inch)

5. Lift P1 planetary module 1 from the


transmission (Figure 421).

HD 4560
1 E01271.01

Figure 421. P1 Module

1 2
4000 MH/HD 4060/4070/4076/B 500 3 2
V01737.02 3

Figure 419. Removal of Main Shaft Module

1
1 C5

2
3

E02516.01 V01272

Figure 422. Removal of Front Support/Charging


Figure 420. P2 Module and C5 Clutch Plates Pump Module

Copyright 2001 General Motors Corp. 411


4000 MH/HD 4000/B 500 SERIES ON-HIGHWAY SERVICE MANUAL

CAUTION:
Always remove the turbine speed sensor be-
fore removing the rotating clutch module to
avoid possible damage to the turbine speed
sensor.
When you remove rotating clutch module 1, 1
carefully place it on the workbench and pre-
vent it from rolling off the bench.

3. Using a hoist and an M16 eye bolt, lift turbine


shaft and rotating clutch module 1 (Figure 423)
from the main housing module and place it on
the workbench.
E01273.01
q. Removal of C3/C4 Clutch Assembly From
Main Housing Module (Figure 424)
Figure 423. Removal of Rotating Clutch Module

CAUTION:
Ensure the main housing module is horizontal
when removing the C3/C4 clutch assembly.

1. Remove fourteen bolts 3 retaining C3/C4


clutch assembly 1 in main housing module 2.
1 3
2. Remove the C3/C4 clutch assembly by sliding
it out of the input end of the main housing.

3. Remove the main housing from the repair


stand for cleaning.
2
4. Inspect the main housing C5 clutch plate E01274.01

splines. Maximum wear allowed is 1.15 mm


(0.045 inch). Figure 424. Removal of C3/C4 Clutch Module

412 Copyright 2001 General Motors Corp.


Section 5 MODULE REBUILD
51. SCOPE 7. Remove turbine assembly 18 from converter
cover assembly 7.
a. Section. This section describes the disassembly 8. Remove stator assembly 22.
and assembly of the modules removed in Section 4.
9. If replacement is necessary, remove thrust
b. Procedures. During rebuild procedures, refer to bearing race 34 from pump assembly 35.
the exploded views (Foldouts 4 through 12) in the 10. Remove thrust bearing assembly 20 from the
back of this manual. turbine. Remove turbine hub sealring 19.
Place turbine hub sealring 19 in its mating
bore. Measure the ID of the sealring at the
52. GENERAL INFORMATION maximum distance from the hook. Replace
FOR MODULE REBUILD the sealring if the maximum ID of 61.77 mm
(2.432 inch) is exceeded.
Refer to Sections 3 and 7 for general overhaul
information as follows: 11. Remove bearing assembly 32, race 31, and
selective shim 30.
Paragraph Description 12. Remove retaining ring 23.
32 Tools, Equipment 13. Remove star plate 21.
33 Replacement Parts
14. Remove thrust plate assembly 24 and
34 Careful Handling measure its thickness. Minimum thickness
35 Cleaning and Inspection allowed is 9.45 mm (0.372 inch).
36 Assembly Procedures
15. Remove thrust washer 25.
71 Wear Limits Data
16. Remove and inspect stator race 26, thirteen
72 Spring Data
springs 27, and rollers 28.
17. From converter cover assembly 7, remove
53. TORQUE CONVERTER MODULE forty-four bolts 16 retaining lockup clutch
backplate 15 to converter cover assembly 8.
a. Disassembly (Foldout 4,B) 18. Remove lockup clutch backplate 15. Measure
1. Before disassembling the torque converter, the thickness of the backplate wear surface.
note balance marks or mark a line across the Minimum thickness allowed is 11.79 mm
converter cover to the pump assembly with a (0.464 inch). Check for distortion of the
scribe. These marks will ensure correct lockup clutch backplate. Maximum distortion
assembly of the torque converter and reduce allowed is 0.15 mm (0.006 inch).
balance problems. 19. Remove lockup clutch damper assembly 14
from converter cover assembly 8. Measure the
2. Place converter assembly 5 on a flat surface
thickness of the lockup clutch. Minimum
pump drive tangs downward.
thickness allowed is 8.51 mm (0.335 inch).
3. Remove thirty-six nuts 6 from the OD of Check for distortion of the lockup clutch.
torque converter cover assembly 7. Maximum allowable distortion is 0.51 mm
(0.020 inch). Check spline wear between the
4. If replacement is necessary, remove damaged
turbine hub and the lockup clutch damper.
T-head bolt(s) 37 from the OD of torque
Maximum allowable wear is 0.38 mm
converter pump assembly 35.
(0.015 inch) on either spline.
5. Carefully remove cover assembly 7 from pump
20. Remove lockup clutch piston 12. Remove in-
assembly 35. Avoid damage to their sealing
ner sealring 11 and outer sealring 13 from the
surfaces.
lockup piston assembly. Measure the thick-
6. Remove O-ring 33 used between the cover ness of the lockup piston assembly. Minimum
assembly and pump assembly. thickness allowed is 6.53 mm (0.257 inch).

Copyright 2001 General Motors Corp. 51


4000 MH/HD 4000/B 500 SERIES ON-HIGHWAY SERVICE MANUAL
21. Inspect the ID of cover bushing 10. Maximum 11. Install lockup clutch backplate 15.
ID of the bushing allowed is 66.91 mm
12. Install forty-four bolts 16. Tighten the bolts to
(2.634 inch). Remove the bushing if
3035 Nm (2226 lb ft).
replacement is necessary.
22. Remove thrust bearing assembly 17. 13. Install the turbine hub sealring 19 onto turbine
assembly 18. Install the turbine assembly 18
into converter cover assembly 8 aligning bal-
b. Assembly (Foldout 4,B and Figure 51) ance mark on the turbine with the balance
1. Install stator race 26 into stator and cam mark on the lockup clutch damper.
assembly 29.
14. Install stator assembly 22.
2. Install thirteen springs 27 and rollers 28 into 15. If removed, install thirty-six T-head bolts 37
stator and cam assembly 29. Be sure springs and into the flange of converter pump assembly 36.
rollers are installed as shown in Figure 51. Use If removed, install thrust bearing race 34 into
oil-soluble grease to help hold the springs and converter pump assembly 35.
rollers in place.
16. Install O-ring 33 onto converter cover assem-
3. Install thrust washer 25 and thrust plate bly 8. With balance marks or scribe mark
assembly 24 onto stator and cam assembly 29. aligned, place converter pump assembly 35
Install star plate 21. over the top of converter cover assembly 8.
4. Install retaining ring 23. 17. Install four nuts 6, evenly spaced, onto four
5. Do not install shim 30 at this time. Install T-head bolts 37. Tighten the nuts to 3035 Nm
thrust bearing race 31 and bearing (2226 lb ft).
assembly 32. 18. Using a depth micrometer, measure from the
top of the drive tang surface to the thrust sur-
CAUTION: face of the turbine hub. This is dimension A (Fig-
When installing thrust bearings, make sure that ure 52).
the locating lip on either the inner or outer thrust 19. Turn the converter on its side and insert tool
bearing race is not preventing the race from J 38548, with bolt removed, into the converter
contacting the thrust surface of the mating part. plug bore. Turn the torque converter so that it
Failure to do this leads to premature thrust
rests on tool J 38548. Repeat the same mea-
bearing failure and incorrect shim selection to
maintain proper internal part clearance. surement as in Step (18). This is dimension B.

20. Subtract dimension B from dimension A to get


6. Install thrust bearing assembly 20.
dimension C.
7. If removed, press a new bushing 10 into
cover 9 bushing bore using J 39949 bushing ROLLER TO BE INSTALLED IN
installer and J 8092 drive handle. Install new SMALL END OF CAM POCKET
sealring 19 onto turbine hub and insert turbine SPRING
assembly 18 into the new bushing and check
for freedom of rotation. STATOR CAM
8. Install thrust bearing assembly 17 in converter
cover 9.
9. Install lockup piston sealring 11 on the hub of
converter cover 9 and lockup piston sealring 13
on the OD of lockup piston assembly 12.
Install the lockup clutch piston.
V01360
10. Install lockup clutch damper assembly 14 into
cover 9. Figure 51. Stator Roller/Spring Installation

52 Copyright 2001 General Motors Corp.


MODULE REBUILD

DRIVE TANG SURFACE SHIM (30) LOCATION DRIVE TANG SURFACE

THRUST
SURFACE
OF THRUST DIM. B
TURBINE DIM. A SURFACE
HUB OF
TURBINE
HUB

J 38548

E02517.01

Figure 52. Torque Converter Selective Shim

21. Dimension C must be 0.080.36 mm (0.003 26. Perform the measurement again. Dimension C
0.014 inch). must be 0.080.36 mm (0.0030.014 inch). If
22. If dimension C is not correct, then a shim is dimension C is not correct, then a shim change
needed. Select the proper shim from Table 51 is needed. Disassemble the converter and reas-
and proceed with Step (24). semble without shim 30, and go back to
Step (17).
23. If dimension C is correct, proceed with
Step (28).
27. If dimension C is correct, proceed with
24. Disassemble the converter and reassemble us- Step (28).
ing selected shim.
25. Install four nuts 6, evenly spaced, onto four 28. Install the remaining thirty-two nuts 6 onto T-head
T-head bolts 37. Tighten the nuts to 3035 Nm bolts 37. Tighten all the nuts to 3035 Nm
(2226 lb ft). (2226 lb ft).

Table 51. Torque Converter Selective Shims

Dimension C Use P/N Shim Thickness

0.080.36 mm (0.0030.014 inch)


0.360.58 mm (0.0140.023 inch) 29503879 0.230.27 mm (0.0090.011 inch)
0.580.81 mm (0.0230.032 inch) 29503880 0.460.50 mm (0.0180.020 inch)
0.810.99 mm (0.0320.039 inch) 29503881 0.690.73 mm (0.0270.029 inch)

Copyright 2001 General Motors Corp. 53


4000 MH/HD 4000/B 500 SERIES ON-HIGHWAY SERVICE MANUAL
2. Remove vent assembly 20.
NOTE:
3. If present, remove ten bolts 24 or 27, PTO
For models without PTO provision, proceed
cover 25 or 28, and gasket 26 or 29.
with Paragraph 54.
For models with PTO provision, skip Para- 4. Remove eleven bolts 2 holding bearing retainer
graph 54 and proceed with Paragraph 55. assembly 3 and PTO gear assembly 10 into
converter housing 19.
54. TORQUE CONVERTER 5. Remove bearing retainer assembly 3 and PTO
HOUSING MODULE gear assembly 10. If necessary, use jack bolts
to loosen the bearing retainer assembly.
(Models without PTO Provision)
a. Disassembly (Foldout 5,A) b. Disassembly of Bearing Retainer
(Foldout 5,B)
1. If not previously removed, remove bolt 7,
1. Remove sealring 8 and 9 from bearing
speed sensor retainer 6, and engine speed
retainer 7. Remove oil seal assembly 4 using
sensor assembly 4. The engine speed sensor
tool J 24171-A.
must have a resistance of 300 30 Ohms.
2. Inspect bushing 6 for damage or wear.
CAUTION: Maximum allowable bushing ID is 89.19 mm
Use the correct wrench size to avoid crushing the (3.511 inch). Remove the bushing if damaged or
vent assembly. worn.
c. Disassembly of PTO Gear Assembly
2. Remove vent assembly 2. (Foldout 5,B)
b. Assembly (Foldout 5,A) 1. Remove oil pump drive hub 13 from PTO
1. Install engine speed sensor assembly 4, speed gear 12.
sensor retainer 6, and bolt 7. Tighten the bolt to 2. Inspect oil pump drive hub for excessive wear
2429 Nm (1821 lb ft). on drive tangs. Maximum allowable tang wear
is 0.31 mm (0.012 inch).
CAUTION:
3. Remove sealring 14 from PTO gear 12. If
Use the correct wrench size to avoid crushing the damaged, press two bearings 11 from PTO
vent assembly. gear 12.
2. Install vent assembly 2. Torque vent assembly d. Assembly of PTO Gear Assembly
to 1216 Nm (912 lb ft). (Foldout 5,B)
3. Skip to Paragraph 56. 1. Press two bearings 11 onto the PTO gear using
tool J 37041.
55. TORQUE CONVERTER
HOUSING MODULE CAUTION:
(Models with PTO Provision)
Oil pump drive hub 13 can be incorrectly
a. Disassembly (Foldout 5,B) installed backwards position the oil pump
drive hub tangs toward the oil pump.
1. If not previously removed, remove bolt 18,
speed sensor retainer 17, and engine speed
2. Install oil pump drive hub 13 into PTO gear 12,
sensor assembly 15. The engine speed sensor
aligned with hub tangs toward the oil pump.
must have a resistance of 300 30 Ohms.
3. Insert sealring 14 into the sealing bore of pump
housing 10 (Foldout 6,A) and measure end gap
CAUTION:
with feeler gauges. Sealring end gap must be
Use the correct wrench size to avoid crushing the 1.181.66 mm (0.0470.065 inch). Refer to
vent assembly. Paragraph 36g.
54 Copyright 2001 General Motors Corp.
MODULE REBUILD
4. Remove sealring 15 (Foldout 5,B) from the 56. FRONT SUPPORT AND OIL
seal bore and install the sealring onto PTO PUMP MODULE
gear 12.
a. Disassembly (Foldout 6,A)
e. Assembly of Bearing Retainer Assembly 1. Remove three sealrings 25 from the hub of
(Foldout 5,B) front support 20.
1. If removed, install bushing 6 using a press, and 2. Remove eight bolts 6 retaining pump housing
tools J 37038 and J 8092. assembly 7 or 10 (PTO unit) to front support
assembly 15.
2. Install sealring 9 onto bearing retainer 7.
Install oil seal 4 using a press, and tools 3. Remove pump housing assembly 7 or 10 and
J 37032 and J 37034. gear set 11.
4. On models without PTO, remove O-ring 4 and
3. Insert sealring 8 into the sealing bore in PTO
oil seal assembly 5 using tool J 24171-A.
gear 12 and measure the end gap using feeler
gauges. Sealring end gap must be 1.181.66 mm 5. Measure gear-cavity depth of pump housing 9
(0.0470.065 inch). Refer to Paragraph 36g. or 10. Maximum depth allowed is 19.04 mm
(0.750 inch) (Figure 53).
4. Remove sealring 8 from sealing bore and
6. Measure gear-cavity diameter of pump
install the sealring onto bearing retainer 7.
housing 9 or 10. Maximum ID allowed is
f. Assembly (Foldout 5,B) 150.25 mm (5.915 inch) (Figure 54).

1. Using a mallet, lightly tap PTO gear 7. For models without PTO provision, inspect
assembly 10 into converter housing 19 until bushing 8 inside pump housing 9 for wear or
the gear assembly is seated. damage. Measure the ID of the pump bushing.
Maximum ID allowed is 89.19 mm
2. Use guide bolts to install bearing retainer (3.511 inch).
assembly 3, rocking the retainer while 8. If worn or damaged, remove bushing 8 from
installing it. pump housing 9.

3. Install eleven bolts 2 to hold bearing retainer 9. Install gear set 11 into pump housing 9.
assembly 3 and PTO gear assembly 10 to Measure pump gear side clearance of both
housing 19. Tighten the bolts to 5161 Nm gears. Maximum allowable clearance is
(3845 lb ft). 0.10 mm (0.004 inch) (Figure 55).

4. If used, install PTO covers 25 or 28 and


gaskets 26 or 29 using ten bolts 24 or 27 in
the cover. Tighten the bolts to 5161 Nm
(3845 lb ft).

5. Install engine speed sensor assembly 15 and


engine speed sensor retaining bolt 18. Tighten PUMP
HOUSING
the bolt to 2429 Nm (1821 lb ft).

CAUTION:
Use the correct wrench size to avoid crushing the MAX DEPTH OF
breather. GEAR CAVITY
19.04 mm (0.75 in.) V01899.01

6. Install breather 20. Tighten the breather to Figure 53. Measuring Gear-Cavity Depth
1216 Nm (912 lb ft). of the Pump Housing

Copyright 2001 General Motors Corp. 55


4000 MH/HD 4000/B 500 SERIES ON-HIGHWAY SERVICE MANUAL
10. Measure gear tooth tip clearance. Maximum 14. Remove fourteen bolts 14 retaining the wear
allowable clearance is 0.15 mm (0.006 inch) plate 13 to front support 20. Remove wear
(Figure 56). plate 13.

15. If damaged, remove bearing 26 from front sup-


11. Measure driven gear to pump housing clear-
port 20 using a drift and hammer.
ance. Maximum clearance allowed is 0.30 mm
(0.012 inch) (Figure 57). 16. Measure the OD of front support sleeve 21.
Minimum diameter is 119.81 mm (4.717 inch).
12. Inspect bushing 12 that is inside the inner Also inspect for wear. If worn or damaged, re-
(drive) gear of gear set 11. Measure the ID of move front support sleeve 21 from front sup-
bushing 12. The maximum allowable ID is port 20.
66.93 mm (2.635 inch).
17. If damaged, remove dowel pins 19 from front
support 20.
13. If bushing 12 is damaged or worn, remove the
bushing. 18. If worn or damaged, remove ground sleeve 16
or 17 by pressing ground sleeve from front
support 20.

PUMP
HOUSING

MAX ID OF
GEAR CAVITY
150.25 mm (5.915 in.)
V01277.01 MAX GEAR TOOTH
TIP CLEARANCE
0.15 mm (0.006 in.)
Figure 54. Measuring Gear-Cavity Diameter V02519
of the Pump Housing
Figure 56. Measuring Gear Tooth Tip Clearance

DRIVE
GEAR
PUMP PUMP HOUSING
HOUSING MAX SIDE DRIVEN GEAR MAX CLEARANCE BETWEEN
CLEARANCE DRIVEN GEAR OD AND PUMP
0.10 mm (0.004 in.) V02518 DRIVEN GEAR HOUSING 0.30 mm (0.012 in.)
V02520

Figure 55. Measuring Gear Side Clearance Figure 57. Measuring Driven Gear
of the Pump Housing Clearance to the Pump Housing

56 Copyright 2001 General Motors Corp.


MODULE REBUILD
19. Compress spring 22, using tool J 41462, until 2. Replace spring 22 if spring load did not meet
load is removed from dowel pin 24. Remove load specifications.
dowel pin 24 and carefully release the load on 3. Install ball 23 and spring 22 into front
spring 22 by rotating the handle on tool J 41462 support 20. Compress spring 22 using tool
in the counter-clockwise direction. When J 41462 until dowel pin 24 can be inserted to
spring 22 has reached its free length, remove tool retain spring 22. Remove tool J 41462.
J 41462. Remove spring 22 and ball 23 from the
4. If removed, install ground sleeve 16 or 17.
front support 20. Place front support 20 on press bed. The
20. Inspect for damage in the ball seat area of front machined flat at the base of the ground sleeve
support 20. Check tension of spring 22 and must align with the arrow cast on the front
compare to value in Table 72. support (Figure 58, View C). Press ground
sleeve 16 or 17 into front support 20 to
shoulder. Total runout of spline OD may not
b. Assembly of Front Support exceed 0.13 mm (0.005 inch).
(Foldout 6,A and Figure 58)
5. If removed, install dowel pins 19. Press the
1. Replace front support 20 if damage to the ball pins to a height of 14.5 mm (0.57 inch) from
seat or other area was found. the surface of front support 20.

FRONT
FRONT SUPPORT (20) TOP
DOWEL PINS E
(19 )
DOWEL PIN
14.5 mm
GROUND SLEEVE (0.57 in.)

INSTALL REMOVE

SPLINE OD T.I.R.
0.13 mm
(0.005 in.)

E
RELIEF VALVE
SECTION E-E BORE
BOTTOM
VIEW A
VIEW B
To install, align flat on
ground sleeve with arrow
on front support.

GROUND SLEEVE (16 OR 17)

20

VIEW C V01344.03

Figure 58. Ground Sleeve Removal and Installation

Copyright 2001 General Motors Corp. 57


4000 MH/HD 4000/B 500 SERIES ON-HIGHWAY SERVICE MANUAL
6. If removed, align the lubrication hole in 3. Inspect thrust bearing 42 for wear. Replace the
sleeve 21 with the relief valve bore (bottom of bearing if it is worn.
front support), and install front support sleeve 4. Remove C2 retaining ring 40.
21 using a press and tools J 37041 and
J 37034. Refer to Figure 58, View B. 5. Remove C2 backplate 39.

7. Install wear plate 13. Secure with fourteen 6. Measure the wear surface thickness of C2
bolts 14. Tighten the bolts to 5161 Nm backplate 39. Minimum thickness allowed is
(3845 lb ft). 7.90 mm (0.311 inch). Check flatness of the
backplate. Maximum allowable distortion is
8. Install bearing 26 using a press, and tools 0.15 mm (0.006 inch).
J 37038 and J 8092. Press bearing 26 flush to
0.25 mm (0.009 inch) below the surface. 7. Remove C2 clutch pack seven friction
plates 38 and seven steel reaction plates 37.
c. Assembly of Pump Housing (Foldout 6,A) 8. Measure the thickness of each friction plate 38.
Minimum thickness allowed is 2.92 mm
NOTE: (0.115 inch). Measure the oil groove depth and
Steps (1), (2), and (3) below apply only to cone of each friction plate. Minimum groove
transmissions without PTO provision. depth allowed is 0.20 mm (0.008 inch).
Maximum cone allowed is 0.25 mm (0.010 inch).
1. If removed, install bushing 8 into pump 9. Measure the thickness and cone of each steel
housing 9 using a press, and tools J 37038 and reaction plate 37. Minimum thickness allowed
J 8092. is 2.41 mm (0.095 inch). Maximum cone
2. Install oil seal 5 using a press, and tools allowable is 0.25 mm (0.010 inch).
J 37032 and J 37034. 10. Remove C2 drive hub 36, including two thrust
3. Install O-ring 4. bearings 35. Inspect the splines of the C2 drive
hub. Maximum spline wear allowed is
4. If removed, install bushing 12 into drive 0.38 mm (0.015 inch).
(inner) gear of gear set 11. Align the staking in
the pre-staked bushing with the slots in the 11. Remove C1 drive hub 34. Inspect the splines of
inside gear of gear set 11. Use tool J 39954. the C1 drive hub. Maximum allowable spline
wear is 0.38 mm (0.015 inch).
5. Lubricate pump gear set 11 and install the gear
set in pump housing 9 or 10.
NOTE:
6. Retain the pump housing to the front support Beginning with S/N 6610032320, the C1 clutch
with eight bolts 6. Tighten the bolts to 5161 Nm apply plate and backplate are not identical. Consult
(3845 lb ft). a current parts catalog and rebuild with the
7. Measure the end gap of three rotating improved design where the apply plate is thinner
sealrings 25 before installation. Insert the and the backplate is thicker. This change provides
improved C1 backplate life and better retention of
sealrings into the rotating clutch hub bore
the backplate retaining ring.
and measure end gap with a feeler gauge.
Sealring end gap must be 1.001.44 mm
(0.0400.056 inch). Refer to Paragraph 36g. 12. Remove C1 retaining ring 33 and C1 clutch
8. Install three rotating sealrings 25 on front pack one backplate 32, seven friction
support 20 hub. plates 30 and six steel reaction plates 31, and
one apply plate 29.
57. ROTATING CLUTCH MODULE 13. Measure the thickness of each friction plate 30.
Minimum allowable thickness is 2.92 mm
a. Disassembly (Foldout 6,B) (0.115 inch). Measure the oil groove depth and
cone of each friction plate. Minimum groove
1. Remove retaining ring 43. depth allowable is 0.20 mm (0.008 inch). Max-
2. Remove P1 sun gear assembly 41. imum cone allowed is 0.25 mm (0.010 inch).

58 Copyright 2001 General Motors Corp.


MODULE REBUILD
14. Measure the thickness of each steel reaction 18. Inspect bushing 5 inside the end of turbine
plate 31. Minimum allowable thickness is shaft 4 or 7. Measure the ID of the turbine
2.41 mm (0.095 inch). Maximum cone allow- shaft bushing. Maximum ID allowed is
able is 0.25 mm (0.010 inch). 36.14 mm (1.423 inch).
15. Measure the wear surface thickness and cone 19. Remove three rotating sealrings 8.
of C1 apply plate 29 and backplate 32. Mini-
mum thickness allowed is 5.90 mm 20. Remove O-ring 2 from turbine shaft
(0.232 inch) and 9.90 mm (0.390 inch), respec- assembly 3 or 6.
tively. Check flatness of the apply plate and
backplate. Maximum allowable distortion is 21. Place rotating clutch on tool base J 37030-3 so
0.15 mm (0.006 inch). rotating drum is supported by tool tangs (Fig-
16. Remove thrust bearing 14 from hub ure 59, View C). Install J 35923-2 (Figure 5
assembly 11. 9, View A), including the bearing, washer and
handle. Tighten tool, compressing C1 balance
17. Remove retaining ring 15 and turbine shaft as- piston 26 and C1 return spring assembly 25,
sembly 3 or 6. and remove retaining ring 28.

J 37030-3
J 37030-3

HANDLE
HANDLE
FLAT WASHER
FLAT WASHER
BEARING J 35923-2
BEARING J 35923-2
J 37030-1

VIEW A VIEW B

J 37030-3

VIEW C
VIEW D
ALIGNMENT SLOTS V06847

Figure 59. Rotating Clutch Disassembly/Assembly

Copyright 2001 General Motors Corp. 59


4000 MH/HD 4000/B 500 SERIES ON-HIGHWAY SERVICE MANUAL
30. Separate C1 piston 24 and sealring 23 from C2
WARNING! piston 19 and sealring 18 by tapping lightly on
Carefully release spring force. Piston springs are the C1 piston.
highly compressed. Personal injury can occur if
the spring force is not controlled. b. Assembly Foldout 6,B)

22. Release spring force by rotating handle in


CAUTION:
counterclockwise direction. Remove handle,
flat washer, bearing, and J 35923-2 tool. Beginning with S/N 6610032320, the C1 clutch
piston 24 and balance piston 26 were redesigned.
23. Remove balance piston 26, sealring 27, and In units prior to this S/N, if either part must be
replaced, BOTH the C1 clutch piston 24 and
C1 spring assembly 25.
balance piston 26 must be replaced with the new
design parts. Intermixing of old and new design
24. Install tools J 37030-3, J 37030-1, J 35923-2 parts will cause part misalignment leading to
(Figure 59, View B), bearing, washer, and damage of C1 return spring assembly 25 and
handle. Tighten tool and remove retaining potential failure of C1 clutch piston 24 or C1
ring 22. Remove tools after relieving spring balance piston 26.
force.

25. Remove C2 spring assembly 20.


NOTE:
26. Lift rotating drum 9 free of hub 13 and C1/C2 Beginning with S/N 6610062126, the C1 piston
pistons 24 and 19. Inspect the clutch splines of return spring assembly 25 was redesigned. In units
the rotating drum. Maximum spline wear al- prior to this S/N, if this part must be replaced, the
lowed is 0.38 mm (0.015 inch). new design part is required and is completely
interchangeable with the original part.
27. Remove C1/C2 pistons 24 and 19 and
sealrings 18 and 23 from hub assembly 11
rocking the piston from side to side. 1. If removed during disassembly, install
bushing 12 into drive hub assembly 11 using
28. Inspect the ID of rotating clutch hub tools J 37040 and J 8092.
bushing 12. Maximum allowable ID of the
bushing is 120.27 mm (4.735 inch). Remove 2. Install piston sealring 16 on hub assembly 13
the bushing from hub assembly 11 if replace- and piston sealring 18 into C2 piston 19. Install
ment is necessary. Avoid damaging the bushing piston sealring 17 on hub assembly 13 and
bore. piston sealring 23 onto C1 piston 24.

3. With a mallet, lightly tap C2 piston 19 (with


29. Remove piston sealrings 16 and 17 from
sealring 18) onto hub assembly 11.
hub 13.
4. Align notch on C1 piston with any lubrication
orifice on the rotating drive hub. With a mallet,
NOTE:
lightly tap C1 piston 24 (with sealring 23) onto
Beginning with S/N 6610037353, the clutch the center of C2 piston 19 and over hub
hub 13 was changed to use a double weld design assembly 13.
to replace the single weld design. Inspect units
prior to this S/N carefully for cracks in the weld 5. Install rotating drum 9 over hub assembly 11
area and replace defective parts with the new and C1/C2 pistons 24 and 19.
design. Use magnetic particle inspection or place
solvent in the C2 piston bore to confirm that a crack 6. Install C2 spring assembly 20. Index the spring
is present. assembly with the drive hub tangs and the
splines on the C2 piston.

510 Copyright 2001 General Motors Corp.


MODULE REBUILD
7. Be sure that the C2 spring assembly has made 14. Install O-ring 2 onto the forward end of the tur-
contact with the bottom of the slots in the C2 bine shaft.
piston. If the spring assembly did not reach the 15. Install each rotating sealring 8 into the
bottom, remove the C2 spring assembly and ground sleeve bore and measure the end gap.
re-index it in the next spline on the rotating Sealring end gap must be 0.651.01 mm
drum 9. Repeat this process until the C2 spring (0.0260.039 inch). Refer to Paragraph 36g.
assembly is in the proper position. Install three rotating sealrings 8, with correct
end gap, onto the rear of the turbine shaft.
8. Install C2 spring plate 21. Index the spring
plate with the drive hub tangs and the splines 16. Install turbine shaft assembly 3 or 6. Retain the
on the C2 piston. turbine shaft with retaining ring 15.

9. Place the rotating clutch on tool base CAUTION:


J 37030-3 so that the rotating drum is
Be sure that thrust bearings are assembled to
supported by tool tangs. Install tool J 37030-1 function correctly. Make sure that the locating
(Figure 59, View B), J 35923-2, that includes lip on either the inner or outer thrust bearing
the bearing, washer, and handle. Tighten tool race is not preventing the race from contacting
to compress C2 spring assembly 20, and install the thrust surface of the mating part. Failure to
retaining ring 22. Remove tools. do this leads to premature thrust bearing failure
and incorrect shim selection to maintain proper
10. Install sealring 27 onto balance piston 26. internal part clearance.

11. Install C1 spring assembly 25. Aligning mark 17. Install thrust bearing 14 onto the rotating as-
on balance piston with slot on the C1 clutch sembly 13.
piston, install balance piston 26 onto the C1
piston. NOTE:
12. Install tool J 35923-2 (Figure 59, View A), Beginning with S/N 6610032320, the C1 clutch
apply plate and backplate are not identical. Consult
that includes the bearing, washer, and handle.
a current parts catalog and rebuild with the
Tighten tool to compress C1 spring assembly improved design where the apply plate is 2.00 mm
and install retaining ring 28 into the hub of the (0.157 inch) thinner and the backplate is 2.00 mm
rotating clutch assembly. Remove tool. (0.157 inch) thicker and reshaped. This change
provides improved C1 backplate life and better
13. If removed, install bushing 5 into turbine shaft retention of the backplate retaining ring. See Figure
assembly 3 or 6 using tools J 37036 and 510 for pictorial information.
J 8092.

C1 Pressure Plate Redesigned C1 Pressure Plate


2 mm thinner than 2 mm thicker than prior
prior pressure plate pressure plate

V05566

Figure 510. Redesigned C1 Apply Plate and Backplate

Copyright 2001 General Motors Corp. 511


4000 MH/HD 4000/B 500 SERIES ON-HIGHWAY SERVICE MANUAL
18. Install C1 clutch pack one apply plate 29, 4. Inspect the inner C5 clutch plate splines of
seven friction plates 30, six steel reaction main housing 43. Maximum allowable spline
plates 31, and one backplate 32. Install clutch wear is 1.15 mm (0.045 inch).
plates alternately, starting with a friction
plate 30. Install C1 retaining ring 33. 5. Remove fourteen bolts 2 retaining the C3
backplate assembly 3 and C3 clutch housing
19. Install C1 drive hub 34. Be sure that the hub assembly 16. Remove C3 backplate
passes over the external splines of all seven assembly 3.
plates 30.

20. Install a thrust bearing 35 on each side of C2 6. Inspect four thrust plates 5 and twelve rivets 6 on
drive hub 36, and install this assembly over C1 clutch backplate 4. Minimum allowable thrust plate 5
drive hub 34. thickness at the contact surface is 2.82 mm
(0.111 inch). Maximum allowable distortion of
21. Install C2 clutch plates seven friction backplate 4 is 0.15 mm (0.006 inch). Maximum
plates 38 and seven steel reaction plates 37. In- allowable step wear of backplate 4 is 0.13 mm
stall clutch plates alternately, starting with a (0.005 inch). If replacement is necessary,
steel reaction plate 37. remove the thrust plates by drilling out the
rivets.
22. Install C2 pressure plate 39. Install C2 retain-
ing ring 40. 7. Remove P1 ring gear 7. Inspect the clutch
splines of the P1 ring gear. Maximum
23. If removed, install thrust bearing 42 on sun
allowable spline wear is 0.38 mm (0.015 inch).
gear assembly 41.

24. Install P1 sun-gear drive hub 41. Install retain- 8. Remove the C3 clutch pack five friction
ing ring 43. plates 8 and four steel reaction plates 9.

9. Measure the thickness and cone of each


58. C3/C4 AND MAIN HOUSING friction plate 8. Minimum thickness is
MODULE 3.485 mm (0.137 inch). Maximum allowable
cone is 0.25 mm (0.010 inch).
a. Disassembly (Foldout 7)
10. Measure the thickness and cone of each steel
reaction plate 9. Minimum allowable thickness
NOTE: is 2.41 mm (0.095 inch). Maximum allowable
When replacing an identification plate, keep the cone is 0.25 mm (0.010 inch).
original identification plate. Stamp the information
from the original identification plate onto the 11. Remove piston return plate 11 with four return
replacement identification plate. spring assemblies 10 attached.

12. Inspect plate 11. Minimum allowable thickness


1. Replace a damaged identification plate of plate 11 is 4.91 mm (0.193 inch).
remove retaining rivet 37 and identification
plate 36. 13. If damaged, and replacement is necessary,
2. If present, remove two bolts 31 retaining remove return spring assemblies 10 from
feedthrough connector 33 (prior to Model Year plate 11. Remove spring retainer assembly 12
1995). Remove the feedthrough connector. and piston 15. Remove sealrings 13 and 14
Also, cover 32 and internal seal 34 may be from piston 15 on non-molded, one-piece
attached to connector 33. pistons. Discard the non-molded piston and
sealrings, if present.
3. If necessary, remove screw 49 and wiring
harness clamp 50. 14. Remove C3 housing assembly 16.

512 Copyright 2001 General Motors Corp.


MODULE REBUILD
15. Inspect four thrust plates 18 and twelve
rivets 17 on C3 housing 19. Minimum allow- CAUTION:
able thrust plate 18 thickness at the contact sur- Beginning with S/N 6610062126, the C3/C4
face is 2.82 mm (0.111 inch). Maximum clutch friction plates have been redesigned. for
allowable distortion of backplate 4 is 0.15 mm increased durability. DO NOT use this clutch
(0.006 inch). Maximum stepwear of 0.13 mm plate material in units prior to this S/N because
(0.005 inch) is allowed. If replacement is nec- they are not calibration compatible. DO be sure
essary, remove the thrust plates by drilling out to use the new material in units beginning with
this S/N. DO NOT mix old and new clutch plate
the rivets. Inspect splines in C3 clutch
material. Plates containing the new friction
housing 19. Maximum spline wear allowed is material are identified by two missing spline
1.15 mm (0.045 inch). teeth approximately 180 degrees apart.

16. Remove C4 clutch pack five friction


plates 21 and five steel reaction plates 20. NOTE:
Beginning with S/N 6610014908, the C3/C4 friction
17. Measure the thickness and cone of each fric- clutch plates had hardened internal splines to
tion plate 21. Minimum allowable thickness is improve durability. These plates are identified by
3.485 mm (0.137 inch). Maximum allowable one missing internal spline tooth or by a blue stripe
cone is 0.25 mm (0.010 inch). on the plate OD. Use these friction plates on all units
up to S/N 6610062126.
18. Measure the thickness and cone of each steel
reaction plate 20. Minimum allowable
thickness is 2.41 mm (0.095 inch). Maximum 4. Install C4 clutch pack. Starting with a friction
allowable cone is 0.25 mm (0.010 inch). plate alternately install five friction
plates 21 and five steel reaction plates 20.

19. Remove piston return plate 23 with four return 5. To assemble the C3 housing (if thrust plates
spring assemblies 22 attached. Inspect were removed), install four thrust plates 18
plate 23. Minimum allowable thickness of using twelve rivets 17 into C3 clutch
plate 23 is 4.91 mm (0.193 inch) housing 19. Use tool J 39534 to cold form
rivets. Insert the rivet from the front so that the
20. Remove spring retainer assembly 24 and pre-formed head is below the active surface of
piston 27 from C4 housing 28. If present, the thrust plate. Use the cold forming tool to
remove sealrings 25 and 26 from non-molded, upset the rivet at the rear of the clutch housing
one-piece piston 27 and discard these parts. to complete the riveted joint. A correctly
Inspect splines in C4 clutch housing 28. formed rivet upset will be 4.00 mm
Maximum spline wear allowed is 1.15 mm (0.157 inch) in diameter and be no more than
(0.045 inch). 1.00 mm (0.039 inch) above the surface of the
clutch housing. The thrust plate must be tightly
attached to the housing; no movement is
b. Assembly (Foldout 7) allowed.
1. Replace non-molded piston 27 with new
6. Replace non-molded piston 15 with a molded
molded piston 27. Install piston 27 into C4
piston 15. Install C3 clutch piston 15 into C3
housing 28. Install spring retainer assembly 24.
clutch-housing assembly 19.

2. If removed, install spring assemblies 22 and 7. Install C3 clutch housing assembly 19 with
attach them securely to piston return plate 23. clutch piston 15 on top of the assembled C4
clutch housing assembly. Ensure index notches
3. Install piston return plate 23 with four return on the clutch housings are aligned. Install
spring assemblies 22. spring retainer assembly 12.

Copyright 2001 General Motors Corp. 513


4000 MH/HD 4000/B 500 SERIES ON-HIGHWAY SERVICE MANUAL
8. Install piston return plate 11 and four return 3. Remove bearing spacer 6.
spring assemblies 10. If removed, install new
spring assemblies and attach them securely to 4. Remove thrust bearing 2.
return plate 11.
5. Remove selective shim 1 (for 4000 MH,
9. Install P1 ring gear 7. HD 4060, HD 4560, and B 500 models only).
Remove non-selective shim 1 (HD 4070/4076
10. Install the C3 clutch pack. Starting with a fric- models only).
tion plate, alternately install five friction
plates 8 and four steel reaction plates 9. 6. On close ratio transmissions (4000 MH,
HD 4060, and B 500), remove P3 sun gear 7
11. To assemble the C3 backplate (if thrust plates
from main shaft 8.
were removed), install four thrust plates 5 us-
ing twelve rivets 6 into C3 backplate 4. Use
7. For all models, inspect main shaft 7 or 8 for
tool J 39534 to cold form rivets. Insert the rivet
wear and damage and for evidence of chipped
from the front so that the pre-formed head is
or cracked splines or gear teeth. Measure the
below the active surface of the thrust plate.
journals as illustrated in Figure 511.
Use the cold forming tool to upset the rivet at
the rear of the clutch housing to complete the
b. Assembly (4000 MH, HD 4060, HD 4560, and
riveted joint. A correctly formed rivet upset
B 500 Models Only) (Foldout 8)
will be 4.00 mm (0.157 inch) in diameter and
be no more than 1.00 mm (0.039 inch) above
the surface of the clutch housing. The thrust NOTE:
plate must be tightly attached to the housing;
no movement is allowed. Do not install thrust bearing 2 or selective shim 1
until final transmission assembly. Measurement for
12. Install C3 backplate assembly 3. Align the selective shim 1 is performed during final buildup.
notch on the C3 backplate with the notches on
the C3 and C4 housings.
1. On close ratio transmissions (4000 MH,
13. Install fourteen retaining bolts 2 into the C3/C4 HD 4060, and B 500), install P3 sun gear 7
clutch assembly. Tighten the bolts to 5161 Nm onto main shaft 8.
(3845 lb ft).
2. Install bearing spacer 6.
14. If removed, install identification plate 36 and
screw 37. 3. Install P2 sun gear 5.
15. If removed, install feedthrough connector 4. Install external spiral retaining ring 4.
assembly 33, seal 34, and cover 32 using two
bolts 31. Tighten the bolts to 2.02.8 Nm
(1825 lb in.). 35.92 mm
(1.414 in.)
16. If removed, install wiring harness clamp 50 52.98 mm
using screw 49. Tighten the screw firmly (2.085 in.)
against the clamp and tighten it to 2429 Nm
(1821 lb ft). 35.92 mm
(1.414 in.)

59. MAIN SHAFT MODULE


a. Disassembly (Foldout 8)
V02524
1. Remove external spiral retaining ring 4.

2. Remove P2 sun gear 5. Figure 511. Measurement of Main Shaft Journals

514 Copyright 2001 General Motors Corp.


MODULE REBUILD
c. Assembly (HD 4070/4076 Models Only) 7. Measure the thickness and any step wear for all
(Foldout 8) thrust washers 10 and 13. Minimum thrust
washer thickness allowed is 1.40 mm
1. Install P3 sun gear 7 onto main shaft 8.
(0.055 inch). Maximum allowable step wear is
2. Install bearing spacer 6. 0.12 mm (.005 inch).

3. Install P2 sun gear 5. 8. Remove thrust bearing assembly 14 from P1


planetary carrier 8.
4. Install external spiral retaining ring 4.
9. Inspect bushing 9 inside P1 planetary carrier 8
5. Install non-selective shim 1.
for wear or damage. Maximum ID allowed is
6. Install thrust bearing 2. 89.32 mm (3.516 inch). If worn, remove
bushing 9.

10. Check spline wear of P1 planetary carrier 8


510. P1 PLANETARY MODULE
and P2 planetary ring gear 15. Maximum al-
lowable spline wear is 0.38 mm (0.015 inch).
a. Disassembly (Foldout 9,A)
1. Remove internal retaining ring 2 from P2 ring b. Assembly (Foldout 9,A)
gear 15.

2. Remove P2 ring gear 15. 1. If replacement is necessary, press a new


bushing 9 into P1 carrier 8 using a press,
3. Check P1 planetary carrier assembly 3 pinion installer J 37038, and drive handle J 8092.
end play. Pinion end play must not exceed Press bushing 9 flush to 0.40 mm (0.157 inch)
0.94 mm (0.037 inch). Check all six pinion below the surface.
gears.
2. Install two bearing assemblies 12 into the
4. Remove retaining ring 4. Remove indexing center of pinion gear 11. Install thrust
ring 5. washers 10 and 13 inside P1 planetary
carrier 8, align thrust washer tangs with the
slots in the planetary, and retain them with oil-
NOTE: soluble grease. Slide the pinion gear and
For units prior to S/N 6610018759, inspect the bearing assemblies into the side of the P1
indexing ring for abnormal wear as shown in Figure planetary carrier between the thrust washers.
512, View A. Repeat the procedure for the five remaining
pinion gears.

5. Remove six pinion spindles 6 from P1


carrier 8. CAUTION:
If abnormal wear existed on the indexing ring of
NOTE: units prior to S/N 6610018759, replace all
spindles with the sharp edge condition shown in
For units prior to S/N 6610018759, inspect the
Figure 512, View B. If the wear on the indexing
planetary spindles for the sharp edge condition as
ring is minor, flip it over to get a fresh reaction
shown in Figure 512, View B.
point for the spindle. Replace the indexing ring if
both corners of the indexing ring are worn.
6. Slide pinion gear 11, thrust washers 10 and 13, Failure to take corrective action may allow the
and two bearing assemblies 12 from the side of spindle to rotate which may reduce or shut off
P1 planetary carrier 8. Repeat the procedure lubrication to the pinion bearings and thrust
with the five remaining pinion gears. washers.

Copyright 2001 General Motors Corp. 515


4000 MH/HD 4000/B 500 SERIES ON-HIGHWAY SERVICE MANUAL

RADIUS ADDED ON
INDEXING FLAT SHARP FLAT EDGE EDGE 0.25-1.50 mm

NO WEAR

ABNORMAL WEAR

INDEXING RING

VIEW A

VIEW A and B Conditions


Prior To S/N 6610018759

PLANETARY SPINDLE

VIEW B

DIMENSION A

VIEW C VIEW D
View C and D New Design Beginning January 1, 2000 V06848

Figure 512. Planetary Spindle and Indexing Ring Changes

4. Install indexing ring 5 and retaining ring 4.


NOTE:
Replacement indexing rings should look like the 5. If components were replaced, check pinion end
example in Figure 512, View C. The ring has
play. Pinion end play must not exceed 0.94 mm
increased hardness for wear resistance and is
stamped with HD5. Replacement spindles should (0.037 inch). Check all six pinion gears.
look like the example in Figure 512, View D. The
spindle has a revised Dimension A for reduced 6. Install P2 ring gear 15 over P1 planetary
clearance with the indexing ring and has a 2 carrier assembly 3.
stamped on the rear end.

3. Install six spindles 6 so the lower step is 7. Install internal retaining ring 2 into P2 ring
positioned for proper installation of indexing gear 15, connecting P1 planetary carrier
ring 5. assembly 3 and the P2 planetary ring gear.

516 Copyright 2001 General Motors Corp.


MODULE REBUILD
7. Inspect bushing 8 inside P2 planetary carrier 7
CAUTION: for wear or damage. Maximum ID of the
Be sure that thrust bearings are assembled to bushing is 53.23 mm (2.096 inch). Remove
function correctly. Make sure that the locating bushing 8 if it is worn or damaged.
lip on either the inner or outer thrust bearing
race is not preventing the race from contacting 8. Check spline wear between P2 planetary
the thrust surface of the mating part. Failure to carrier 7 and P3 planetary ring gear 15.
do this leads to premature thrust bearing failure Maximum wear allowed is 0.38 mm
and incorrect shim selection to maintain proper (0.015 inch).
internal part clearance.
b. Assembly (Foldout 9,B)
8. Install thrust bearing assembly 14 on P1 1. If replacement is necessary, press a new
planetary carrier assembly 3. bushing 8 into P2 carrier 7 using a press,
installer J 37036, and driver J 8092.

511. P2 PLANETARY MODULE 2. Install two roller bearings 10 into the center of
pinion gear 11. Install thrust washers 9 and 12
a. Disassembly (Foldout 9,B) in P2 planetary carrier 7, align thrust washer
tangs with slots in the planetary, and retain
1. Remove retaining ring 2. them with oil-soluble grease. Slide the pinion
gear and two bearing sets, into the side of the
2. Remove P3 ring gear 15. Remove and inspect
P2 planetary carrier between the thrust
thrust bearing assembly 14.
washers. Repeat the procedure with the three
3. Check P2 planetary carrier pinion end play. remaining pinion gears.
Pinion end play must not exceed 0.94 mm
(0.037 inch). Check all four pinion gears. CAUTION:
4. Remove internal retaining ring 4. Remove If abnormal wear existed on the indexing ring of
indexing ring 5. Remove four pinion units prior to S/N 6610018759, replace all
spindles 13 from P2 carrier 7. spindles with the sharp edge condition shown in
Figure 512, View B. If the wear on the indexing
ring is minor, flip it over to get a fresh reaction
NOTE: point for the spindle. Replace the indexing ring if
both corners of the indexing ring are worn.
For units prior to S/N 6610018759, inspect the Failure to take corrective action may allow the
indexing ring for abnormal wear as shown in spindle to rotate which may reduce or shut off
Figure 512, View A. Also inspect the planetary lubrication to the pinion bearings and thrust
spindles for the sharp edge condition as shown in washers.
Figure 512, View B.

5. Slide a pinion gear 11, thrust washers 9 and 12, NOTE:


and two roller bearings 10 from the side of P2 Replacement indexing rings should look like the
planetary carrier 7. Repeat the procedure with example in Figure 512, View C. The ring has
the three remaining pinion gears. increased hardness for wear resistance and is
stamped with HD5. Replacement spindles should
6. Measure the thickness and any step wear for all look like the example in Figure 512, View D. The
thrust washers 9 and 12. Minimum allowable spindle has a revised Dimension A for reduced
thickness of the thrust washers is 1.40 mm clearance with the indexing ring and has a 2
(0.055 inch). Maximum allowable step wear is stamped on the rear end.
0.12 mm (0.005 inch).

Copyright 2001 General Motors Corp. 517


4000 MH/HD 4000/B 500 SERIES ON-HIGHWAY SERVICE MANUAL
3. Install four spindles 13 so the lower step is b. Assembly (Foldout 9,C)
positioned for proper installation of indexing 1. Install two roller bearing assemblies 10 into
ring 5. the center of pinion gear 9. Install thrust
washers 8 in P3 planetary carrier 4, align the
4. Install indexing ring 5 and internal retaining
thrust washer tangs with the slots in the carrier,
ring 4.
and retain them with oil-soluble grease. Slide
the pinion gear and bearings into the side of the
5. If components were replaced, check pinion end
P3 planetary carrier between the thrust
play. Pinion end play must not exceed 0.94 mm
washers. Repeat the procedure with the three
(0.037 inch). Check all four pinion gears.
remaining pinion gears.
Install thrust bearing 14.
2. Install four planetary spindles 7 so the lower
6. Install P3 ring gear 15 over P2 carrier step is positioned for proper installation of
assembly 3. indexing ring 3.
7. Install retaining ring 2 into P3 ring gear 15 so 3. Install indexing ring 3. Install internal retaining
that the P2 carrier and P3 ring gear are linked. ring 2.

4. If components were replaced, check pinion end


NOTE: play. Pinion end play must not exceed 0.94 mm
(0.037 inch). Check all four pinion gears 9.
For 4000 MH, HD 4060, HD 4560, and B 500
models with retarder, proceed to Paragraph
514. NOTE:
For 4000 MH, HD 4060, HD 4560, and B 500 Do not install shim locating ring 6 or selective
models without retarder, skip Paragraph 514 shim 12 until final transmission assembly.
and 515 and proceed to Paragraph 516. Measurement for selective shim is performed
during final buildup.

512. P3 PLANETARY MODULE


(HD 4070/4076 Models Only) 513. C6 ADAPTER HOUSING
MODULE (HD 4070/4076 Models
a. Disassembly (Foldout 9,C) Only) (Foldout 9,C)

1. Check pinion end play. Pinion end play must a. Disassembly of Ring Gear And Hub Assembly
not exceed 0.94 mm (0.037 inch). Repeat the
check on the three remaining pinion gears 9. 1. Remove ring gear and hub assembly 45.

2. Remove retaining ring 48 from ring gear and


2. Remove retaining ring 2. Remove indexing
hub assembly 45 and separate ring gear 46 and
ring 3. Remove four planetary spindles 7.
hub 47.
3. Slide pinion gear 9, thrust washers 8, and two 3. Remove thrust bearing 44.
bearing assemblies 10 from the side of P3
planetary carrier 4. Repeat the procedure for b. Disassembly
three remaining pinion gears. 1. Remove backplate 29.
4. Measure the thickness and any step wear for 2. Thread three M8 eye bolts into 3 tapped holes
eight thrust washers 8. Minimum allowable of P4 planetary carrier assembly 32.
thickness of the thrust washers is 1.40 mm
(0.055 inch). Maximum step wear allowed is 3. Attach hoist and remove P4 planetary carrier
0.12 mm (0.005 inch). assembly 32 from C6 adapter housing 22.

518 Copyright 2001 General Motors Corp.


MODULE REBUILD
c. Disassembly of P4 Planetary Carrier Assembly 6. Place special tool J 43025 onto return spring
assembly 17 (Figure 513).
1. Remove internal retaining ring 33 from P4
carrier assembly 32.
7. Compress return spring assembly 17 using
2. Turn P4 carrier assembly over and remove J 35923-4 tool base, washer, bearing, handle,
hub 43. and piston spring compressor J 43025 (Figure
514). Remove external retaining ring 16 and
3. Remove internal retaining ring 34 and indexing slowly release the spring force.
ring 35 from P4 carrier assembly 32.
8. Remove return spring assembly 17.
4. Remove six spindles 39 from P4 carrier 37.
9. Remove C5 piston 18 from C6 adapter housing
5. Check pinion end play. Pinion end play must module 14.
not exceed 0.94 mm (0.037 inch). Repeat the
check on the five remaining pinion gears.
J 35923

6. Remove six pinion gears 41 from P4 carrier


assembly 32. J 43025

7. Remove twelve washers 40 and twelve needle


bearings 42 from the pinion gears.

8. Measure the thickness and any step wear for


twelve thrust washers 40. Minimum allowable
thickness of the thrust washers is 1.40 mm
(0.055 inch). Maximum step wear allowed is
0.12 mm (0.005 inch).
V05581

9. Inspect bushing 38 in carrier 37 for wear or


damage. Maximum allowable bushing ID is Figure 513. Compression of Spring and
Retainer Assembly
113.33 mm (4.462 inch). Remove bushing 38
if it is worn or damaged.

J 35923-4
d. Disassembly of Remaining C6 Parts
1. Lift C6 clutch pack from C6 adapter housing
module eight friction plates 28 and nine
steel reaction plates 27.

2. Measure the thickness and cone of each


friction plate 28. Minimum thickness is
3.68 mm (0.145 inch). Maximum allowable
cone is 0.25 mm (0.010 inch).

3. Measure thickness and cone of each steel


reaction plate 27. Minimum thickness is
3.24 mm (0.128 inch). Maximum allowable
cone is 0.25 mm (0.010 inch).
V05582

4. Remove thrust bearing 31.


Figure 514. Bottom View of C6 Adapter
5. Remove P4 sun gear 30. Housing and J 35923-4

Copyright 2001 General Motors Corp. 519


4000 MH/HD 4000/B 500 SERIES ON-HIGHWAY SERVICE MANUAL
10. Remove internal sealring 20 from C5
piston 18. Remove external sealring 19 from
C5 piston 18.
J 37034
11. Place C6 adapter housing module 21 on press
stand. Place special tool J 43047 and J 37034
onto ball bearing 26 (Figure 515). Support J 43047
ball bearing from falling with a block of wood.
12. Using press, remove ball bearing 26.
13. Inspect ball bearing 26. Refer to Paragraph 35d
and 35e.

e. Assembly
1. Turn C6 adapter housing assembly 21 over and
place on press stand.
V05583
2. Place ball bearing 26 in C6 adapter housing
assembly 21.
Figure 515. Removal of Ball Bearing from
3. Place special tool J 43047 and J 37034 on ball C6 Adapter Housing
bearing 26 (Figure 516).

NOTE:
Bearing 26 is properly seated when it is against the
shoulder at the bottom of the bearing bore and is
1.573.35 mm (0.0620.132 inch) below the machined
J 37034
face of the adapter housing at the top of the bearing
bore. J 43047

4. Press ball bearing 26 into C6 adapter housing


assembly 21 until it is properly seated.
5. Install internal sealring 20 onto C5 piston 18.
Install external sealring 19 onto C5 piston 18.
6. Align the tang notch on the back of the C5
clutch piston 18 with the tang on the C6
adapter housing 22 before installing C5 clutch
piston 18. Install C5 clutch piston 18 into C6 V05584

adapter housing module 14. Use a rubber


mallet to seat the piston. Figure 516. Installation of Ball Bearing
into C6 Adapter Housing
7. Place spring return assembly 17 in C6 adapter
housing assembly 21. Use alignment notch to
guide installation. 8. Place retaining ring 16 in C6 adapter housing
assembly 21.

WARNING! 9. Compress spring and retainer assembly 17


Piston springs are highly compressed. Be using J 35923-4 tool base, washer, bearing,
extremely careful during installation. Personal handle, and piston spring compressor J 43025.
injury can occur if the spring force is not Install retaining ring 16 and slowly release the
controlled. spring force (Figures 517 and 518).

520 Copyright 2001 General Motors Corp.


MODULE REBUILD
3. Install indexing ring 35 and internal retaining
J 35923 ring 34.

J 43025 4. If components were replaced, check pinion end


play. Pinion end play must not exceed 0.94 mm
(0.037 inch). Check all six pinion gears. Install
thrust bearing 44.

5. Install P4 planetary carrier assembly 32 into


the P4 planetary carrier hub 43.

6. Support P4 planetary carrier hub 43 slightly off


of the work table so P4 planetary carrier
V05581
assembly 32 can fall through. Install retaining
ring 33 into P4 planetary carrier hub 43.
Figure 517. Compression of Spring and
Retainer Assembly 7. Thread three M10 eye bolts into the P4
planetary carrier assembly 32.

J 35923-4 8. If replacing, install P4 carrier bushing 38 in P4


carrier 37 using special tool J 43023 and
J 37034 (Figure 519).

9. Install thrust bearing 31 on P4 sun gear 30.

10. With thrust bearing 31 facing up, place the


thrust bearing and P4 sun gear inside P4 carrier
assembly 32. While holding onto P4 sun
gear 30, carefully install both P4 sun gear 30
and P4 carrier assembly 32 into C6 adapter
housing 22 using a sling and hoist.

V05582
NOTE:
Do not install ring gear and hub assembly 45 in the
Figure 518. Bottom View of C6 Adapter Housing
C6 adapter housing module until final transmission
and J 35923-4
assembly. Measurement for selective shim is
f. Assembly of P4 Planetary Carrier Assembly performed during final buildup.
1. Install two needle bearings 42 into the center
of pinion gear 41. Install thrust washers 40 in g. Assembly of C6 Clutch
P4 planetary carrier 37. Align thrust washer
tangs with slots in carrier 37 and retain them 1. Install the C6 clutch pack in the C6 adapter
with oil-soluble grease. Slide pinion gear 41 housing nine steel reaction plates 27 and
and two bearings 42 into the side of P4 eight friction plates 28, stacked alternately,
planetary carrier 37 between thrust washers 40. starting with a steel reaction plate 27. Stack all
Repeat the procedure for the five remaining plates so plate cone faces the same direction.
pinion gears. Steel plates 27 mesh with the C6 adapter
housing and friction plates 28 mesh with C6
2. Install six spindles 39 so the lower step is clutch hub 43.
positioned for proper installation of indexing
ring 35. 2. Install C6 backplate 29.

Copyright 2001 General Motors Corp. 521


4000 MH/HD 4000/B 500 SERIES ON-HIGHWAY SERVICE MANUAL
2. Remove nine bolts 64 retaining retarder control
body assembly 65 to retarder housing
assembly 31 and remove control body
assembly 65.

J 37034
3. Remove channel plate gasket 91, channel
plate 90, two separator plate gaskets 88, and
solenoid separator plate 89.
J 43023

4. Remove five bolts 66, solenoid cover 69, and


solenoid cover gasket 70. Disconnect solenoid
connector 68 from solenoid 71 to remove
cover 69 and gasket 70.

5. Remove retaining pin 79 from the back side of


V05587
the retarder control body. Remove solenoid
Figure 519. Installation of P4 Planetary Bushing assembly 71 from control body 78. Remove
and discard O-rings 72 and 73.

NOTE: 6. Check the resistance of retarder solenoid 71.


For HD 4070 models with a retarder, proceed Resistance must be 25 Ohms.
to Paragraph 515.
For HD 4070 models without a retarder, skip 7. Remove retarder control valve 74 from retarder
Paragraphs 514 through 516 and proceed to control body 78.
Paragraph 517.
8. Remove pressure tap plug assembly 85 from
retarder control body. Remove and discard
514. RETARDER AND P3 PLANETARY O-ring 86.
MODULE (4000 MH, HD 4060,
HD 4560, And B 500 Models 9. Remove retaining ring 84, plug 83, O-ring 82,
and spring 81 from retarder control body 78.
Equipped With Retarder)
10. Remove pin 80, valve stop 75, spring 76, and
NOTE: exhaust backfill valve 77 from retarder control
For units prior to S/N 6610066447, proceed to body 78.
Paragraph (a).
For units beginning with S/N 6610066447, skip b. Disassembly of Temperature Sensor
Paragraphs (a) through (i) and proceed to (Foldout 10,A)
Paragraph (j).
1. Remove temperature sensor retainer bolt 44 or
49 and temperature sensor retainer 43 or 48.
a. Disassembly of Retarder Valve Body Carefully remove temperature sensor
(Foldout 10,A) assembly 41 or 45 from retarder housing 40.
1. If not previously done, remove any external
wiring harness elements from solenoid 2. Check retarder temperature sensor resistance
connector 68 on retarder control body measured with an ohmmeter. Use Table 52 or
assembly 65. Figure 520.

522 Copyright 2001 General Motors Corp.


MODULE REBUILD
Table 52. Temperature Sensor Chart Units Prior To S/N 6610026472

TEMP C TEMP F OHMS


2900 -50 -58 525
-40 -40 577
2700 -30 -22 632 7.0C
-20 -4 691
2500 -10 14 754
0 32 820
TEMPERATURE SENSOR RESISTANCE IN OHMS 10 50 889
2300 20 68 962 5.0C
30 86 1039
2100 40 104 1118
50 122 1202
1900 60 140 1288 4.0C
70 158 1379
80 176 1472
1700 90 194 1569
3.0C
100 212 1670
1500 110 230 1774
120 248 1882 2.0C
1300 130 266 1993
140 284 2107
150 302 2225
1100 183 361 2628
1.6C
900

700 LOW PT
3.0C

500 SUMP TEMPERATURE IN F


4 32 68 104 140 176 212 248 284 320 356

-60 -40 --20 0 20 40 60 80 100 120 140 160 180


SUMP TEMPERATURE IN C V01602.02

1,000,000

100,000
SENSOR RESISTANCE ()

10,000

1,000

100

10

1
40 14 68 122 176 230 284 338 392 F

40 10 20 50 80 110 140 170 200 C


TEMPERATURE
V04641.01

Figure 520. Temperature Sensor Chart Units Beginning With S/N 6610026472

Copyright 2001 General Motors Corp. 523


4000 MH/HD 4000/B 500 SERIES ON-HIGHWAY SERVICE MANUAL
c. Disassembly of Retarder Housing 8. Remove three bolts 53 to allow removal of
(Foldout 10,A) retarder stator assembly 18 from retarder
housing 40. Remove retarder housing
gasket 28.
CAUTION:
Be sure to remove speed sensor 54. Failure to 9. Remove rotor assembly 29. Remove
remove the speed sensor will result in equipment sealrings 27 and 30 from rotor
damage. assembly 29. Inspect splines inside rotor 29.
Maximum spline wear allowed is 0.38 mm
(0.015 inch).
1. Remove output speed sensor bolt 57, sensor
retainer 56, and output speed sensor 10. If replacement is required, remove cone and
assembly 54 from the retarder housing. Remove roller bearing assembly 58 from the retarder
O-ring 55 and discard. Check output speed housing. If necessary to replace, remove bear-
sensor resistance (should be 300 30 Ohms). ing cup 52 using bearing tool J 3940.
2. Remove tachograph plug 38 and brass
washer 39. (Some earlier models may have an d. Disassembly of P3 Planetary Carrier Assembly
O-ring rather than a brass washer at this (Foldout 10,A)
location.)

3. Remove retaining ring 51 and plug 50. WARNING!


Place the P3 planetary assembly on its side to
4. Use J 42048 to compress plug 33. Remove avoid possible injury while disassembling the
retaining ring 32 and tool J 42048. Remove planetary.
plug 33, O-ring 34, spring 35, and retarder
valve 36. Remove spring pin 37 only if
damaged. 1. Remove retaining ring 11 and thrust washer 10
from P3 planetary carrier assembly 3.
NOTE:
Output seal 61 must be removed before retainer NOTE:
locknut 60 can be removed.
For HD 4560 (wide ratio) transmissions, skip
to Step (3).
5. If not removed, remove output oil seal
assembly 61 using seal removal tool For all other models, proceed with Step (2).
J 24171-A.
2. On a close ratio transmission, remove output
6. Straighten the tangs of locknut retainer 59 to
shaft assembly 4. Inspect the splines on output
allow rotation and removal of bearing retainer
shaft assembly 4. Maximum spline wear
locknut 60. Remove locknut 60 using special
allowed is 0.38 mm (0.015 inch).
tool J 37035. Remove locknut retainer 59.

7. Support retarder housing 40 so that P3 3. If replacement is necessary, remove cone and


planetary carrier assembly 3 can be removed roller bearing assembly 17.
from the retarder housing. Place special tool
J 37035-1 over the output shaft splines and 4. Check pinion end play. Pinion end play must
against the threaded shoulder of the P3 not exceed 0.94 mm (0.037 inch). Repeat the
planetary carrier. Press on J 37035-1 with a check on the three remaining pinion gears.
hydraulic press or drive on J 37035-1 with a
mallet until the P3 planetary carrier is 5. Remove retaining ring 7. Remove indexing
separated from the retarder housing. ring 8. Remove four planetary spindles 12.

524 Copyright 2001 General Motors Corp.


MODULE REBUILD
2. Remove C5 clutch piston 21 from retarder
NOTE: stator 25 by compressing spring and retainer
For units prior to S/N 6610018759, inspect the assembly 20 using J 37030-3 tool base,
indexing ring for abnormal wear as shown in washer, bearing, handle, and piston spring
Figure 512, View A. Also inspect the planetary compressor J 37030-2. Remove retaining
spindles for the sharp edge condition as shown in ring 19 and slowly release the spring force.
Figure 512, View B.
3. Remove outer sealring 22 from C5 clutch
piston 21.
6. Slide pinion gear 14, thrust washers 13 and 16,
and two bearing assemblies 15 from the side of 4. Remove inner sealring 23 from C5 clutch
P3 planetary carrier 9. Repeat the procedure piston 21.
with three remaining pinion gears.
5. If replacement is necessary, remove bearing
cup 24 using bearing tool J 3940.
7. Measure the thickness and any step wear for
eight thrust washers 13 and 16. Minimum
f. Assembly of Retarder Stator
allowable thickness of the thrust washers is
(Foldout 10,A)
1.40 mm (0.055 inch). Maximum step wear
allowed is 0.12 mm (0.005 inch). 1. If removed, install bearing cup 24 using
bearing tool J 37033 and drive sleeve J 37034.

NOTE: 2. Install inner sealring 23 onto C5 clutch


piston 21. Install outer sealring 22 onto C5
For HD 4560 (wide ratio) transmissions, pro-
clutch piston 21.
ceed with Step (8).
For all other models, skip Step (8) and proceed 3. Align the tang notch on the back of the C5
with Step (9). clutch piston with the tang on the retarder
stator before installing C5 clutch piston 21 into
retarder stator 25. Install C5 clutch piston 21
8. On HD 4560 transmissions, remove output
into retarder stator 25.
shaft assembly 4. Inspect the splines on output
shaft assembly 4. Maximum spline wear 4. Install spring and retainer assembly 20,
allowed is 0.38 mm (0.015 inch). aligning the tab in the spring and retainer
assembly with the notch in retarder stator 25.
9. Inspect bushing 5 inside the end of output
shaft 6 for wear or damage. Measure the ID of
the output shaft bushing. Maximum allowable WARNING!
ID is 36.14 mm (1.423 inch).
Piston springs are highly compressed. Be
extremely careful during installation. Personal
e. Disassembly of Retarder Stator Assembly injury can occur if the spring force is not
(Foldout 10,A) controlled.
1. Remove O-ring 26 from stator assembly 18.
5. Compress spring and retainer assembly 20
using J 37030-3 tool base, washer, bearing,
WARNING! handle, and piston spring compressor
Piston springs are highly compressed. Be J 37030-2. Install retaining ring 19 and slowly
extremely careful during removal and release the spring force.
installation. Personal injury can occur if the
spring force is not controlled. 6. Install O-ring 26 on retarder stator 25.

Copyright 2001 General Motors Corp. 525


4000 MH/HD 4000/B 500 SERIES ON-HIGHWAY SERVICE MANUAL
g. Assembly of P3 Planetary Carrier Assembly 6. Install four planetary spindles 12 so the lower
(Foldout 10,A) step is positioned for proper installation of
indexing ring 8.
1. If removed, install cone and roller bearing
assembly 17. Use drive sleeve J 37034 and
7. Install indexing ring 8. Install internal retaining
press the bearing against the shoulder on the
ring 7.
P3 carrier.

2. If removed, install bushing 5 inside the end of 8. If components were replaced, check pinion end
output shaft 6 using installer J 37036, drive play. Pinion end play must not exceed 0.94 mm
handle J 8092, and a press. (0.037 inch). Check all four pinion gears.

3. Install output shaft assembly 4 into P3


planetary carrier 9. h. Assembly of Retarder Housing Assembly
(Foldout 10,A)
4. Install thrust washer 10 and retaining ring 11.
1. If removed, install bearing cup 52 using
5. Install two roller bearing assemblies 15 into bearing tool J 37033 and drive sleeve J 37034.
the center of pinion gear 14. Install thrust
washers 13 and 16 in P3 planetary carrier 9, 2. Place P3 carrier assembly 3 on the work table
align the thrust washer tangs with the slots in (output shaft up) and place stator assembly 18
the carrier, and retain them with oil-soluble over the output shaft.
grease. Slide the pinion gear and bearings into
the side of the P3 planetary carrier between the 3. Install sealrings 27 and 30 onto rotor 29. Install
thrust washers. Repeat the procedure with the the rotor assembly over the output shaft.
three remaining pinion gears.
4. Install two M8 guide bolts into retarder
housing 40. Install gasket 28 onto the guide bolts.
CAUTION: Place retarder housing 40 over the output shaft
If abnormal wear existed on the indexing ring of and guide bolts, aligning the holes of the housing
units prior to S/N 6610018759, replace all with the holes of the stator assembly. Remove the
spindles with the sharp edge condition shown in guide bolts as you install three bolts 53. Tighten
Figure 512, View B. If the wear on the indexing bolts 53 to 1215 Nm (911 lb ft).
ring is minor, flip it over to get a fresh reaction
point for the spindle. Replace the indexing ring if 5. If removed, install cone and roller bearing
both corners of the indexing ring are worn. assembly 58 using installer J 37034. Press
Failure to take corrective action may allow the
cone and roller bearing assembly 58 into
spindle to rotate which may reduce or shut off
lubrication to the pinion bearings and thrust retarder housing 40 while rotating the retarder
washers. housing.

6. Install a new locknut retainer 59.

NOTE:
Replacement indexing rings should look like the CAUTION:
example in Figure 512, View C. The ring has Over-tightening bearing retainer locknut 60 will
increased hardness for wear resistance and is damage cone and roller bearing assemblies 17
stamped with HD5. Replacement spindles should and 58 and cups 24 and 52.
look like the example in Figure 512, View D. The
spindle has a revised Dimension A for reduced
clearance with the indexing ring and has a 2 7. Using tool J 37035, install and tighten
stamped on the rear end. bearing retainer locknut 60 to 193207 Nm
(143152 lb ft).

526 Copyright 2001 General Motors Corp.


MODULE REBUILD
8. Support retarder housing 40 so that the turning 13. Install O-ring 39 (earlier models) or brass
torque of the P3 carrier assembly 3 can be washer 39 (later models) onto tachograph
checked after installation of bearing retainer plug 38. Install plug 38 into retarder
locknut 60 (Figure 521). Use tool J 37035-1 housing 40. If O-ring-type plug 38 is used,
to check turning torque. Maximum turning tighten the plug to 2429 Nm (1821 lb ft); if
torque is 3 Nm (27 lb in.). later model plug 38 is used with brass washer,
tighten the plug to 6067 Nm (4549 lb ft).

NOTE: i. Assembly of the Retarder Valve Body


Delay bending the retainer tang and installing (Foldout 10,A)
output oil seal assembly 61 until final assembly of 1. Install O-ring seal 86 and pressure tap plug 87.
the transmission. Tighten the plug to 1013 Nm (710 lb ft).

2. Install retarder control valve 74, valve


9. Install plug 50 and retaining ring 51. spring 81, O-ring 82, plug 83, and retaining
ring 84 into retarder control body 78.
NOTE: 3. Install exhaust backfill valve 77, spring 76,
If there was an O-ring on the OD of plug 50, the part stop 75, and pin 80.
is obsolete and should be replaced by the latest
4. Install new O-rings 72 and 73 onto solenoid 71
design. Consult Parts Catalog PC2456EN, latest
and insert into solenoid mounting bore of the
revision, for the correct part number.
retarder control body 78.

10. If removed, install spring pin 37 into retarder


valve 36 and insert into valve bore. Install CAUTION:
spring 35, O-ring 34, and plug 33. and retain- When inserting solenoid retaining pin 79, be
ing ring 32. Use J 42048 to compress plug 33 certain it is installed into the off-center hole in
and install retaining ring 32. the solenoid bore. Installing the pin in the bore
centerline hole will destroy the solenoid.
11. Install output speed sensor assembly 54 with a
new O-ring 55 and output speed sensor bolt 57.
5. Install, smooth end first, solenoid retaining
Tighten the bolt to 2429 Nm (1821 lb ft).
pin 79 into the off-center hole in the solenoid
12. Carefully install temperature sensor assembly bore of retarder control body 78.
41 or 45 into retarder housing 40. Install tem- 6. Connect solenoid connector 68 on cover 69 to
perature sensor retainer 43 or 48 and retainer solenoid 71 after gasket 70 is properly
bolt 44 or 49. Tighten the bolt to 2429 Nm positioned. Install gasket 70, solenoid
(1821 lb ft). cover 69, and five bolts 66. Tighten the bolts to
2429 Nm (1821 lb ft).

7. Install two guide pins into the retarder control


body mounting flange bolt holes on retarder
housing 40.
J 37035-1
8. Install gasket 91, channel plate 90, solenoid
separator plate gaskets 88 on both sides of
separator plate 89, and solenoid separator
V01281.02
plate 89.

Figure 521. P3 Carrier Turning Torque 9. Install retarder control body assembly 65 and
Check Retarder Equipped nine bolts 64 that retain it to retarder

Copyright 2001 General Motors Corp. 527


4000 MH/HD 4000/B 500 SERIES ON-HIGHWAY SERVICE MANUAL
housing 40. Tighten the bolts to 2429 Nm 2. Check retarder temperature sensor resistance
(1821 lb ft). measured with an ohmmeter. Refer to
Figure 520.
10. Skip to Paragraph 518.
l. Disassembly of Retarder Housing
j. Disassembly of Retarder Valve Body
(Foldout 10,E)
(Foldout 10,E)
1. If not previously done, remove any external
wiring harness elements from solenoid CAUTION:
connector 67 on retarder control body Be sure to remove speed sensor 53. Failure to
assembly 64. remove the speed sensor will result in equipment
damage.
2. Remove nine bolts 63 retaining retarder control
body assembly 64 to retarder housing
assembly 38 and remove control body 1. Remove output speed sensor bolt 56, sensor
assembly 64. retainer 55, and output speed sensor
assembly 53 from the retarder housing. Remove
3. Remove channel plate gasket 90, channel
O-ring 54 and discard. Check output speed
plate 89, two separator plate gaskets 87, and
sensor resistance (should be 300 30 Ohms).
solenoid separator plate 88.

4. Remove five bolts 65, solenoid cover 68, and 2. Remove tachograph plug 39 and brass
solenoid cover gasket 69. Disconnect solenoid washer 40.
connector 67 from solenoid 70 to remove
3. Remove retaining ring 50 and plug 49.
cover 68 and gasket 69.

5. Remove retaining pin 78 from the back side of 4. Use J 42048 to compress plug 33. Remove
the retarder control body. Remove solenoid retaining ring 32 and tool J 42048. Remove
assembly 70 from control body 77. Remove plug 33, O-ring 34, spring 35, and retarder
and discard O-rings 71 and 72. valve 36. Remove spring pin 37 only if
damaged.
6. Check the resistance of retarder solenoid 70.
Resistance must be 25 Ohms.
NOTE:
7. Remove retarder control valve 73 from retarder Output seal 60 must be removed before retainer
control body 77. locknut 59 can be removed.
8. Remove pressure tap plug assembly 84 from
retarder control body. Remove and discard 5. If not removed, remove output oil seal
O-ring 85. assembly 60 using seal removal tool
J 24171-A.
9. Remove retaining ring 83, plug 82, O-ring 81,
and spring 80 from retarder control body 77. 6. Straighten the tangs of locknut retainer 58 to
allow rotation and removal of bearing retainer
10. Remove pin 79, valve stop 74, spring 75, and locknut 59. Remove locknut 59 using special
exhaust backfill valve 76 from retarder control tool J 37035. Remove locknut retainer 58.
body 77.
7. Support retarder housing 41 so that P3
k. Disassembly of Temperature Sensor planetary carrier assembly 3 can be removed
(Foldout 10,E) from the retarder housing. Place special tool
1. Remove temperature sensor retainer bolt 48 J 37035-1 over the output shaft splines and
and temperature sensor retainer 47. Carefully against the threaded shoulder of the P3
remove temperature sensor assembly 45 from planetary carrier. Press on J 37035-1 with a
retarder housing 41. hydraulic press or drive on J 37035-1 with a

528 Copyright 2001 General Motors Corp.


MODULE REBUILD
mallet until the P3 planetary carrier is 3. If replacement is necessary, remove cone and
separated from the retarder housing. roller bearing assembly 17.

8. Remove three bolts 52 to allow removal of 4. Check pinion end play. Pinion end play must
retarder stator assembly 18 from retarder not exceed 0.94 mm (0.037 inch). Repeat the
housing 41. Remove retarder housing check on the three remaining pinion gears.
gasket 28.
5. Remove retaining ring 7. Remove indexing
9. Remove rotor assembly 29. Remove ring 8. Remove four planetary spindles 12.
sealrings 27 and 30 from rotor
assembly 29. Inspect splines inside rotor 29. 6. Slide pinion gear 14, thrust washers 13 and 16,
Maximum spline wear allowed is 0.38 mm and two bearing assemblies 15 from the side of
(0.015 inch). P3 planetary carrier 9. Repeat the procedure
with three remaining pinion gears.
10. If replacement is required, remove cone and
roller bearing assembly 57 from the retarder 7. Measure the thickness and any step wear for
housing. If necessary to replace, remove bear- eight thrust washers 13 and 16. Minimum
ing cup 51 using bearing tool J 3940. allowable thickness of the thrust washers is
1.40 mm (0.055 inch). Maximum step wear
11. Remove bolt 96, jumper manifold 95 or remote allowed is 0.12 mm (0.005 inch).
side manifold 97, and gasket 94 from the rear
of retarder housing 41.
NOTE:
12. Remove nine bolts 44, cover 43, and gasket 42 For HD 4560 (wide ratio) transmissions, pro-
from the bottom of retarder housing 41. ceed with Step (8).
m. Disassembly of P3 Planetary For all other models, skip Step (8) and proceed
Carrier Assembly (Foldout 10,E) with Step (9).

8. On HD 4560 transmissions, remove output


WARNING! shaft assembly 4. Inspect the splines on output
Place the P3 planetary assembly on its side to shaft assembly 4. Maximum spline wear
avoid possible injury while disassembling the allowed is 0.38 mm (0.015 inch).
planetary.
9. Inspect bushing 5 inside the end of output
shaft 6 for wear or damage. Measure the ID of
1. Remove retaining ring 11 and thrust washer 10 the output shaft bushing. Maximum allowable
from P3 planetary carrier assembly 3. ID is 36.14 mm (1.423 inch).

n. Disassembly of Retarder Stator


NOTE: Assembly (Foldout 10,E)
For HD 4560 (wide ratio) transmissions, skip 1. Remove O-ring 26 from stator assembly 18.
to Step (3).
For all other models, proceed with Step (2).
WARNING!
2. On a close ratio transmission, remove output Piston springs are highly compressed. Be
shaft assembly 4. Inspect the splines on output extremely careful during removal and
shaft assembly 4. Maximum spline wear installation. Personal injury can occur if the
allowed is 0.38 mm (0.015 inch). spring force is not controlled.

Copyright 2001 General Motors Corp. 529


4000 MH/HD 4000/B 500 SERIES ON-HIGHWAY SERVICE MANUAL
2. Remove C5 clutch piston 21 from retarder p. Assembly of P3 Planetary Carrier Assembly
stator 25 by compressing spring and retainer (Foldout 10,E)
assembly 20 using J 37030-3 tool base,
1. If removed, install cone and roller bearing
washer, bearing, handle, and piston spring
assembly 17. Use drive sleeve J 37034 and
compressor J 37030-2. Remove retaining
press the bearing against the shoulder on the
ring 19 and slowly release the spring force.
P3 carrier.
3. Remove outer sealring 22 from C5 clutch 2. If removed, install bushing 5 inside the end of
piston 21. output shaft 6 using installer J 37036, drive
handle J 8092, and a press.
4. Remove inner sealring 23 from C5 clutch
piston 21. 3. Install output shaft assembly 4 into P3
planetary carrier 9.
5. If replacement is necessary, remove bearing
cup 24 using bearing tool J 3940. 4. Install thrust washer 10 and retaining ring 11.

5. Install two roller bearing assemblies 15 into


o. Assembly of Retarder Stator the center of pinion gear 14. Install thrust
(Foldout 10,E) washers 13 and 16 in P3 planetary carrier 9,
align the thrust washer tangs with the slots in
1. If removed, install bearing cup 24 using the carrier, and retain them with oil-soluble
bearing tool J 37033 and drive sleeve J 37034. grease. Slide the pinion gear and bearings into
the side of the P3 planetary carrier between the
2. Install inner sealring 23 onto C5 clutch thrust washers. Repeat the procedure with the
piston 21. Install outer sealring 22 onto C5 three remaining pinion gears.
clutch piston 21.
6. Install four planetary spindles 12 so the lower
3. Align the tang notch on the back of the C5 step is positioned for proper installation of
clutch piston with the tang on the retarder indexing ring 8.
stator before installing C5 clutch piston 21 into
7. Install indexing ring 8. Install internal retaining
retarder stator 25. Install C5 clutch piston 21
ring 7.
into retarder stator 25.
8. If components were replaced, check pinion end
4. Install spring and retainer assembly 20, play. Pinion end play must not exceed 0.94 mm
aligning the tab in the spring and retainer (0.037 inch). Check all four pinion gears.
assembly with the notch in retarder stator 25.
q. Assembly of Retarder Housing Assembly
(Foldout 10,E)
WARNING!
1. If removed, install bearing cup 51 using
Piston springs are highly compressed. Be bearing tool J 37033 and drive sleeve J 37034.
extremely careful during installation. Personal
injury can occur if the spring force is not 2. Install new gasket 42, cover 43, and nine bolts 44.
controlled.
Tighten bolts to 2429 Nm (1821 lb ft).

3. Install remote side manifold 97 or jumper


5. Compress spring and retainer assembly 20 manifold 95 and new gasket 94 to retarder
using J 37030-3 tool base, washer, bearing, housing 41 using bolt 96. Tighten the bolt to
handle, and piston spring compressor 5161 Nm (3845 lb ft).
J 37030-2. Install retaining ring 19 and slowly
release the spring force. 4. Place P3 carrier assembly 3 on the work table
(output shaft up) and place stator assembly 18
6. Install O-ring 26 on retarder stator 25. over the output shaft.
530 Copyright 2001 General Motors Corp.
MODULE REBUILD
5. Install sealrings 27 and 30 onto rotor 29. Install spring 35, O-ring 34, plug 33, and retaining
the rotor assembly over the output shaft. ring 32. Use J 42048 to compress plug 33 and
install retaining ring 32.
6. Install two M8 guide bolts into retarder
housing 41. Install gasket 28 onto the guide 13. Install output speed sensor assembly 53, with
bolts. Place retarder housing 41 over the new O-ring 54, and output speed sensor bolt 56.
output shaft and guide bolts, aligning the Tighten the bolt to 2429 Nm (1821 lb ft).
holes of the housing with the holes of the
stator assembly. Remove the guide bolts as 14. Carefully install temperature sensor assembly 45
you install three bolts 52. Tighten bolts 52 to into retarder housing 41. Install temperature sen-
1215 Nm (911 lb ft). sor retainer 47 and retainer bolt 48. Tighten the
bolt to 2429 Nm (1821 lb ft).
7. If removed, install cone and roller bearing
assembly 57 using installer J 37034. Press 15. Install brass washer 40 onto tachograph
cone and roller bearing assembly 57 into plug 39. Install plug 39 into retarder housing 41.
retarder housing 41 while rotating the retarder Tighten the plug to 6067 Nm (4549 lb ft).
housing.
r. Assembly of the Retarder Valve Body
8. Install a new locknut retainer 58. (Foldout 10,E)
1. Install O-ring seal 85 and pressure tap plug 86.
CAUTION: Tighten the plug to 1013 Nm (710 lb ft).
Over-tightening bearing retainer locknut 59 will 2. Install retarder control valve 73, valve
damage cone and roller bearing assemblies 17
spring 80, O-ring 81, plug 82, and retaining
and 57 and cups 24 and 51.
ring 83 into retarder control body 77.

9. Using tool J 37035, install and tighten 3. Install exhaust backfill valve 76, spring 75,
bearing retainer locknut 59 to 193207 Nm stop 74, and pin 79.
(143152 lb ft).
4. Install new O-rings 71 and 72 onto solenoid 70
10. Support retarder housing 41 so that the turning and insert into solenoid mounting bore of the
torque of the P3 carrier assembly 3 can be retarder control body 77.
checked after installation of bearing retainer
locknut 59 (Figure 521). Use tool J 37035-1
to check turning torque. Maximum turning CAUTION:
torque is 3 Nm (27 lb in.). When inserting solenoid retaining pin 78, be
certain it is installed into the off-center hole in
the solenoid bore. Installing the pin in the bore
NOTE: centerline hole will destroy the solenoid.
Delay bending the retainer tang and installing
output oil seal assembly 60 until final assembly of
5. Install, smooth end first, solenoid retaining
the transmission.
pin 78 into the off-center hole in the solenoid
bore of retarder control body 77.
11. Install plug 49 and retaining ring 50.
6. Connect solenoid connector 67 on cover 68 to
12. If removed, install spring pin 37 into retarder solenoid 70 after gasket 69 is properly
valve 36 and insert into valve bore. Install positioned. Install gasket 69, solenoid

Copyright 2001 General Motors Corp. 531


4000 MH/HD 4000/B 500 SERIES ON-HIGHWAY SERVICE MANUAL
cover 68, and five bolts 65. Tighten the bolts to connector 52 from solenoid 58 to remove cover
2429 Nm (1821 lb ft). cover 53 and gasket 54.

7. Install two guide pins into the retarder control 5. Remove retaining pin 63 from the back side of
body mounting flange bolt holes on retarder the retarder control body. Remove solenoid 58
housing 41. from control body 62. Remove and discard
O-rings 59 and 60.
8. Install gasket 90, channel plate 89, solenoid
separator plate gaskets 87 on both sides of 6. Check the resistance of retarder solenoid 58.
separator plate 88, and solenoid separator Resistance must be 25 Ohms.
plate 88.
7. Remove retarder control valve 61 from retarder
9. Install retarder control body assembly 64 and control body 62.
nine bolts 63 that retain it to retarder
housing 41. Tighten the bolts to 2429 Nm 8. Remove pressure tap plug 71 and O-ring 70
(1821 lb ft). from retarder control body.

10. Skip to Paragraph 518. 9. Remove pin 64, retaining ring 68, plug 67,
O-ring 66, and spring 65 from retarder control
body 62.
515. RETARDER AND OUTPUT
10. Remove pin 64, valve stop 55, spring 56, and
SHAFT MODULE (HD 4070 exhaust backfill valve 57 from retarder control
Models Equipped With Retarder) body 62.

b. Disassembly of Temperature Sensor


NOTE: (Foldout 10,C)
For units prior to S/N 6610066447, proceed to
Paragraph (a). 1. Remove temperature sensor retainer bolt 34
and thermistor protection bracket 33. Carefully
For units beginning with S/N 6610066447, skip remove temperature sensor assembly 32 from
Paragraphs (a) through (k) and proceed to retarder housing 31.
Paragraph (l).
2. Check retarder temperature sensor resistance
measured with an ohmmeter. Refer to
a. Disassembly of Retarder Valve Body Figure 520.
(Foldout 10,C)
c. Disassembly of Retarder Housing
1. If not previously done, remove any external
(Foldout 10,C)
wiring harness elements from solenoid
connector 52 on retarder control assembly 1. Remove output speed sensor bolt 46, sensor
body 49. retainer 45, and output speed sensor
assembly 43 from the retarder housing. Remove
2. Remove nine bolts 48 retaining retarder control O-ring 44 and discard. Check output speed
body assembly 49 to retarder housing sensor resistance (should be 300 30 Ohms).
assembly 28 and remove control body
assembly 49. 2. Remove tachograph plug 29 and brass
washer 30 if replacement is necessary.
3. Remove channel plate gasket 76, channel
plate 75, separator plate gasket 74, solenoid 3. Remove retaining ring 37 and plug 36.
separator plate 73, and separator plate
gasket 72. 4. Use J 42048 to compress plug 23. Remove
retaining ring 22, plug 23, O-ring 24,
4. Remove five bolts 50, solenoid cover 53, and spring 25, and retarder valve 26. Remove
solenoid cover gasket 54. Disconnect solenoid spring pin 27 only if damaged.

532 Copyright 2001 General Motors Corp.


MODULE REBUILD

NOTE:
Output seal 42 must be removed before bearing re-
tainer locknut 41 can be removed.

5. If not removed, remove output oil seal


assembly 42 using seal removal tool
J 24171-A.

6. Straighten the tangs of locknut retainer 40 to


allow rotation and removal of bearing retainer
locknut 41. Remove locknut 41 using special
tools J 37035-2 and J 43278. Remove locknut
retainer 40.

7. Support retarder housing 31 so that output V05585


shaft 3 can be removed from the retarder
housing 31. Place special tool J 37035-3 over Figure 522. Removal of Output Shaft
the output shaft splines. Press on output shaft from Retarder Housing
assembly 3 with a press until output shaft
assembly 3 is separated from the retarder f. Disassembly of Retarder Stator Assembly
housing 31 (Figure 522). (Foldout 10,C)
1. Remove and discard O-ring 15 from stator
d. Disassembly of Output Shaft Assembly assembly 7.
(Foldout 10,C)
2. Remove C6 clutch piston 10 from retarder
1. Inspect the splines on output shaft assembly 3.
stator 14 by compressing spring and retainer
Maximum spline wear allowed is 0.38 mm
assembly 9 using J 37030-3 tool base, washer,
(0.015 inch).
bearing, handle, and piston spring compressor
2. If replacement is necessary, remove cone and J 37030-2. Remove retaining ring 8 and slowly
roller bearing assembly 6. release the spring force.

3. If replacement is necessary, remove output 3. Remove outer sealring 11 from C6 clutch


shaft bushing 4. piston 10.

4. Remove inner sealring 12 from C6 clutch


e. Completion of Retarder Housing Disassembly
piston 10.
(Foldout 10,C)
1. Remove three bolts 20 to allow removal of 5. If replacement is necessary, remove bearing
retarder stator assembly 7 from retarder cup 13 using bearing tool J 3940.
housing 31. Remove and discard retarder
housing gasket 17. g. Assembly of Retarder Stator Assembly
(Foldout 10,C)
2. Remove rotor assembly 18. Remove 1. If removed, install bearing cup 13 using
sealrings 16 and 19 from rotor assembly 18. bearing tool J 37033 and drive sleeve J 37034.
Inspect splines inside rotor 18. Maximum
spline wear allowed is 0.38 mm (0.015 inch). 2. Install inner sealring 12 onto C6 clutch
piston 10. Install outer sealring 11 onto C6
3. If replacement is required, remove cone and clutch piston 10.
roller bearing assembly 39 from the retarder
housing. If replacement is necessary, remove 3. Align the tang notch on the back of the C6
bearing cup 38 using bearing tool J 3940. clutch piston with the tang on the retarder

Copyright 2001 General Motors Corp. 533


4000 MH/HD 4000/B 500 SERIES ON-HIGHWAY SERVICE MANUAL
stator before installing C6 clutch piston 10 into
retarder stator 14. Install C6 clutch piston 10
into retarder stator 14.

4. Install spring and retainer assembly 9, aligning J 37034


the tab in the spring and retainer assembly with
the notch in retarder stator 14.

5. Compress spring and retainer assembly 9 using


J 37033 tool base, washer, bearing, handle, and J 43202
piston spring compressor J 37032. Install
retaining ring 8 and slowly release the spring
force.

6. Install new O-ring 15 on retarder stator 14.

h. Assembly of Retarder Housing


(Foldout 10,C) V05586

1. If removed, install bearing cup 38 using


bearing tool J 37033 and drive sleeve J 37034. Figure 523. Installation of Cone and Roller Bearing
onto Output Shaft
2. Place stator assembly 7 onto the retarder
housing 31. j. Completion of Retarder Housing Assembly
(Foldout 10,C)
3. Install sealrings 16 and 19 onto rotor
assembly 18. Install the rotor assembly 18 onto 1. If removed, install cone and roller bearing
the retarder housing 31. assembly 39 using installer J 37034. Press
cone and roller bearing assembly 39 into
4. Install two M8 guide bolts into retarder retarder housing 31 while rotating the retarder
housing 31. Install gasket 17 onto the guide bolts. housing 31.
Place stator assembly 7 over the guide bolts, 2. Install a new locknut retainer 40.
aligning the holes of the retarder housing 31 with
the holes of the stator assembly 7. Remove the
guide bolts as you install three bolts 20. Tighten
bolts 20 to 1215 Nm (911 lb ft). CAUTION:
Over-tightening bearing retainer locknut 41 will
i. Assembly of Output Shaft Assembly damage roller bearings 6 and 39 and bearing
(Foldout 10,C) cups 13 and 38. If the torque wrench and breaker
bar positions in Figure 524 are reversed, the
1. If removed, install bushing 4 inside the end of bearing retainer locknut will be overtorqued. Be
output shaft 5 using installer J 37036, drive sure wrenches are positioned ONLY as shown in
handle J 8092, and a press. Figure 524.

2. If removed, install cone and roller bearing


assembly 6. Use special tools J 43202 with 3. Install and tighten bearing retainer locknut 41
J 37034 and press the bearing onto output using special tools J 37035 and J 43278. Place
shaft 5 (Figure 523). the torque wrench and a breaker bar as shown
in Figure 524. Rotate the torque wrench in the
3. Support output shaft assembly 3. Place retarder counterclockwise direction and tighten the nut
housing 31 over the output shaft assembly. to 193207 Nm (143152 lb ft) (Figure 524).

534 Copyright 2001 General Motors Corp.


MODULE REBUILD

J 43278
J 43278
J 37035-3

V05588
V05592

Figure 524. Bearing Retainer Nut


Torque Retarder Equipped Figure 525. Output Shaft Turning Torque
Check Retarder Equipped
4. Support retarder housing 31 so that the turning
torque of the output shaft can be checked after k. Assembly of The Retarder Valve Body
installation of bearing retainer locknut 41 (Foldout 10,C)
(Figure 524). Use tool J 43278 to check
turning torque. Maximum turning torque is 1. If removed, install O-ring seal 70 and pressure
3 Nm (27 lb in.) (Figure 525). tap plug 71. Tighten the plug to 1013 Nm
(710 lb ft).

NOTE: 2. Install retarder control valve 61, valve


Delay bending the retainer tangs and installing spring 65, O-ring 66, plug 67, and internal
output oil seal assembly 42 until final assembly of retaining ring 68 into retarder control body 62.
the transmission.
3. Install exhaust backfill valve 57, spring 56,
stop 55, and pin 64.
5. Install plug 36 and retaining ring 37.
4. Install new O-rings 59 and 60 on solenoid 58
6. If removed, install spring pin 27 into retarder
and assemble solenoid 58 into the solenoid
valve 26 and insert into valve bore. Install
mounting bore of the retarder control body 62.
spring 25, O-ring 24, and plug 23. Use J 42048
to compress plug 23 and install retaining
CAUTION:
ring 22.
When inserting solenoid retaining pin 63, be
7. Install output speed sensor assembly 43, with certain it is installed into the off-center hole in
new O-ring 44, and output speed sensor bolt 46. the solenoid bore. Installing the pin in the bore
Tighten the bolt to 2429 Nm (1821 lb ft). centerline hole will destroy the solenoid.
8. Carefully install temperature sensor assembly 32
into retarder housing 31. Install temperature 5. Install solenoid retaining pin 63, smooth end
sensor retainer 33 and retainer bolt 34. Tighten first, into the off-center hole in the solenoid
the bolt to 2429 Nm (1821 lb ft). bore of retarder control body 62.

9. If removed, install brass washer 30 onto 6. Connect solenoid connector 52 to solenoid 58


tachograph plug 29. Install plug 29 into retarder after gasket 54 is properly positioned. Install
housing 31. Tighten plug 29 to 6067 Nm gasket 54, solenoid cover 53, and five bolts 50.
(4549 lb ft). Tighten the bolts to 2429 Nm (1821 lb ft).

Copyright 2001 General Motors Corp. 535


4000 MH/HD 4000/B 500 SERIES ON-HIGHWAY SERVICE MANUAL
7. Install two guide bolts into the retarder control 10. Remove pin 67, valve stop 62, spring 63, and
body mounting face bolt holes on retarder exhaust backfill valve 64 from retarder control
housing 31. body 65.
8. Install gasket 76, channel plate 75, solenoid m. Disassembly of Temperature Sensor
separator plate gasket 74, solenoid separator (Foldout 10,F)
plate 73, and separator plate gasket 72 onto
guide bolts. 1. Remove temperature sensor retainer bolt 38
and temperature sensor retainer 37. Carefully
9. Install retarder control body assembly 49 and remove temperature sensor assembly 35 from
nine bolts 48 that retain it to retarder housing 31. retarder housing 31.
Two bolts will replace guide bolts. Tighten the
bolts to 2429 Nm (1821 lb ft). 2. Check retarder temperature sensor resistance
measured with an ohmmeter. Refer to
10. Skip to Paragraph 518.
Figure 520.
l. Disassembly of Retarder Valve Body
(Foldout 10,F) n. Disassembly of Retarder Housing
(Foldout 10,F)
1. If not previously done, remove any external
wiring harness elements from solenoid
connector 55 on retarder control body CAUTION:
assembly 53. Be sure to remove speed sensor 46. Failure to
remove the speed sensor will result in equipment
2. Remove nine bolts 52 retaining retarder control damage.
body assembly 53 to retarder housing
assembly 28 and remove control body
assembly 53. 1. Remove output speed sensor bolt 49, sensor
retainer 48, and output speed sensor
3. Remove channel plate gasket 78, channel assembly 46 from the retarder housing. Remove
plate 77, two separator plate gaskets 75, and O-ring 47 and discard. Check output speed
solenoid separator plate 76. sensor resistance (should be 300 30 Ohms).
4. Remove five bolts 54, solenoid cover 56 and
2. Remove tachograph plug 29 and brass
solenoid cover gasket 57. Disconnect solenoid
washer 30.
connector 55 from solenoid 58 to remove
cover 56 and gasket 57.
3. Remove retaining ring 40 and plug 39.
5. Remove retaining pin 66 from the back side of
the retarder control body. Remove solenoid 4. Use J 42048 to compress plug 23. Remove
assembly 58 from control body 65. Remove retaining ring 22 and tool J 42048. Remove
and discard O-rings 59 and 60. plug 23, O-ring 24, spring 25, and retarder
valve 26. Remove spring pin 27 only if
6. Check the resistance of retarder solenoid 58. damaged.
Resistance must be 25 Ohms.

7. Remove retarder control valve 61 from retarder NOTE:


control body 65.
Output seal 45 must be removed before retainer
8. Remove pressure tap plug assembly 72 from locknut 44 can be removed.
retarder control body. Remove and discard
O-ring 73.
5. If not removed, remove output oil seal
9. Remove retaining ring 71, plug 70, O-ring 69, assembly 45 using seal removal tool
and spring 68 from retarder control body 65. J 24171-A.

536 Copyright 2001 General Motors Corp.


MODULE REBUILD
6. Straighten the tangs of locknut retainer 43 to q. Disassembly of Retarder Stator Assembly
allow rotation and removal of bearing retainer (Foldout 10,F)
locknut 44. Remove locknut 44 using special
tool J 37035. Remove locknut retainer 43. 1. Remove O-ring 15 from stator assembly 7.
7. Support retarder housing 31 so that output
shaft 3 can be removed from the retarder WARNING!
housing 31. Place special tool J 37035-3 over
the output shaft splines. Press on output shaft Piston springs are highly compressed. Be
assembly 3 with a press until output shaft extremely careful during removal and
installation. Personal injury can occur if the
assembly 3 is separated from the retarder
spring force is not controlled.
housing 31 (Figure 522).

o. Completion of Retarder Housing Disassembly 2. Remove C5 clutch piston 10 from retarder


(Foldout 10,F) stator 14 by compressing spring and retainer
1. Remove three bolts 20 to allow removal of assembly 9 using J 37030-3 tool base, washer,
retarder stator assembly 7 from retarder bearing, handle, and piston spring compressor
housing 31. Remove and discard retarder J 37030-2. Remove retaining ring 8 and slowly
housing gasket 17. release the spring force.

2. Remove rotor assembly 18. Remove 3. Remove outer sealring 11 from C5 clutch
sealrings 16 and 19 from rotor assembly 18. piston 10.
Inspect splines inside rotor 18. Maximum
spline wear allowed is 0.38 mm (0.015 inch). 4. Remove inner sealring 12 from C5 clutch
piston 10.
3. If replacement is required, remove cone and
roller bearing assembly 42 from the retarder
5. If replacement is necessary, remove bearing
housing. If replacement is necessary, remove
cup 13 using bearing tool J 3940.
bearing cup 41 using bearing tool J 3940.

4. Remove bolt 82, jumper manifold 81 or remote r. Assembly of Retarder Stator


side manifold 83, and gasket 80 from the rear (Foldout 10,F)
of retarder housing 31.
1. If removed, install bearing cup 13 using
bearing tool J 37033 and drive sleeve J 37034.
5. Remove nine bolts 34, cover 33, and gasket 32
from the bottom of retarder housing 31.
2. Install inner sealring 12 onto C5 clutch
piston 10. Install outer sealring 11 onto C5
p. Disassembly of Output Shaft Assembly
clutch piston 10.
(Foldout 10,F)

1. Inspect the splines on output shaft assembly 3. 3. Align the tang notch on the back of the C5
Maximum spline wear allowed is 0.38 mm clutch piston with the tang on the retarder
(0.015 inch). stator before installing C5 clutch piston 10 into
retarder stator 14. Install C5 clutch piston 10
2. If replacement is necessary, remove cone and into retarder stator 14.
roller bearing assembly 6.
4. Install spring and retainer assembly 9, aligning
3. If replacement is necessary, remove output the tab in the spring and retainer assembly with
shaft bushing 4. the notch in retarder stator 14.

Copyright 2001 General Motors Corp. 537


4000 MH/HD 4000/B 500 SERIES ON-HIGHWAY SERVICE MANUAL
u. Completion of Retarder Housing Assembly
WARNING! (Foldout 10,F)
Piston springs are highly compressed. Be
1. If removed, install cone and roller bearing
extremely careful during installation. Personal
injury can occur if the spring force is not assembly 42 using installer J 37034. Press
controlled. cone and roller bearing assembly 42 into
retarder housing 31 while rotating the retarder
housing 31.
5. Compress spring and retainer assembly 9 using
J 37030-3 tool base, washer, bearing, handle, 2. Install a new locknut retainer 43.
and piston spring compressor J 37030-2.
Install retaining ring 8 and slowly release the
spring force. CAUTION:
Over-tightening bearing retainer locknut 44 will
6. Install O-ring 15 on retarder stator 14. damage roller bearings 6 and 42 and bearing
cups 13 and 41. If the torque wrench and breaker
s. Assembly of Retarder Housing bar positions in Figure 524 are reversed, the
(Foldout 10,F) bearing retainer locknut will be overtorqued. Be
sure wrenches are positioned ONLY as shown in
1. If removed, install bearing cup 41 using Figure 524.
bearing tool J 37033 and drive sleeve J 37034.
3. Install and tighten bearing retainer locknut 44
2. Place stator assembly 7 onto the retarder using special tools J 37035 and J 43278. Place
housing 31. the torque wrench and a breaker bar as shown
in Figure 524. Rotate the torque wrench in the
3. Install sealrings 16 and 19 onto rotor counterclockwise direction and tighten the nut
assembly 18. Install the rotor assembly 18 onto to 193207 Nm (143152 lb ft) (Figure 524).
the retarder housing 31.
4. Support retarder housing 31 so that the turning
4. Install two M8 guide bolts into retarder torque of the output shaft can be checked after
housing 31. Install gasket 17 onto the guide installation of bearing retainer locknut 44
bolts. Place stator assembly 7 over the guide (Figure 524). Use tool J 43278 to check
bolts, aligning the holes of the retarder turning torque. Maximum turning torque is
housing 31 with the holes of the stator 3 Nm (27 lb in.) (Figure 525).
assembly 7. Remove the guide bolts as you
install three bolts 20. Tighten bolts 20 to
1215 Nm (911 lb ft). NOTE:
Delay bending the retainer tangs and installing
t. Assembly of Output Shaft Assembly output oil seal assembly 45 until final assembly of
(Foldout 10,F) the transmission.

1. If removed, install bushing 4 inside the end of


output shaft 5 using installer J 37036, drive 5. Install plug 39 and retaining ring 40.
handle J 8092, and a press. 6. If removed, install spring pin 27 into retarder
valve 26 and insert into valve bore. Install
2. If removed, install cone and roller bearing spring 25, O-ring 24, and plug 23. Use J 42048
assembly 6. Use special tools J 43202 with to compress plug 23 and install retaining
J 37034 and press the bearing onto output ring 22.
shaft 5 (Figure 523).
7. Install output speed sensor assembly 46, with
3. Support output shaft assembly 3. Place retarder new O-ring 47, and output speed sensor bolt 49.
housing 31 over the output shaft assembly. Tighten the bolt to 2429 Nm (1821 lb ft).

538 Copyright 2001 General Motors Corp.


MODULE REBUILD
8. Carefully install temperature sensor assembly 35 9. Install retarder control body assembly 53 and
into retarder housing 31. Install temperature nine bolts 52 that retain it to retarder housing 31.
sensor retainer 37 and retainer bolt 38. Tighten Tighten the bolts to 2429 Nm (1821 lb ft).
the bolt to 2429 Nm (1821 lb ft).
10. Skip to Paragraph 518.
9. If removed, install brass washer 30 onto
tachograph plug 29. Install plug 29 into retarder
housing 31. Tighten plug 29 to 6067 Nm 516. REAR COVER MODULE
(4549 lb ft). (4000 MH, HD 4060, HD 4560,
B 500 Models Equipped With
v. Assembly of the Retarder Valve Body Rear Cover)
(Foldout 10,F)
1. Install O-ring seal 73 and pressure tap plug 74. a. Disassembly (Foldout 10,B)
Tighten the plug to 1013 Nm (710 lb ft). 1. Remove retaining bolt 35 and output speed
sensor assembly 32. The output speed sensor
2. Install retarder control valve 61, valve
must have a resistance of 270330 Ohms.
spring 68, O-ring 69, plug 70, and retaining
ring 71 into retarder control body 65. 2. If used, remove the tachograph sensor. If
present, remove plug 29 and washer or
3. Install exhaust backfill valve 64, spring 63, O-ring 28.
stop 62, and pin 67.
3. If not previously removed, remove output
4. Install new O-rings 59 and 60 onto solenoid 58 seal 40 using seal removal tool J 24171-A.
and insert into solenoid mounting bore of the
retarder control body 65.
NOTE:
Output seal 40 must be removed before retainer
CAUTION: locknut 39 can be removed.
When inserting solenoid retaining pin 66, be
certain it is installed into the off-center hole in 4. Straighten the tangs of locknut retainer 38 to
the solenoid bore. Installing the pin in the bore
allow rotation and removal of bearing retainer
centerline hole will destroy the solenoid.
locknut 39.

5. Remove bearing retainer locknut 39 using


5. Install, smooth end first, solenoid retaining
special tool J 37035.
pin 66 into the off-center hole in the solenoid
bore of retarder control body 65. 6. Remove locknut retainer 38.
6. Connect solenoid connector 55 on cover 56 to 7. Support rear cover assembly 27 so that P3
solenoid 58 after gasket 57 is properly planetary carrier assembly 5 can be removed.
positioned. Install gasket 57, solenoid Place special tool J 37035-1 over output shaft
cover 56, and five bolts 54. Tighten the bolts to splines and against the threaded shoulder of the
2429 Nm (1821 lb ft). P3 planetary carrier. Press on special tool
J 37035-1 with a hydraulic press or drive on
7. Install two guide pins into the retarder control J 37035-1 with a mallet until the P3 planetary
body mounting flange bolt holes on retarder carrier assembly is separated from the rear
housing 31. cover assembly.

8. Install gasket 78, channel plate 77, solenoid 8. If replacement is required, remove cone and
separator plate gaskets 75 on both sides of roller bearing 37 from rear cover assembly 27.
separator plate 76, and solenoid separator If necessary to replace, remove bearing cup 36
plate 76. using bearing tool J 3940.

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4000 MH/HD 4000/B 500 SERIES ON-HIGHWAY SERVICE MANUAL
b. Disassembly of P3 Planetary
Carrier Assembly (Foldout 10,B) NOTE:
For HD 4560 (wide ratio) transmissions, pro-
ceed with Step (8).
WARNING! For all other models, skip Step (8) and proceed
Place the P3 planetary assembly on its side to with Step (9).
avoid possible hand injury during disassembly.
8. On HD 4560 transmissions, remove output
shaft assembly 6. Inspect the splines on output
1. Remove retaining ring 13 and thrust washer 12
shaft assembly 6. Maximum spline wear
from P3 planetary carrier assembly 5.
allowed is 0.38 mm (0.015 inch).

9. Inspect bushing 7 inside the end of output


NOTE:
shaft 8 for wear or damage. Measure the ID of
For HD 4560 (wide ratio) transmissions, skip the output shaft bushing. Maximum allowable
to Step (3). ID is 36.14 mm (1.423 inch).
For all other models, proceed with Step (2).
c. Completion of Rear Cover Disassembly
(Foldout 10,B)
2. On a close ratio transmission, remove output
shaft assembly 6. Inspect the splines on output
shaft assembly 6. Maximum spline wear WARNING!
allowed is 0.38 mm (0.015 inch).
Piston springs are highly compressed. Be
3. If replacement is necessary, remove cone and extremely careful during removal and
roller bearing assembly 19. installation. Personal injury can occur if the
spring force is not controlled.
4. Check pinion end play. Pinion end play should
not exceed 0.94 mm (0.037 inch). Repeat the 1. Remove C5 clutch piston 23 from rear cover
check on the three remaining pinion gears. assembly 27 by compressing spring and
retainer assembly 22 using J 37030-3 tool
5. Remove retaining ring 9. Remove indexing
base, washer, bearing, handle, and piston
ring 10. Remove four planetary spindles 14.
spring compressor J 37030-2. Remove
retaining ring 21 and slowly release the spring
NOTE: force.
For units prior to S/N 6610018759, inspect the 2. Remove outer sealring 24 from C5 clutch
indexing ring for abnormal wear as shown in piston 23.
Figure 512, View A. Also inspect the planetary
spindles for the sharp edge condition as shown in 3. Remove inner sealring 25 from C5 clutch
Figure 512, View B. piston 23.

4. If replacement is necessary, remove bearing


6. Slide pinion gear 16, thrust washers 15 and 18, cup 26 using bearing tool J 3940.
and two bearing assemblies 17 from the side of
P3 planetary carrier 11. Repeat the procedure 5. If replacement is necessary, remove dowel
with three remaining pinion gears. pins 31.

7. Measure the thickness and any step wear for d. Beginning Rear Cover Assembly
eight washers 15 and 18. Minimum allowable (Foldout 10,B)
thickness of the thrust washers is 1.40 mm 1. If removed, install bearing cup 26 using
(0.055 inch). Maximum step wear allowed is bearing tool J 37033, and bearing cup 36 using
0.12 mm (0.005 inch). bearing tool J 37033 and drive sleeve J 37034.

540 Copyright 2001 General Motors Corp.


MODULE REBUILD
2. If removed, install dowel pins 31. the carrier and retain them with oil-soluble
grease. Slide the pinion gear and bearings into
3. Install inner sealring 25 onto C5 clutch the side of the P3 planetary carrier between the
piston 23. Install outer sealring 24 onto C5 thrust washers. Repeat the procedure with the
clutch piston 23. three remaining pinion gears.
4. Align the tang notch on the back of the C5
clutch piston with the tang in the rear cover CAUTION:
before installing C5 clutch piston 23 into the
rear cover. Install C5 clutch piston 23 into rear If abnormal wear existed on the indexing ring of
cover assembly 27. units prior to S/N 6610018759, replace all
spindles with the sharp edge condition shown in
5. Install spring and retainer assembly 22, Figure 512, View B. If the wear on the indexing
aligning the tab in the spring and retainer ring is minor, flip it over to get a fresh reaction
point for the spindle. Replace the indexing ring if
assembly with the notch in rear cover
both corners of the indexing ring are worn.
assembly 27. Failure to take corrective action may allow the
spindle to rotate which may reduce or shut off
lubrication to the pinion bearings and thrust
WARNING! washers.
Piston springs are highly compressed. Be
extremely careful during installation. Personal
injury can occur if the spring force is not
controlled. NOTE:
Replacement indexing rings should look like the
6. Compress spring and retainer assembly 22 example in Figure 512, View C. The ring has
using J 37030-3 tool base, washer, bearing, increased hardness for wear resistance and is
handle, and piston spring compressor stamped with HD5. Replacement spindles should
J 37030-2. Install retaining ring 21 and slowly look like the example in Figure 512, View D. The
release the spring force. spindle has a revised Dimension A for reduced
clearance with the indexing ring and has a 2
e. Assembly of P3 Planetary Carrier Assembly stamped on the rear end.
(Foldout 10,B)
1. If removed, install cone and roller bearing 6. Install four pinion spindles 14 so the lower step
assembly 19. Use driver sleeve J 37034 and is positioned for proper installation of indexing
press the bearing against the shoulder on the ring 10.
P3 carrier.
7. Install indexing ring 10. Install internal
2. If removed, press bushing 7 inside the end of
retaining ring 9.
output shaft 8 using installer J 37036, drive
handle J 8092, and a press.
8. If components were replaced, check pinion end
3. Install output shaft assembly 6 into P3 play. Pinion end play must not exceed 0.94 mm
planetary carrier 11. (0.037 inch). Check all four pinion gears.

4. Install thrust washer 12 and retaining ring 13. f. Completion of Rear Cover Assembly
(Foldout 10,B)
5. Install two roller bearing assemblies 17 into
the center of pinion gear 16. Install thrust 1. Place P3 carrier assembly 5 on the work table
washers 15 and 18 in P3 planetary carrier 11. (with the output shaft up) and place rear cover
Align the thrust washer tangs with the slots in assembly 27 over the output shaft.

Copyright 2001 General Motors Corp. 541


4000 MH/HD 4000/B 500 SERIES ON-HIGHWAY SERVICE MANUAL
2. If removed, install cone and roller bearing 517. REAR COVER AND OUTPUT
assembly 37 into rear cover assembly 27 using SHAFT MODULE (HD 4070/4076
drive sleeve J 37034. Models Equipped With Rear Cover)
3. Install a new locknut retainer 38.
a. Disassembly (Foldout 10,D)

CAUTION: 1. Remove retaining bolt 23 and output speed


sensor assembly 22. The output speed sensor
Over-tightening bearing retainer locknut 39 will
must have a resistance of 270330 Ohms.
damage cone and roller bearing assemblies 19
and 37 and cups 26 and 36. 2. If used, remove the tachograph sensor. If
present, remove plug 19 and washer 20.
4. Using tool J 37035-1, install and tighten
bearing retainer locknut 39 to 7488 Nm 3. If not previously removed, remove output
(5565 lb ft). seal 30 using seal removal tool J 24171-A.

5. Support rear cover assembly 4 so that turning


torque of P3 carrier assembly 5 can be checked NOTE:
after installation of bearing retainer locknut 39 Output seal 30 must be removed before retainer
(Figure 526). Use tool J 37035-1 to check locknut 29 can be removed.
turning torque. Maximum turning torque is
3 Nm (27 lb in.).
4. Straighten the tangs of locknut retainer 28 to
6. Install output speed sensor assembly 32, with allow rotation and removal of bearing retainer
new O-ring 33, and output speed sensor bolt 35. locknut 29.
Tighten bolt to 2429 Nm (1821 lb ft). 5. Remove bearing retainer locknut 29 using
special tool J 37035-2 and J 43278.
7. If a tachograph is used, install tachograph
sensor and tighten to manufacturers 6. Remove locknut retainer 28.
specification. If a tachograph is used and the
sensor is not installed, install O-ring 28 (earlier 7. Support rear cover assembly 17 so that the
models) or brass washer 28 (later models) onto output shaft assembly 6 can be removed. Press
tachograph plug 29. Install plug 29 into the on output shaft assembly 6 until it is separated
rear cover. If O-ring-type plug 29 is used, from the rear cover assembly 17 (Figure 527).
tighten the plug to 2429 Nm (1821 lb ft); if
later model plug 29 is used with brass washer,
tighten the plug to 6067 Nm (4549 lb ft).

J 73035-1

V00223.02

V05598

Figure 526. P3 Carrier Turning Torque


Check Rear Cover Equipped Figure 527. Removal of Output Shaft Assembly

542 Copyright 2001 General Motors Corp.


MODULE REBUILD
b. Disassembly of Output Shaft Assembly 4. Install spring and retainer assembly 12,
(Foldout 10,D) aligning the tab in the spring and retainer
assembly with the notch in rear cover 18.
1. Inspect splines on the output shaft assembly.
Maximum spline wear allowed is 0.38 mm
(0.015 inch). WARNING!
2. If replacement is required, remove bushing 7 Piston springs are highly compressed. Be
from output shaft 8. If replacement is needed, extremely careful during installation. Personal
remove bearing 9. injury can occur if the spring force is not
controlled.
c. Completion of Rear Cover Disassembly
(Foldout 10,D)
5. Compress spring and retainer assembly 12
using J 35923-4 tool base, washer, bearing,
WARNING! handle, and piston spring compressor J 43025.
Piston springs are highly compressed. Be Install retaining ring 11 and slowly release the
extremely careful during removal and spring force. Remove the special tools.
installation. Personal injury can occur if the
spring force is not controlled.
e. Assembly of Output Shaft Assembly
(Foldout 10,D)
1. Remove C6 clutch piston 13 from rear
cover 18 by compressing spring and retainer 1. If removed, install bushing 7 inside the end of
assembly 12 using J 37030-3 tool base, output shaft 8 using installer J 37036, drive
washer, bearing, handle, and piston spring handle J 8092, and a press.
compressor J 37030-2. Remove retaining
ring 11 and slowly release the spring force. 2. If removed, install cone and roller bearing
assembly 9. Use special tools J 43202 with
2. Remove outer sealring 14 from C6 clutch J 37034 and press the bearing onto output
piston 13. shaft 8 (Figure 528).
3. Remove inner sealring 15 from C6 clutch
piston 13.

4. If replacement is necessary, remove bearing


J 37034
cup 16 using bearing tool J 3940.

d. Beginning Rear Cover Assembly


(Foldout 10,D)
1. If removed, install bearing cup 16 using
J 43202
bearing tool J 37033, and bearing cup 21 using
bearing tool J 37033 and drive sleeve J 37034.

2. Install inner sealring 15 onto C6 clutch


piston 13. Install outer sealring 14 onto C6
clutch piston 13.

3. Align the tang notch on the back of the C6


clutch piston with the tang in the rear cover V05586

before installing C6 clutch piston 13 into the


rear cover. Install C6 clutch piston 13 into rear Figure 528. Installation of Cone and Roller Bearing
cover 18. onto Output Shaft

Copyright 2001 General Motors Corp. 543


4000 MH/HD 4000/B 500 SERIES ON-HIGHWAY SERVICE MANUAL
f. Completion of Rear Cover Assembly 7. Install output speed sensor assembly 22, with
(Foldout 10,D) new O-ring 25, and output speed sensor bolt
23. Tighten bolt to 2429 Nm (1821 lb ft).
1. Support output shaft assembly 6 and place rear
cover 18 over the output shaft assembly 6.

2. If removed, install cone and roller bearing


assembly 27 into rear cover 18 using drive
J 43278
sleeve J 37034. J 37035-3

3. Install a new locknut retainer 28.

CAUTION:
Over-tightening bearing retainer locknut 29 will
damage roller bearings 9 and 27 and bearing
cups 16 and 21. If the torque wrench and breaker
bar positions in Figure 529 are reversed, the
bearing retainer nut will be overtorqued. Be sure
V05589
wrenches are positioned ONLY as shown in
Figure 529.

4. Install and tighten bearing retainer locknut 29 Figure 529. Bearing Retainer Locknut
Torque Rear Cover Equipped
using special tools J 37035 and J 43278.
Place the torque wrench and a breaker bar as
shown in Figure 529. Rotate the torque
wrench in the counterclockwise direction and
tighten the nut to 7488 Nm (5565 lb ft).

5. Support rear cover assembly 17 so that turning


torque of output shaft assembly 6 can be J 43278
checked after installation of bearing retainer
locknut 29. Use tool J 43278 to check turning
torque. Maximum turning torque is 3 Nm
(27 lb in.) (Figure 530).

6. If removed, install tachograph sensor or


plug 19 and washer 20.

NOTE:
V05593
Delay bending the retainer tangs and installing
output seal assembly 30 until final assembly of the
transmission. Figure 530. Turning Torque Check Rear
Cover Equipped

544 Copyright 2001 General Motors Corp.


MODULE REBUILD
518. CONTROL VALVE MODULE 3. Remove four bolts 8 and wiring harness cover
(Foldout 11) plate 9. Skip Step (4) and go to Step (5).

4. If not previously removed, remove two filter


CAUTION: covers 206, two gaskets 207, two O-rings 208,
two O-rings 209, and two filters 210.
Control valve module parts fit together closely
and have close operating clearances. They can
bind if damaged. Valves, when dry, must move NOTE:
freely by their own weight in their bores. Con-
trol valve module parts depend upon smooth Refer to Troubleshooting Manual TS2470EN or
sealing surfaces and may leak if the sealing TS2973EN for electrical inspection and repair
surface is scratched. Carefully handle all such procedures.
parts. Protect control module parts during re-
moval, cleaning, inspection, and installation.
Keep them in clean containers until they are 5. Disconnect all electrical connectors.
installed.
Control valve module assembly springs and 6. Remove three bolts 14 and either control
other parts can be mistakenly interchanged. harness assembly 15 or 61.
Tag each part with its item number as it is re-
moved and use Valve Tray Set J 33163 to sim-
plify correct valve body reassembly. NOTE:
Solenoid body parts retained by pins are under
Control harness 15 contained a sump temperature
light spring force.
thermistor with attached connector beginning at
S/N 6610026472.

NOTE:
7. Remove two retaining bolts 171 or 181 and oil
Part callout numbers 1128 are on Foldout 11,A level sensor assembly 170 or 182. Clean the oil
and 129214 on Foldout 11,B. level sensor with a soft clean cloth. Refer to
Troubleshooting Manual TS2470EN or
TS2973EN for proper sensor operation.
a. Disassembly of Control Valve Module
(Foldout 11) 8. Remove either bolt 5, two bolts 7, suction-filter
housing 4, face seal 6, suction filter 3, and
gasket 2 or three bolts 10, face seal 11, suction
NOTE:
filter assembly 12, and gasket 13. Discard
For units prior to S/N 661009730, proceed to suction filter 3 or 12 and install a new filter at
Step (1). rebuild.
For units with S/N 661009730 up to
6610015591, skip Step (1) and go to Step (2). 9. Remove either three bolts 93 or seven bolts 93
(when plate 9 is not present), face seal 94, and
For units beginning with S/N 15591, skip
rotating clutch solenoid body assembly 95.
Step (1) through (3) and go to Step (4).
10. Remove eight bolts 115, two face seals 116, and
1. If not previously removed, remove two filter stationary clutch solenoid body assembly 117.
covers 206, two square-cut seals 208, two
O-rings 209, and two filters 210. Skip Step (2) 11. Remove two bolts 130 and main valve body as-
and go to Step (3). sembly 131.

2. If not previously removed, remove two filter 12. If present, remove five bolts 147, cover 148,
covers 206, two gaskets 207, two O-rings 208, and C6 control valve body assembly 149 (Fig-
two O-rings 209, and two filters 210. ure 531).

Copyright 2001 General Motors Corp. 545


4000 MH/HD 4000/B 500 SERIES ON-HIGHWAY SERVICE MANUAL
c. Disassembly of Stationary Clutch
147 Solenoid Body (Foldout 11)

148
150
151 NOTE:
Solenoid retention pins 119 must be removed from
152 149 the BOTTOM of the solenoid body. Note the
154
153 grooved end of pin for positive retention.
160 155
159 156
1. Remove three solenoid retention pins 119 from
161
bottom of solenoid body.
162
164 157 2. Remove three solenoids 123, three O-rings 125,
165 158
163 166 167
three O-rings 124, three valves 121, and three
springs 120. Check resistance of the solenoids.
V06864
Solenoid resistance must be 25 Ohms.
Figure 531. Disassembly/Assembly of C6 Control
Valve Body 3. Remove valve retention pin 122.

b. Disassembly of Rotating Clutch Solenoid Body 4. Remove stop 126, spring 127, and valve 128.
(Foldout 11)
5. Remove solenoid separator plate 129.
1. Remove two bolts 96 and then remove C3
pressure switch assembly 97.
d. Disassembly of C6 Control Valve Body
2. Check contact resistance of the C3 pressure (HD 4070/4076 Models Only)
switch. Maximum allowable resistance is 1. Remove retaining pin 159 and C6 regulator
2 Ohms when the contacts are closed and must valve solenoid 154 (Figure 531).
be 20,000 Ohms minimum when the contacts
are open. Check the pressure at which the 2. Remove regulator valve 153 and spring 152
switch opens and closes. Both events must (Figure 531).
occur between 159255 kPa (2337 psi). Test
block J 33884-25 is available to help make 3. Remove retaining pin 159 and C6 interlock
these checks. valve solenoid 163 (Figure 531).

NOTE: 4. Remove interlock valve 166 and spring 167


Solenoid retention pins 109 must be removed from (Figure 531).
the BOTTOM of the solenoid body. Note the
grooved end of pin for positive retention. e. Disassembly of Main Valve Body
(Foldout 11)
3. Remove two solenoids 103 and one 1. If damaged, remove retaining pin 153.
solenoid 106 by removing three pins 109.

4. Remove O-rings 104 and 105 from each NOTE:


solenoid 103 and O-ring 107 and 108 from
solenoid 106. Check the resistance of each Solenoid retention pin 148 must be removed from
solenoid. Solenoid resistance must be 25 Ohms. the BOTTOM of the solenoid body. Note the
grooved end of pin for positive retention.
5. Remove three valves 102 and three springs 101.

6. Remove valve retention pin 114. Remove 2. Remove solenoid retention pin 148 from
stop 113, spring 112, and valve 111. bottom of the solenoid body.

546 Copyright 2001 General Motors Corp.


MODULE REBUILD
3. Remove solenoid 149, small O-ring 150, and 11. Slowly release pressure against stop 147 and
large O-ring 151. Check resistance of the remove stop 147, spring 146, and control main
solenoid. Solenoid resistance must be 25 Ohms. valve 145.

4. Remove valve retention pin 132. 12. Remove valve retention pin 154.

5. Remove stop 135, spring 134, and lockup 13. Remove stop 157, spring 156, and C2 latch
valve 133. valve 155.

6. Remove valve retention pin 136. 14. Remove valve retention pin 158.

7. Remove stop 139, spring 138, and lube 15. Remove stop 161, spring 160, and exhaust
regulator valve 137. back pressure valve 159.

16. Remove valve retention pin 162.


WARNING!
17. Remove stop 165, spring 164, and C1 latching
Spring 142 is highly compressed. Be extremely valve 163.
careful during disassembly. Personal injury can
occur if the spring force is not controlled. 18. Remove valve retention pin 166.

19. Remove stop 169, spring 168, and converter


8. Install spring compressor J 35924 (Figure 532). regulator valve 167.
Compress spring 142, then remove valve
retention pin 140. Carefully release the spring 20. Remove gasket 214, separator plate 188, and
force by rotating the handle on J 35924 gasket 189.
counterclockwise. Remove spring compressor
J 35924. f. Disassembly of Channel Plate (Foldout 11)

9. Remove stop 143, spring 142, and main 1. If damaged, remove two dowel pins 191 or
regulator valve 141. 199.

2. Remove drain plug assemblies 193 or 201.


10. Push against stop 147 to compress spring 146
Inspect threads for damage caused by drain
and remove valve retention pin 144.
plug.

3. Remove eight pressure-tap plug assemblies


195 or 203.

g. Assembly of Channel Plate (Foldout 11)

CAUTION:
If threads were damaged by the drain plug or if
proper drain plug torque could not be attained,
refer to SIL 5-WT-98, Rev. A for an approved
channel plate rework procedure and information
about a longer drain plug for improved thread
life and torque holding capability.

1. Install eight pressure tap plug assemblies 195 or


Figure 532. Main Pressure Regulator 203. Replace O-ring 196 or 204 as required.
Valve Spring Tool Tighten plug assemblies to 1013 Nm (710 lb ft).

Copyright 2001 General Motors Corp. 547


4000 MH/HD 4000/B 500 SERIES ON-HIGHWAY SERVICE MANUAL
2. Install drain plug assembly 193 or 201. 14. Install valve retention pin 136.
Replace O-ring 194 or 202 as required. Tighten
plug to 2532 Nm (1824 lb ft). 15. Install converter flow valve 133, spring 134,
and stop 135.
3. If removed, install two pins 191 or 199.
16. Install valve retention pin 132.
4. Install gasket 189, separator plate 188, and
gasket 214. 17. Install small O-ring 150 and large O-ring 151
on solenoid 149 and install solenoid.
h. Assembly of Main Valve Body
(Foldout 11) 18. Install solenoid retention pin 148, smooth end
first, from the bottom of the main valve body
1. Install converter regulator valve 167, assembly.
spring 168, and stop 169.
19. Install retaining pin 153, if removed.
2. Install valve retention pin 166 by pushing
against stop 169 to compress spring 168. i. Assembly of C6 Control Valve Body
(HD 4070/4076 Models Only)
3. Install C1 latching valve 163, spring 164, and
stop 165. 1. Inspect interlock valve 166 and its bore for
nicks, wear, and damage (Figure 531).
4. Install valve retention pin 162.
2. Insert interlock valve 166 in the bore and check
5. Install exhaust back pressure valve 159, it for free movement (Figure 531).
spring 160, and stop 161.
3. Install interlock valve 166 and spring 167 in
6. Install valve retention pin 158. the valve bore (Figure 531).

7. Install C2 latch valve 155, spring 156, and 4. Inspect solenoid filter screen 150, if present,
stop 157. for debris and damage. Replace it if necessary
(Figure 531).
8. Install valve retention pin 154.
5. Install new O-rings 164 and 165 on interlock
9. Install control main valve 145, spring 146, and valve solenoid 163, and install the solenoid in
stop 147. the valve bore (Figure 531).
10. Install valve retention pin 144. 6. Check regulator valve 153 and its bore for
wear and damage (Figure 531).
11. Install main regulator valve 141, spring 142,
and stop 143. 7. Insert regulator valve 153 in the bore and
check it for free movement (Figure 531).
WARNING! 8. Install regulator valve 153 and spring 152 in
Spring 142 is highly compressed. Be extremely the valve bore (Figure 531).
careful during assembly. Personal injury can
occur if the spring force is not controlled. 9. Install new O-rings 155 and 156 on the
regulator valve solenoid (Figure 531).

12. Install spring compressor J 35924 10. Install regulator valve solenoid 154 in its bore
(Figure 532). Compress spring 142, install (Figure 531).
valve retention pin 140, and carefully remove
J 35924 tool. 11. Insert solenoid retention pins 159, smooth end
first, from the bottom (separator plate side) of
13. Install lube regulator valve 137, spring 138, body 151 into body 151. Seat pins using ham-
and stop 139. mer and countersink the pins (Figure 531).

548 Copyright 2001 General Motors Corp.


MODULE REBUILD
12. Position the valve body on the channel plate 2. Install either control harness assembly 61 or 15
(Figure 531). using three bolts 14. Tighten bolts to 23 Nm
(1826 lb in.).
13. Install C6 valve body cover plate 148
(Figure 531). 3. Install either gasket 2, face seal 6, suction
filter 3, bolt 5, and two bolts 7 or gasket 13,
14. Install five bolts 147 (Figure 531) and attach filter assembly 12, face seal 11, and three
the C6 control valve body to the channel plate. bolts 10. Tighten bolts finger tight.
Tighten bolts 147 to 1013 Nm (710 lb ft).
4. Install solenoid separator plate 129.
j. Assembly of Stationary Clutch Solenoid Body
5. Install stationary clutch solenoid body
(Foldout 11)
assembly 117 and eight bolts 115. Tighten
1. Install valve 128, spring 127, and stop 126. bolts finger tight.
Install valve retention pin 122.
6. Install rotating clutch solenoid body 95 and
2. Install springs 120, solenoid regulator three bolts 93 if plate 9 is present or seven
valves 121, small O-rings 125, large bolts 93 if plate 9 is not used. Tighten bolts
O-rings 124, and solenoids 123. finger tight.

7. Install oil level sensor assembly 182 or 170


3. As valve bores are filled, install solenoid
using two bolts 181 or 171. Tighten bolts to
retention pins 119, smooth end first, from the
1013 Nm (710 lb ft).
bottom of the solenoid body.
8. If used, install wiring harness cover plate 9 and
4. Install two seals 116. four bolts 8. Tighten bolts finger tight.
k. Assembly of Rotating Clutch Solenoid Body 9. Reconnect all electrical connectors.
(Foldout 11)
10. Evenly tighten cover plate bolts 8 if present,
1. Install valve 111, spring 112, and stop 113. suction filter bolts 5, 7, or 10, valve body bolts
Install valve retention pin 114. 130, 115, and 93. Tighten all bolts to 1013 Nm
(710 lb ft).
2. Install three springs 101, three solenoid
regulator valves 102, small seals 104 and 108,
large seals 105 and 107, and two solenoids 103 NOTE:
and one solenoid 106. For units prior to S/N 661009730, proceed to
Step (11).
3. Install solenoid retention pins 109, smooth end
For units with S/N 661009730 up to
first, from the bottom of the rotating clutch
6610015591, skip Step (11) and go to Step (12).
solenoid body.

4. Install pressure switch assembly 97 and two 11. Prepare two filter covers 206, two square-cut
bolts 96. Tighten bolts to 58 Nm (4471 lb in.). seals 208, two O-rings 209, and two filters 210
for installation at final transmission assembly.
l. Assembly of Control Valve Module
(Foldout 11) 12. Prepare two filter covers 206, two gaskets 207,
two O-rings 208, two O-rings 209, and two fil-
1. Install main valve body assembly 131 and two ters 210 for installation at final transmission
bolts 130. Tighten bolts finger tight. assembly.

Copyright 2001 General Motors Corp. 549


Section 6 TRANSMISSION ASSEMBLY
61. SCOPE 1. Install C3/C4 clutch assembly 1 through the
input end of main housing 2, aligning the bolt
a. Section. This section covers the assembly of the holes in the clutch assembly with the holes in
4000 MH/HD 4000/B 500 Series transmissions. The the main housing.
assembly sequence is continuous and includes all
models. 2. Install two bolts 3, 180 degrees from each
other, to hold clutch assembly 1 in place.
b. Procedures. When a procedure does not apply to
your specific model, go to the next applicable 3. Rotate the transmission housing using repair stand
procedure. controls and install remaining twelve bolts 3.
c. Illustrations. Illustrations will not always show Tighten all bolts to 5161 Nm (3845 lb ft).
your model, but when an operation is identical for all
models, the correct procedure is shown. b. Installation of Rotating Clutch Module (Figure
62). Use repair stand controls to put main housing in
d. General Information. Refer to Section 3 for the vertical position. Use a hoist and an M16 eye bolt
general information as follows: to insert rotating clutch module 1 in the front of the
main housing.
Paragraph Description
32 Tools, Equipment
33 Replacement Parts
34 Careful Handling
36 Assembly Procedures
1 3

e. Foldouts. Refer to Foldouts 4 through 12 for


disassembled views and torque specifications.

NOTE:
All parts must be cleaned and lubricated before
assembly. 2 E01274.01

Figure 61. Main Housing and C3/C4 Clutch Installation

62. ASSEMBLY OF TRANSMISSION


a. Assembly of Main Housing Module
(Figure 61)

CAUTION: 1

Before beginning assembly, attach bracket


J 41445 and holding fixture J 35926 to the main
housing. Use a hoist to mount the fixture and
housing on repair stand J 29109.

CAUTION:
E01273.01
Ensure that main housing is horizontal when
installing the C3/C4 clutch module. Figure 62. Rotating Clutch Module Installation

Copyright 2001 General Motors Corp. 61


4000 MH/HD 4000/B 500 SERIES ON-HIGHWAY SERVICE MANUAL
c. Installation of Front Support/Charging f. Installation of C5 Clutch Pack (Figure 65). Install
Pump Module (Figure 63) the C5 clutch pack in the main housing nine steel
reaction plates 2 and eight friction plates 3, stacked
1. Lower front support and charging pump
alternately, starting with a steel reaction plate. Stack
module 3 over the top of the turbine shaft.
all plates so plate cone faces the same direction. Steel
plates mesh with the main housing and reaction plates
2. Align bolt holes in front support 3 with the
mesh with the P3 ring gear.
threaded holes in the main housing.
g. Installation of Main Shaft Module (4000 MH,
3. Install seven bolts 1 and seven bolts 2. Tighten HD 4060, HD 4560, and B 500 Models Only)
bolts to 5161 Nm (3845 lb ft). (Figure 66). Install main shaft 1 as assembled in
Section 5, without selective shim 2 and thrust bearing 3.
4. Rotate the repair stand so the rear of the main
housing is facing upward.

d. Installation of P1 Planetary Module


(Figure 64)
1. Install P1 planetary module 1 consisting of
1
the P1 carrier and P2 ring gear.

2. Mesh the P1 pinion gears with the P1 ring gear


inside the C3/C4 clutch assembly.

e. Installation of P2 Planetary Module E01271.01

(Figure 65) Figure 64. P1 Planetary Module Installation


1. Install P2 planetary module 1 consisting of
the P2 carrier and the P3 ring gear.

2. Mesh the P2 pinions with the P2 ring gear 1 C5


during installation. 2
3
2
3

E02516.01

Figure 65. P2 Planetary Module and


C5 Clutch Installation

HD 4560
1

V01272
1 2
HD 4060/B 500 3
V01737
Figure 63. Front Support/Charging
Pump Module Installation Figure 66. Main Shaft Module Installation

62 Copyright 2001 General Motors Corp.


TRANSMISSION ASSEMBLY
h. Installation of Main Shaft Module 4. Place the retarder or rear cover module output
(HD 4070/4076 Models Only) end down (facing the bench top). Install an
uncompressed gasket on the retarder or rear
1. Install main shaft module as assembled in cover mounting surface and place a straight
Section 5. edge across the P3 planetary carrier.

i. Main Shaft Selective Shim Measurement 5. Measure dimension D, from top of the straight
(Close Ratio Models) (Figure 67) edge to the gasket.
1. Place a straight edge across the retarder or rear 6. Measure dimension E, the thickness of the
cover mounting surface of the main housing. straight edge. Subtract dimension E from
dimension D the remainder is dimension F.
2. Measure dimension A, from top of the straight
edge to the selective shim thrust surface on the 7. Dimension G is the remainder of C minus
main shaft bearing spacer. F and determines the thickness of the
selective shim.
3. Measure dimension B, thickness of straight
edge. Subtract dimension B from dimension A 8. Install the proper thickness selective shim and
the remainder is dimension C. the thrust bearing.

4000 MH/HD 4060/B 500 CLOSE RATIO


BEARING AND UNCOMPRESSED
STRAIGHT EDGE SHIM REMOVED GASKET IN PLACE STRAIGHT EDGE DIM. E

DIM. A DIM. B
DIM. F
DIM. C
DIM. D

RETARDER NON-
MAIN SHAFT MODULE MODEL RETARDER
MODEL
PROCEDURE: FORMULA (C)(F)=G

DIM. G USE P/N SHIM ID DIM. G USE P/N SHIM ID


5.71356.033 mm 6.8447.113 mm
29501117 1 NOTCH 0.2700.280 in. 29501121 5 NOTCHES
0.2310.237 in.
6.0346.303 mm 7.1147.383 mm
29501118 2 NOTCHES 29501122 6 NOTCHES
0.2380.247 in. 0.2810.290 in.
6.3046.573 mm 7.3847.484 mm
29501119 3 NOTCHES 29512774 0 NOTCHES
0.2480.258 in. 0.2910.295 in.
6.5746.843 mm
29501120 4 NOTCHES
0.2590.269 in. V03210.05

Figure 67. Main Shaft Selective Shim Measurement For 4000 MH/HD 4060/B 500 (Close Ratio)

Copyright 2001 General Motors Corp. 63


4000 MH/HD 4000/B 500 SERIES ON-HIGHWAY SERVICE MANUAL
j. Main Shaft Selective Shim Measurement 6. Measure dimension E, the thickness of the
(Wide Ratio Models) (Figure 68) straight edge. Subtract dimension E from
dimension D the remainder is dimension F.
1. Place a straight edge across the retarder or rear
cover mounting surface of the main housing. 7. Dimension G is the remainder of C minus F
and determines the thickness of the selective
2. Measure dimension A, from top of the straight shim.
edge to the selective shim thrust surface on the
main shaft bearing spacer. 8. Install the proper thickness selective shim and
the thrust bearing.
3. Measure dimension B, thickness of straight
edge. Subtract dimension B from dimension A
the remainder is dimension C. CAUTION:
4. Place retarder or rear cover output end down Be sure that thrust bearings are assembled to
(facing the bench top). Install an uncompressed function correctly. Make sure that the locating
gasket on the retarder or rear cover mounting lip on either the inner or outer thrust bearing
surface and place a straight edge across the P3 race is not preventing the race from contacting
planetary carrier. the thrust surface of the mating part. Failure to
do this leads to premature thrust bearing failure
5. Measure dimension D, from top of the straight and incorrect shim selection to maintain proper
edge to the gasket. internal part clearance.

HD 4560 WIDE RATIO


BEARING AND UNCOMPRESSED
STRAIGHT EDGE SHIM REMOVED GASKET IN PLACE STRAIGHT EDGE DIM. E

DIM. A DIM. B
DIM. F
DIM. C
DIM. D

RETARDER NON-
MAIN SHAFT MODULE MODEL RETARDER
MODEL
PROCEDURE: FORMULA (C)(F)=G

DIM. G USE P/N SHIM ID DIM. G USE P/N SHIM ID


4.61774.843 mm 5.6545.923 mm
0.1800.190 in. 29503218 1 NOTCH 0.2240.233 in. 29503222 5 NOTCHES
4.8445.113 mm 5.9246.193 mm
29503219 2 NOTCHES 29503223 6 NOTCHES
0.1920.201 in. 0.2340.244 in.
5.1145.383 mm 6.1946.380 mm
29503220 3 NOTCHES 29503224 7 NOTCHES
0.2020.212 in. 0.2450.254 in.
5.3845.653 mm
29503221 4 NOTCHES
0.2130.223 in.
V03211.02

Figure 68. Main Shaft Selective Shim Measurement For HD 4560 (Wide Ratio)

64 Copyright 2001 General Motors Corp.


TRANSMISSION ASSEMBLY
k. Installation of P3 Planetary Module
(HD 4070/4076 Retarder Models Only) CAUTION:
(Figure 69) Over-tightening bolt 3 will damage the bolt. Use
the torque formula in Figure 612 to find the
1. Thread special tool J 43020 onto P3 Planetary correct torque value to apply to bolt 3.
Module 1 and use chain hoist to install P3
Planetary Module 2 in Main Housing 3. Install fourteen bolts 3 through C6 adapter
Module 1. housing module 4 into main housing 1. Tighten
bolts using special tool J 43046 and torque
2. Install P4 shaft flange 3.
wrench to 100120 Nm (7488 lb ft) in the
star pattern (Figure 611). Use the formula in
NOTE: Figure 612 to find the correct torque value to
Do not install shim locating ring or selective shim apply to bolt 3.
until final transmission assembly. Measurement for
selective shim is performed during final buildup.
1
J 43046
l. Installation of C6 Adapter Housing Module 2
(HD 4070/4076 Retarder Models Only) 3
(Figure 610)
4
1. Install new C6 adapter housing gasket 2.

WARNING!
Get help when lifting the C6 adapter housing
module. Assistance from a hoist or another
person may be required. The C6 adapter housing
module weighs approximately 68 kg (150 lb).
5

2. Thread two M12 bolts and attach a sling to the V05374

C6 adapter housing module 4 by positioning


Figure 610. Installation of C6 Adapter
the housing connections equal distance from Housing Module
each other. Using a chain hoist, carefully lift
and install the C6 adapter housing 4 onto the
transmission.

J 43046

3
4

J 43020
V05590
V05375

Figure 611. Tightening C6 Adapter Housing


Figure 69. Installation of P3 Planetary Module To Main Housing Bolts

Copyright 2001 General Motors Corp. 65


4000 MH/HD 4000/B 500 SERIES ON-HIGHWAY SERVICE MANUAL

;
BOLT
(C6 adapter housing
to main housing)
A
TORQUE WRENCH
J 43046

Tw Ta
CLOCKWISE
ROTATION
L

C6 ADAPTER HOUSING

L TOP VIEW
Tw = Ta X
L+A
L = Effective length of torque wrench
A = Effective length of special tool
Tw = Torque applied at the wrench (adjusted torque value to be applied with wrench)
Ta = Torque applied at the bolt (ACTUAL torque value specified by service manual)
V05591

Figure 612. C6 Adapter Housing To Main Housing Bolt Torque Formula

m. P3 Planetary Selective Shim Measurement surface. Place the P4 ring gear hub over the
(HD 4070/4076 Models Equipped With output shaft. Place two measuring blocks
Retarder) (Figure 613) included in special tool J 43922 on the front
face of retarder. Place the straight edge
1. Place a straight edge across the rear face of the
included in J 43922 across the top of the
C6 adapter housing with uncompressed
measuring blocks included in J 43922.
retarder housing gasket.

2. Measure dimension A, from top of the straight 6. Measure dimension D from top of the straight
edge to the selective shim thrust surface on the edge to the face of the retarder.
P3 carrier face.
7. Measure dimension E from the top of the
3. Measure dimension B, thickness of straight straight edge J 43922 to the face of the P4 ring
edge. Subtract dimension B from dimension A gear hub.
the remainder is dimension C (measurement
between rear face of adapter housing with 8. Subtract dimension E from dimension D
uncompressed gasket and P3 carrier face). remainder is dimension F (measurement
between front face of retarder and P4 ring gear
4. Remove retarder housing gasket. hub face)

5. Place the retarder module output end down 9. Dimension G is the remainder of C minus F
(facing the bench top) on supports, so the and determines the thickness of the selective
output shaft is not contacting the bench shim, dimension G.

66 Copyright 2001 General Motors Corp.


4000 MH/HD 4000/B 500 SERIES ON-HIGHWAY SERVICE MANUAL
n. P3 Planetary Selective Shim Measurement between rear face of adapter housing with
(HD 4070/4076 Models Equipped With Rear uncompressed gasket and P3 carrier face).
Cover) (Figure 614)
4. Remove rear cover gasket.
1. Place a straight edge across the rear face of the
C6 adapter housing with uncompressed rear 5. Place the rear cover module output end down
cover gasket. (facing the bench top) on supports, so the
2. Measure dimension A, from top of the straight output shaft is not contacting the bench
edge to the selective shim thrust surface on the surface. Place the P4 ring gear hub over the
P3 carrier face. output shaft. Place the two measuring blocks
included in special tool J 43922 on the front
3. Measure dimension B, thickness of straight face of rear cover. Place the straight edge
edge. Subtract dimension B from dimension A included in J 43922 across the top of the
the remainder is dimension C (measurement measuring blocks included in J 43922.

;;; DIM. B
STRAIGHT EDGE

;;; GASKET

;;
;;; ;;;
J 43922 INSTALLED
STRAIGHT EDGE MEASURING
J 43922 BLOCK (2), J 43922

;;; ;;;;;;; ;;;


DIM. A DIM. C

; DIM. F DIM. E

;;;
;; ;;;;;;; ;;;
;;
DIM. D

;;; ;
; ; ;;;;;;;;;
;;
;;;
;;
;;; ;
;;;;;;;
No Gasket

SUPPORTS

C6 ADAPTER HOUSING MODULE RETARDER AND OUTPUT SHAFT MODULE


PROCEDURE: FORMULA CF=G
DIM. G USE P/N SHIM ID
0.88301.1534 mm
29503516 0
0.03470.0454 in.
1.15351.4234 mm
29503517 1 NOTCH
0.04550.0560 in.
1.42351.6934 mm
29503518 2 NOTCHES
0.05610.0666 in.
1.69351.9634 mm
29503519 3 NOTCHES
0.06670.0772 in.
1.96352.2334 mm
29503520 4 NOTCHES
0.07730.0879 in.
2.23352.5034 mm
29503521 5 NOTCHES
0.08800.0985 in.
2.50352.7734 mm
29503522 6 NOTCHES
0.09860.1091 in.
2.77353.0434 mm
29503523 7 NOTCHES
0.10920.1198 in.
3.04353.3134 mm
29503524 8 NOTCHES
0.11990.1304 in.
HD 4070R AND HD 4070PR
V05380

Figure 613. P3 Planetary Shim Measurement (HD 4070/4076 Models Equipped With Retarder)

Copyright 2001 General Motors Corp. 67


4000 MH/HD 4000/B 500 SERIES ON-HIGHWAY SERVICE MANUAL

;;; DIM. B
STRAIGHT EDGE

;;; GASKET

;;
;;; ;;;
J 43922 INSTALLED
STRAIGHT EDGE MEASURING

;; ;;;
J 43922 BLOCK (2), J 43922

;;; ;;;
DIM. A DIM. C
DIM. F DIM. E

;;;
;;;; ;; ;;; ;; ;;;
DIM. D

;; ;;; ;; ;;;
;; ;;
;;

;; ;;;
No Gasket

; ;
SUPPORTS

C6 ADAPTER HOUSING MODULE REAR COVER AND OUTPUT SHAFT MODULE


PROCEDURE: FORMULA CF=G
DIM. G USE P/N SHIM ID
0.88301.1534 mm
29503516 0
0.03470.0454 in.
1.15351.4234 mm
29503517 1 NOTCH
0.04550.0560 in.
1.42351.6934 mm
29503518 2 NOTCHES
0.05610.0666 in.
1.69351.9634 mm
29503519 3 NOTCHES
0.06670.0772 in.
1.96352.2334 mm
29503520 4 NOTCHES
0.07730.0879 in.
2.23352.5034 mm
29503521 5 NOTCHES
0.08800.0985 in.
2.50352.7734 mm
29503522 6 NOTCHES
0.09860.1091 in.
2.77353.0434 mm
29503523 7 NOTCHES
0.10920.1198 in.
3.04353.3134 mm
29503524 8 NOTCHES
0.11990.1304 in.
HD 4070 AND HD 4070P
V05612

Figure 614. P3 Planetary Shim Measurement (HD 4070/4076 Models Equipped With Rear Cover)

6. Measure dimension D from top of the straight o. Installation of Remainder of P3 Planetary


edge to the face of the rear cover. Module And C6 Adapter Housing Module
(HD 4070/4076 Models Only)
7. Measure dimension E from the top of the (Foldout 9,C)
straight edge J 43922 to the face of the P4 ring
gear hub. 1. Install shim locating ring 6.

8. Subtract dimension E from dimension D 2. Install the proper selective shim 12 from
remainder is dimension F (measurement previous step.
between front face of rear cover and P4 ring
gear hub face). 3. Install P4 ring gear 46 and hub 47 into P4 ring
gear 46. Install retaining ring 48 into P4 ring
9. Dimension G is the remainder of C minus F gear and hub assembly 45.
and determines the thickness of the selective
shim dimension G. 4. Install ring gear and hub 45 (Foldout 9,C).

68 Copyright 2001 General Motors Corp.


TRANSMISSION ASSEMBLY
p. Installation of Tolerance Rings Module 4. Install twelve bolts 8, two bolts 4, four bolts 3,
(HD 4070/4076 Models Equipped With and seven bolts 5 (Figure 617). Tighten
Retarder) bolts 8, 4, and 3 to 100120 Nm (7488 lb ft).
1. Insert eleven tolerance rings 49 (Foldout 9,C) Tighten bolts 5 to 5161 Nm (3845 lb ft).
in counterbores flush to slightly below rear 5. Retighten the spanner nut using tool J 37035-1
mounting surface at locations shown in to 7488 Nm (55-64 lb ft).
Figure 615.
q. Installation of Retarder Module (4000 MH, CAUTION:
HD 4060, HD 4560, and B 500 Models Do not reuse a tang once it has been bent. Install
Equipped With Retarders) a new locknut retainer.

NOTE: 6. Locate two locking tabs on retainer 59


(Foldout 10,A) and bend them up to hold
For units prior to S/N 6610066447, proceed to
locknut 60 in position.
Step (1).
For units beginning with S/N 6610066447, skip 7. Install output shaft oil seal 61, using tool
Steps (1) through (7) and proceed to Step (8). J 37031.

1. Install guide bolts to ease retarder module 2


(Figure 616) installation and keep gasket 1 in
place.
2. Install a NEW retarder gasket 1 on main
2
housing 6.
8

WARNING! 6 7
Get help when lifting the retarder module.
Assistance from a hoist or another person may be 1
required. The retarder module weighs 3
approximately 34 kg (75 lb). 4
5
V06865
3. Place retarder module 2 on main housing 6
using a hoist and sling as a lifting fixture. If Figure 616. Retarder Module Installation
used, install the rear support bracket. (Units Prior to S/N 6610066447)

8 8
BOLT, M12 x 1.45 x 55 8 8
(12) MARKED 8
8 8

8 8

8 8

4 8
8
BOLT, M12 x 1.45 x 105 4
3 3
(2) MARKED 4 3 3 5
5
A
TOLERANCE BOLT, M10 x 1.5 x 385 5
A A A
A A RING (11) 5 5 5 5
(7) MARKED 5
LOCATION
MARKED A BOLT, M12 x 1.45 x 350
A A A A A (4) MARKED 3 V06876
REAR VIEW OF C6 ADAPTER HOUSING V05391
Figure 617. Retarder Module Bolts
Figure 615. Tolerance Ring Locations (Units Prior to S/N 6610066447)

Copyright 2001 General Motors Corp. 69


4000 MH/HD 4000/B 500 SERIES ON-HIGHWAY SERVICE MANUAL
8. Install guide bolts to ease retarder module 1 13. Locate two locking tabs on retainer 58 and
(Figure 618) installation and keep gasket 7 in bend them up to hold locknut 59 in position.
place.
14. Install output shaft oil seal 60, using tool
9. Install retarder gasket 7 over the guide bolts J 37031.
and against the main housing module 8.
r. Installation of Retarder And Output Shaft
WARNING! Module (HD 4070/4076 Models Equipped
With Retarders)
Get help when lifting the retarder module.
Assistance from a hoist or another person may be
required. The retarder module weighs NOTE:
approximately 34 kg (75 lb).
For units prior to S/N 6610066447, proceed to
Step (1).
10. Thread an M14 eye bolt into the retarder out- For units beginning with S/N 6610066447, skip
put shaft and lift retarder module 1 onto main Steps (1) through (9) and proceed to Step (10).
housing module 8. If used, install the rear sup-
port bracket.
1. Thread an M10 eye bolt into the output shaft
11. Install twelve bolts 2 (Figure 618), three assembly 9 (Figure 619).
bolts 3, two bolts 4, four bolts 5, and four
2. Install new stator housing gasket 3.
bolts 6 that secure retarder module 1 to main
housing module 8. Tighten bolts 2, 4, and 5 to 3. Install guide bolts to ease retarder and output
100120 Nm (7488 lb ft). Tighten bolts 3 and shaft module 5 installation, and keep the gasket
6 to 5161 Nm (3845 lb ft). in place.
12. Retighten spanner nut 59 (Foldout 10,E) using 4. Lift with hoist, and install retarder and output
tool J 37035-1 to 7488 Nm (55-64 lb ft). shaft module onto C6 adapter housing
module 2.
CAUTION:
5. Install 12 bolts 4, 2 bolts 7, and 4 bolts 6.
Do not reuse a tang once it has been bent. Install Tighten bolts to 100120 Nm (7488 lb ft)
a new locknut retainer 58. (Figure 620).

2 2
2 2
2 2

2 2
1
2 2 2

8 4 2
4 2
5
7 6 5 5 5
3
3 OR
4 6 6 6
6 5 3 3
V06844

Figure 618. Retarder Module Installation (Units Beginning With S/N 6610066447)

610 Copyright 2001 General Motors Corp.


TRANSMISSION ASSEMBLY
6. Install 7 bolts 8. Tighten bolts to 5161 Nm 8. Locate two locking tabs on retainer 40 and
(3845 lb ft) (Figure 620). bend them up to hold bearing retainer nut 41 in
position. If only one tang is aligned with a
7. Use special tool J 43278 and J 37035-2 and bearing retainer locknut slot, continue to
tighten bearing retainer lock nut 41 to 7488 Nm torque the bearing retainer locknut (but do not
(5564 lb ft) (Foldout 10,C). exceed the tightening torque or drag torque
limits) until two tangs can be bent up into slots
NOTE: on the bearing retainer locknut. (Foldout 10,C)

DO NOT reuse a tang once it has been bent. Use a 9. Install output shaft oil seal 42 (Foldout 10,C)
new locknut retainer 40 (Foldout 10,C). using special tools J 43024 and J 37034, and
rubber mallet (Figure 621).

10. Thread an M10 eye bolt into the output shaft


1
assembly 3 (Foldout 10,F).
2 11. Install new retarder stator housing gasket 1.

3 4 12. Install guide bolts to ease retarder and output


shaft module 5 installation, and keep the gasket
5 in place (Figure 619).

13. Lift with hoist, and install retarder and output


shaft module onto C6 adapter housing
module 2.
6
14. Install 12 bolts 4, 2 bolts 7, and 4 bolts 8.
9 8 7 Tighten bolts to 100120 Nm (7488 lb ft)
(Figure 622).
V05373

Figure 619. Installation of Retarder and Output


15. Install 4 bolts 9 and 3 bolts 6. Tighten bolts to
Shaft Module (Units Prior to S/N 6610066447) 5161 Nm (3845 lb ft) (Figure 622).

4 4
BOLT, M12 x 1.75 x 55 4 4
(12) MARKED 4
4 4

4 4 J 37034

4 4
J 43024
7 4
4
BOLT, M12 x 1.75 x 105 7
6 6
(2) MARKED 7 6 6 8
8
BOLT, M10 x 1.5 x 345 8
8 8 8 8
(7) MARKED 8
BOLT, M12 x 1.75 x 350
(4) MARKED 6 V06866
V05594

Figure 620. Installation of Retarder and Output Figure 621. Installation of Output Shaft Oil Seal
Shaft Module Bolts (Units Prior to S/N 6610066447) (HD 4070/4076 Models Equipped With Retarder)

Copyright 2001 General Motors Corp. 611


4000 MH/HD 4000/B 500 SERIES ON-HIGHWAY SERVICE MANUAL

1
4 4
4 4
2 4 4

4 4
3 4

4 4
5
7 4
7 4
8
9 8 8 8
6 6 OR
9 9 9 6 6
7 8
9
V06845

Figure 622. Installation of Retarder and Output Shaft Module (Units Beginning With S/N 6610066447)

16. Use special tool J 43278 and J 37035-2 and


tighten bearing retainer locknut 44 to 7488 Nm
(5564 lb ft) (Foldout 10,F).

NOTE:
DO NOT reuse a tang once it has been bent. Use a
new locknut retainer 43 (Foldout 10,F).

17. Locate two locking tabs on retainer 43 and


bend them up to hold bearing retainer nut 44 in 4
position. If only one tang is aligned with a 1
3
bearing retainer locknut slot, continue to
torque the bearing retainer locknut (but do not 2 5 V06867

exceed the tightening torque or drag torque


limits) until two tangs can be bent up into slots Figure 623. Rear Cover Module Installation
on the bearing retainer locknut (Foldout 10,F).
4. Install nineteen bolts 3. Tighten bolts to
18. Install output shaft oil seal 42 (Foldout 10,F) 100120 Nm (7488 lb ft).
using special tools J 43024 and J 37034, and
rubber mallet (Figure 621). 5. Retighten the spanner nut using tool J 37035-1
to 7488 Nm (5564 lb ft).
s. Installation of Rear Cover Module (4000 MH,
HD 4060, HD 4560, and B 500 Models Only)
CAUTION:
(Figure 623)
Do not reuse a tang once it has been bent. Install
1. Install guide bolts to ease rear cover 2 a new locknut retainer 38.
installation and keep gasket 1 in place.

2. Install a NEW rear cover gasket 1 on main 6. Locate two locking tabs on retainer 38
housing 4. (Foldout 10,B) and bend them up into notches
on locknut 39.
3. Place rear cover module 2 on main housing 4
using a hoist and sling as a lifting fixture. 7. Install output shaft oil seal 5 (Figure 623)
Install rear support bracket, if used. using tool J 37031.

612 Copyright 2001 General Motors Corp.


TRANSMISSION ASSEMBLY
t. Installation of Rear Cover Module 6. Locate two new locking tabs on retainer 28 and
(HD 4070/4076 Models Only) (Figure 624) bend them up into slots on locknut 29 (Foldout
10,D). If only one tang is aligned with a
1. Install guide bolts to ease rear cover 6 bearing retainer locknut slot, continue to
installation and keep gasket 3 in place. torque the bearing retainer locknut (but do not
exceed the tightening torque or drag torque
2. Install a NEW rear cover gasket 3 on main limits) until two tangs can be bent up into slots
housing 1. on the bearing retainer locknut.

3. Place rear cover module 6 on main housing 1 7. Install output shaft oil seal 30 (Foldout 10,D)
using a hoist and sling as a lifting fixture. using tool J 43024 and J 37034 and rubber
Install rear support bracket, if used. mallet (Figure 627).

4. Install fourteen bolts 4 and install five bolts 5. BOLT, M12 x 1.75 x 45
Tighten bolts to 100120 Nm (7488 lb ft) (14) MARKED 4
4 4
(Figure 625). 4 4
4 4
5. Retighten bearing retainer locknut using tool 4 4
J 37035 and J 43278. Place the torque wrench
and a breaker bar as shown in Figure 626. 4 4
Rotate the torque wrench in the
counterclockwise direction and tighten the nut 4 4
to 7488 Nm (5564 lb ft). BOLT, 4 4
5 5
METRIC HEAVY 5 5
(5) MARKED 5 5

CAUTION:
Do not reuse a tang once it has been bent. Install
a new locknut retainer 28 (Foldout 10,D).
V05576

Figure 625. Rear Cover and Output Shaft


Module Bolts
1

3 4 J 43278
J 37035-3

V05580
V05589

Figure 624. Installation of Rear Cover and Output Figure 626. Tightening Bearing Retainer Locknut
Shaft Module Rear Cover Equipped

Copyright 2001 General Motors Corp. 613


4000 MH/HD 4000/B 500 SERIES ON-HIGHWAY SERVICE MANUAL

J 37034

1
J 43024 3

2
4

V06868

Figure 628. Converter Housing Module Installation

V05595
2. The splines of the ground sleeve and turbine
Figure 627. Installation of Output Shaft Oil Seal shaft must engage with their respective splines
(HD 4070/4076 Models Equipped With Rear Cover)
in the torque converter module. The tangs on
u. Installation of Converter Housing Module the converter-pump hub must engage the
(Figure 628) charging pumps drive gear or the PTO oil
pump drive hub.
1. Install guide bolts to ease converter housing 1
installation and keep gasket 2 in place. 3. Using a hoist and sling, install torque converter
module 6 into the converter housing module
2. Position the transmission input end up. Install
(Figure 629, View A).
a NEW converter housing gasket 2 on main
housing module 4.
4. Ensure that the torque converter is properly
3. Lower converter housing 1 onto main seated. If PTO equipped, rotate the PTO gear
housing 4. If the transmission is PTO to engage the pump hub with the charging
equipped, rotate the PTO drive gear to align pump. Proceed with the selective shim
the gear tangs with the charging pump. measurement.
4. Install seven bolts 3 into the inside of converter
housing 1. Use mechanical fingers, or a similar 5. Install converter end play gauge J 38548
tool, when installing these bolts. and tighten the attaching bolt to 2734 Nm
(2025 lb ft). Prevent turbine shaft rotation by
5. Remove the two guide bolts and install the using one of the following methods:
remaining bolts 3. Tighten all bolts 3 to 5161 Nm
(3845 lb ft). Insert a screwdriver into the vanes on the
v. Installation of Torque Converter Module rotating clutch module (Figure 629,
(Figure 629) View B).
1. The torque converter is installed over the If the control module is in place, apply air
turbine shaft which rotates inside the stator pressure through the lockup pressure tap
shaft or ground sleeve. The splines on the and use a heel bar, screwdriver, and bolts.
ground sleeve engage the converter stator. The Insert the heel bar into a torque converter
splines on the turbine shaft engage the housing bolt hole. Insert two bolts into the
converter turbine. The end of the turbine shaft flexplate adapter bolt holes. Then place a
is threaded and machined to accept the screwdriver at an angle to prevent converter
converter retaining bolt and lockup sealring. rotation (Figure 629, View C).

614 Copyright 2001 General Motors Corp.


TRANSMISSION ASSEMBLY
Table 61. Torque Converter Selective Shims

ID
Dimension C Use P/N Shim Thickness (Ref.) No.
0.41290.6598 mm (0.01630.0259 inch) 29505688 4.000 mm (0.157 inch) 0
0.65990.8378 mm (0.02600.0329 inch) 29505681 4.203 mm (0.165 inch) 1
0.83791.0158 mm (0.03300.0399 inch) 29505682 4.381 mm (0.172 inch) 2
1.01591.1938 mm (0.04000.0469 inch) 29505683 4.559 mm (0.179 inch) 3
1.19391.3708 mm (0.04700.0539 inch) 29505684 4.736 mm (0.186 inch) 4
1.37091.5488 mm (0.05400.0609 inch) 29505685 4.914 mm (0.193 inch) 5
1.54891.7268 mm (0.06100.0679 inch) 29505686 5.092 mm (0.200 inch) 6
1.72691.9048 mm (0.06800.0749 inch) 29507793 5.270 mm (0.207 inch) 7
1.90491.9733 mm (0.07500.0776 inch) 29507794 5.448 mm (0.214 inch) 8

8. Install selective shim 5 with the step side


NOTE: toward the turbine shaft. Install bolt 4,
Dimension C shown in the table above includes a converter bolt tightening tool J 38564, and
correction due to internal deflection caused by the retaining ring 1 (Figure 629, View A). The
2734 Nm (2025 lb ft) bolt torque applied to gauge turbine and turbine shaft may rotate while
J 38548. Correct torque value is critical to selection attempting to tighten this retaining bolt
of the proper shim. prevent turbine shaft rotation as in Step (5).
Tighten the bolt to 100120 Nm (7489 lb ft).
6. Measure from top of tool J 38548 to face of
turbine shaft and record it as dimension B. 9. Remove retaining ring 1 and tool J 38564.
Subtract dimension B from dimension A to Install converter end plug 2, Oring 3, and
determine dimension C (dimension A is the retaining ring 1. Proceed to Step (12).
height of tool J 38548, 100.00 mm
(3.937 inch)) (Figure 629, View D). 10. Keep the torque converter cover from turning
7. Use dimension C and Table 61 to determine by using a heel bar, two bolts, and a screw-
proper selective shim part number. Remove driver (Figure 629, View C).
tool J 38548 and continue with installation of
the torque converter. 11. Install threaded plug 7 and O-ring 8 using a
34 inch Allen socket. Tighten plug to 5060 Nm
NOTE: (3744 lb ft).
For units prior to S/N 6610032772, proceed to
Step (8). 12. Install converter shipping brackets (Foldout
For units beginning with S/N 6610032772, skip 12), or equivalent, to prevent torque converter
Steps (8) and (9) and proceed to Step (10). movement. Tighten the shipping bracket bolts
to 5161 Nm (3845 lb ft).

Copyright 2001 General Motors Corp. 615


4000 MH/HD 4000/B 500 SERIES ON-HIGHWAY SERVICE MANUAL

Cupped end down


6 Restrict movement
Use hoist and sling
2 3
4 5

7 8

J 38564

VIEW A

VIEW B
LOCKUP
PRESSURE
TAP

VIEW C VIEW D E06869

Figure 629. Torque Converter Module Installation and Selective Shim Measurement

616 Copyright 2001 General Motors Corp.


TRANSMISSION ASSEMBLY
w. Installation of Control Module
(Figure 630)
1. Place the transmission in a vertical position,
front end upward.
2. Install two guide pins in two main housing bolt
holes. Install a NEW control module gasket 1
over the guide pins.

WARNING!
Get help when lifting the control module.
Assistance from another person may be
required. The control module weighs 1
approximately 25 kg (55 lb).

3. Lubricate the feedthrough hole in the main 3


housing with oil-soluble grease.
4. Guide control module 2 onto the main housing
and pass feedthrough harness connector 3 (if 2 2
so equipped) through the feedthrough hole in
5
the main housing. For earlier control modules, 4
ensure that the internal feedthrough connectors V01735

on the control module properly engages the Figure 630. Control Module Installation
external connector in the main housing.
5. Align the control module bolt holes with the x. Installation of Externally Mounted Parts
guide pins. Ensure the feedthrough harness (Figure 631)
standoff is aligned with the feedthrough hole in 1. If not previously installed, install
the main housing. transmission breather 25. Tighten breather to
6. Lower the control module over the guide pins 1216 Nm (912 lb ft).
until it seats against the main housing and the
2. Install fill tube seal 9, fill tube 8, bracket 6,
feedthrough harness standoff seats against the
and screw 5. Tighten screw to 24-29 Nm
tapered feedthrough hole in the main housing
(1821 lb ft). Install dipstick 7.
or engages the external main transmission
connector. 3. If used, install new cooler port gasket 10. Install
7. Install filter cover assemblies prepared in remote mount manifold 11 and six bolts 12.
Paragraph 518. Tighten bolts to 5161 Nm (3845 lb ft).
4. Install output flange 13 or yoke 14.
NOTE: 5. Install O-ring 16 on plug 18 or 20.
Apply transmission fluid to the control module bolts
as they are installed. This will provide lubrication
during the installation and tightening and prevent NOTE:
thread seizure. Bolts 23 and washers 24 are available in Service
Bolt Kit P/N 29535910 as described in
SIL 15-WT-98. The convex end of belleville washer
8. Remove the guide pins and install thirty-four
24 MUST contact the head of bolt 23 as shown in
bolts 4 and nine bolts 5 (4 inch sump) or 43 Figure 632. DO NOT use locktab 21 with
bolts 5 (2 inch sump). Tighten the bolts to washer 24 and bolt 23.
5161 Nm (3845 lb ft).
9. Install clip 19 (Foldout 11) on the exterior of 6. Insert two bolts 23 through belleville washers
the feedthrough harness connector near the 24 and retainer plug 20 or one bolt 19 through
main housing. plug 18.

Copyright 2001 General Motors Corp. 617


4000 MH/HD 4000/B 500 SERIES ON-HIGHWAY SERVICE MANUAL

25 ENGINE
SPEED 1 2 7
SENSOR
TURBINE 4
SPEED 3 5
SENSOR 6

13
9

OUTPUT
SPEED
SENSOR 13

18
19
16
14
17
20
21
22

24
10 23
11 12

V06837

Figure 631. Installation of Externally Mounted Parts

2. Install PTO gasket 3 and PTO assembly 2.


BELLEVILLE Insert one bolt 1 into each of the 6 oclock and
WASHER
12 oclock positions. Install the remaining six
bolts. Tighten bolts to 5768 Nm (4250 lb ft).

z. Removal of Transmission From Repair Stand


BOLT
WARNING!
Be sure that lifting equipment and the repair
stand can properly support the weight of the
V05151.02
transmission being serviced. The dry weight of
Figure 632. Installing Redesigned Two-Bolt
the HD 4060/4560/B 500PR Series transmissions
Flange Retention Kit is 440 kg (968 lb); the dry weight of the HD 4060/
4560/B 500P Series transmissions is 406 kg
7. Install an O-ring 17 over the threaded end of (893 lb); the dry weight of the HD 4070PR is
each bolt 19 or 23, so that the O-ring seats 640 kg (1411 lb); the dry weight of the HD 4070P
against the retainer plug. is 606 kg (1336 lb).

8. Install retainer plug 18 or 20 into the yoke Using hoist, remove transmission and holding fixture
or flange. Tighten bolts 23 to 3035 Nm from repair stand and prepare for vehicle installation.
(2226 lb ft). Tighten bolt 19 to 7080 Nm
(5160 lb ft). NOTE:
y. Installation of Power Takeoff Refer to Mechanics Tips MT2159EN or MT3004EN
(Figure 633) for preparing transmission for installation and
installing the transmission into a vehicle.
1. If removed, install two PTO pilot screws 4.

618 Copyright 2001 General Motors Corp.


TRANSMISSION ASSEMBLY

1 2
4
3

3
1

4
V06836

Figure 633. PTO Installation

Copyright 2001 General Motors Corp. 619


Section 7 WEAR LIMITS AND SPRING DATA
71. WEAR LIMITS DATA adjacent parts, or permanent set. Discard springs
which do not meet the load height specifications
a. Maximum Variations. Wear limit information in according to Table 72, Spring Data.
this Section shows the maximum wear at which
components are expected to function satisfactorily. b. Inspection. Inspection criteria (load vs. height)
Table 71 lists the Wear Limits Data and is referenced and identification characteristics of the springs are
to the exploded views (Foldouts 4 through 12) in the presented in Table 72. The Spring Data are keyed to
back of this manual. the exploded views (Foldouts 4 through 12) in the
back of this manual.
b. Cleaning and Inspection. Parts must be clean to
permit effective inspection for wear or damage. Refer
to Section 3. NOTE:
When more than one spring part number is listed
72. SPRING DATA for the same location, refer to the HD/B 500 Series
Parts Catalog PC2456EN to determine which
a. Spring Replacement. Springs should be replaced spring is used in your specific assembly number.
if there are signs of overheating, wear due to rubbing

Table 71. Wear Limits Data

Wear Limit
Illustration Description mm (inches)
Foldout 4,B TORQUE CONVERTER MODULE
10 Converter Cover Bushing, Maximum ID 66.91 2.634
12 Lockup Piston Assembly, Minimum Thickness 6.53 0.257
14 Damper Assembly Plate, Maximum Distortion 0.51 0.020
14 Damper Assembly Plate, Minimum Thickness 8.51 0.335
14, 18 Turbine-To-Damper, Maximum Spline Wear 0.38 0.015
15 Backplate, Maximum Distortion 0.15 0.006
15 Backplate, Minimum Wear Surface Thickness 11.79 0.464
18 Turbine Hub, Minimum OD 66.69 2.626
19 Turbine Hub Sealring, Maximum ID 61.77 2.432
24 Stator Thrust Plate, Minimum Thickness 9.45 0.372
36 Converter Pump Hub, Minimum OD 88.99 3.504

Foldout 5,B TORQUE CONVERTER HOUSING MODULE PTO EQUIPPED


6 Bearing Retainer Bushing, Maximum ID 89.19 3.511
8, 14 Oil Pump Drive Hub Seal, Minimum End Gap 1.18 0.047
8, 14 Oil Pump Drive Hub Seal, Maximum End Gap 1.66 0.065
13 Oil Pump Drive Hub, Maximum Tang Wear 0.31 0.012

Copyright 2001 General Motors Corp. 71


4000 MH/HD 4000/B 500 SERIES ON-HIGHWAY SERVICE MANUAL
Table 71. Wear Limits Data (contd)

Wear Limit
Illustration Description mm (inches)
Foldout 6,A FRONT SUPPORT AND CHARGING PUMP MODULE
8 Pump Housing Bushing, Maximum ID 89.19 3.511
9, 10 Pump Housing Gear, Maximum Cavity Depth 19.04 0.750
9, 10 Pump Housing Gear, Maximum Cavity Diameter 150.25 5.915
9, 10, 11 Driven Gear-To-Pump Housing, Maximum Diametric Clearance 0.30 0.012
9, 10, 13 Gear-To-Plate, Maximum Side Clearance 0.10 0.004
11 Gear Set, Maximum Gear Tooth Tip Clearance 0.15 0.006
12 Pump Gear Bushing, Maximum ID 66.93 2.635
16, 17 Ground Sleeve, Minimum OD In Bushing Area 66.67 2.625
16, 17, 20 Spline OD, Maximum Total Runout 0.13 0.005
20 Front Support, Minimum OD 119.81 4.717
25 Front Support Seal, Minimum End Gap 1.00 0.040
25 Front Support Seal, Maximum End Gap 1.44 0.056

Foldout 6,B ROTATING CLUTCH MODULE


5 Turbine Shaft Bushing, Maximum ID 36.14 1.423
8 Turbine Seal, Minimum End Gap 0.65 0.026
8 Turbine Seal, Maximum End Gap 1.01 0.039
9 Drum Spline, Maximum Wear 0.38 0.015
12 Rotating Clutch Hub Bushing, Maximum ID 120.27 4.735
29 C1 Clutch Apply Plate, Minimum Thickness 5.90 0.232
29, 39 C1 Clutch Apply Plate or C2 Backplate, Maximum Distortion 0.15 0.006
30, 38 C1, C2 Friction Plate, Maximum Cone 0.25 0.010
30, 38 C1, C2 Friction Plate, Minimum Thickness 2.92 0.115
30, 38 C1, C2 Friction Plate, Minimum Oil Groove Depth 0.20 0.008
31, 37 C1, C2 Reaction Steel Plate, Maximum Cone 0.25 0.010
31, 37 C1, C2 Reaction Steel Plate, Minimum Thickness 2.41 0.095
32 C1 Clutch Backplate, Minimum Thickness @ ID 9.90 0.390
34, 36 C1, C2 Drive Hub, Maximum Spline Wear 0.38 0.015
39 C2 Backplate, Minimum Thickness 7.90 0.311
39 C2 Backplate, Maximum Distortion 0.15 0.006

72 Copyright 2001 General Motors Corp.


WEAR LIMITS AND SPRING DATA
Table 71. Wear Limits Data (contd)

Wear Limit
Illustration Description mm (inches)

Foldout 7 MAIN HOUSING MODULE


4 Backplate, Maximum Step Wear 0.13 0.005
4 Backplate, Maximum Distortion 0.15 0.006
5, 18 P1 Ring Thrust Plate, Minimum Thickness At Wear Point 2.82 0.111
7 P1 Ring Gear Spline, Maximum Wear 0.38 0.015
8, 21, 29 C3, C4, C5 Friction Plate, Maximum Cone 0.25 0.010
8, 21, 29 C3, C4, C5 Friction Plate, Minimum Thickness 3.485 0.137
9, 20, 30 C3, C4, C5 Reaction (Steel) Plate, Maximum Cone 0.25 0.010
9, 20, 30 C3, C4, C5 Reaction (Steel) Plate, Minimum Thickness 2.41 0.095
11, 23 C3, C4 Piston Return Plate, Minimum Thickness 4.91 0.193
19, 28 C3, C4 Clutch Housings, Maximum Spline Wear 1.15 0.045
43 Main Housing, Maximum Spline Wear 1.15 0.045

Foldout 8 MAIN SHAFT MODULE WIDE RATIO AND CLOSE RATIO


7, 8 Main Shaft Bearing Journal, Minimum OD 52.98 2.085
7, 8 Main Shaft Pilots (both ends), Minimum OD 35.92 1.414

Foldout 9,A P1 PLANETARY MODULE


3 P1 Planetary Carrier Assembly, Maximum Pinion End Play 0.94 0.037
9 P1 Carrier Bushing, Maximum ID 89.32 3.516
10, 13 P1 Pinion Thrust Washer, Minimum Thickness 1.40 0.055
10, 13 P1 Pinion Thrust Washer, Maximum Step Wear 0.12 0.005
15 P2 Ring Gear Spline, Maximum Wear 0.38 0.015

Foldout 9,B P2 PLANETARY MODULE


1 P2 Planetary Carrier Assembly, Maximum Pinion End Play 0.94 0.037
8 P2 Carrier Bushing, Maximum ID 53.23 2.096
9, 12 P2 Pinion Thrust Washer, Minimum Thickness 1.40 0.055
9, 12 P2 Pinion Thrust Washer, Maximum Step Wear 0.12 0.005
15 P3 Ring Gear Spline, Maximum Wear 0.38 0.015

Copyright 2001 General Motors Corp. 73


4000 MH/HD 4000/B 500 SERIES ON-HIGHWAY SERVICE MANUAL
Table 71. Wear Limits Data (contd)

Wear Limit
Illustration Description mm (inches)

Foldout 9,C P3 PLANETARY AND C6 ADAPTER HOUSING MODULE


(HD 4070/4076 MODELS)
1 P3 Carrier Module, Maximum Pinion End Play 0.94 0.037
8 P3 Pinion Thrust Washer, Minimum Thickness 1.40 0.055
8 P3 Pinion Thrust Washer, Maximum Step Wear 0.12 0.005
27 C6 Reaction Plate, Minimum Thickness 3.24 0.128
27, 28 C6 Friction and Reaction Plate, Maximum cone 0.25 0.010
28 C6 Friction Plate, Minimum Thickness 3.68 0.145
32 P4 Carrier Assembly, Maximum Pinion End Play 0.94 0.037
38 P4 Carrier Bushing, Maximum ID 113.33 4.462
40 P4 Planetary Thrust Washer, Minimum Thickness 1.40 0.055
40 P4 Planetary Thrust Washer, Maximum Step Wear 0.12 0.005

Foldout 10,A RETARDER AND P3 MODULE (4000 MH, HD 4060, HD 4560,


and B 500 MODELS PRIOR TO S/N 6610066447)
3 P3 Planetary Carrier Assembly, Maximum Pinion End Play 0.94 0.037
5 Output Shaft Bushing, Maximum ID 36.14 1.423
13, 16 P3 Pinion Thrust Washer, Minimum Thickness 1.40 0.055
13, 16 P3 Pinion Thrust Washer, Maximum Step Wear 0.12 0.005
27, 30 Retarder Rotor Sealring, Maximum ID 139.72 5.501
29 Rotor Hub, Maximum Spline Wear 0.38 0.015

Foldout 10,B REAR COVER AND P3 MODULE (4000 MH, HD 4060, HD 4560,
and B 500 MODELS)
5 P3 Planetary Carrier Assembly, Maximum End Play 0.94 0.037
7 Output Shaft Bushing, Maximum ID 36.14 1.423
8 Output Shaft, Maximum Spline Wear 0.38 0.015
15, 18 P3 Pinion Thrust Washer, Minimum Thickness 1.40 0.055
15, 18 P3 Pinion Thrust Washer, Maximum Step Wear 0.12 0.005

74 Copyright 2001 General Motors Corp.


WEAR LIMITS AND SPRING DATA
Table 71. Wear Limits Data (contd)

Wear Limit
Illustration Description mm (inches)

Foldout 10,C RETARDER AND OUTPUT SHAFT MODULE (HD 4070/4076 MODELS
PRIOR TO S/N 6610066447)
4 Output Shaft Bushing, Maximum ID 36.14 1.423
5 Output Shaft, Maximum Spline Wear 0.38 0.015
16, 19 Retarder Rotor Sealring, Maximum ID 139.72 5.501
18 Rotor Assembly 0.38 0.015

Foldout 10,D REAR COVER AND OUTPUT SHAFT MODULE (HD 4070/4076 MODELS)
7 Output Shaft Bushing, Maximum ID 36.14 1.423
8 Output Shaft, Maximum Spline Wear 0.38 0.015

Foldout 10,E RETARDER AND P3 MODULE (ALL MODELS EXCEPT HD 4070/4076


STARTING WITH S/N 6610066447)
3 P3 Planetary Carrier Assembly, Maximum Pinion End Play 0.94 0.037
5 Output Shaft Bushing, Maximum ID 36.14 1.423
13, 16 P3 Pinion Thrust Washer, Minimum Thickness 1.40 0.055
13, 16 P3 Pinion Thrust Washer, Maximum Step Wear 0.12 0.005
27, 30 Retarder Rotor Sealring, Maximum ID 139.72 5.501
29 Rotor Hub, Maximum Spline Wear 0.38 0.015

Foldout 10,F RETARDER AND OUTPUT SHAFT MODULE (HD 4070/4076 MODELS
STARTING WITH S/N 6610066447)
4 Output Shaft Bushing, Maximum ID 36.14 1.423
5 Output Shaft, Maximum Spline Wear 0.38 0.015
16, 19 Retarder Rotor Sealring, Maximum ID 139.72 5.501
18 Rotor Assembly 0.38 0.015

Foldout 12,A OUTPUT FLANGE AND YOKE


1, 2, 8 Output Seal Journal, Minimum OD 85.0 3.346

Copyright 2001 General Motors Corp. 75


76

Table 71. Spring Data


Length under load

4000 MH/HD 4000/B 500 SERIES ON-HIGHWAY SERVICE MANUAL


Approx.
Spring Free
No. of Wire Dia OD Length mm N
Foldout Ref. Spring Part No. Color Code Coils mm (in.) mm (in.) mm (in.) (in.) (lb)
4,B 27 Stator 29501300 No Code N/A N/A N/A 17.8 5.7 0.9
(0.70) (0.224) (0.2)
6,A 22 Main Relief 29507709 No Code 10 3.25 17.96 52.4 40.7 474
(0.128) (0.707) (2.06) (1.60) (106.5)
6,B 20 C2 Return 29505719 No Code 11.5* 2.04* 19.06* 70.76* 28.2 5185**
(0.080) (0.750) (2.786) (1.110) (1165.6)
6,B 25 C1 Return 29509453 No Code 12* 2.10* 16.0* 57.53* 34.8 4649**
Copyright 2001 General Motors Corp.

(0.083) (0.630) (2.265) (1.37) (1045.4)


6,B 25 C1 Return 29537301 No Code 11.8* 2.17* 16.8* 52.89* 34.5 4893**
(0.085) (0.661) (2.082) (1.358) (1100.0)
7 10 C3 Return 29506206 No Code 13* 2.10* 15.0* 52.3* 35.4 274.4**
(0.083) (0.590) (2.06) (1.39) (61.69)
7 12 C3 Retainer 29507882 No Code 4* 2.36* 12.62* 11.2* 9.3 16 408**
(0.093) (0.497) (0.44) (0.37) (3689)
7 12 C3 Retainer 29515628 No Code 4* 2.36* 12.62* 11.1* 10.40 15 403**
(0.093) (0.497) (0.44) (0.41) (3463)
7 22 C4 Return 29506206 No Code 13* 2.10* 15.0* 52.3* 35.4 274.4**
(0.083) (0.590) (2.06) (1.39) (61.69)
7 24 C4 Retainer 29507882 No Code 4* 2.36* 12.62* 11.2* 9.3 16 408**
(0.093) (0.497) (0.44) (0.37) (3689)
7 24 C4 Retainer 29515628 No Code 4* 2.36* 12.62* 11.1* 10.40 15 403**
(0.093) (0.497) (0.44) (0.41) (3463)
9,C 17 C5 Return 29530488 No Code 11.6* 2.03* 17.00* 53.80 37.7 3611**
(0.080) (0.669) (2.11) (1.48) (811.8)
10,A 20, 22, 9, 12, C5 Return 29503036 No Code 12* 2.10* 17.00* 57.3* 37.6 3086**
through F 20, 9 (0.083) (2.26) (1.48) (693.8)
10,A 35 Retarder Flow Valve 29512751 Silver (End) 10.5 2.16 19.05 61.5 25.9 186.9
(0.085) (0.750) (2.42) (1.020) (42.02)

* Individual springs
** For the complete spring assembly
Table 71. Spring Data (contd)
Length under load
Approx.
Spring Free
No. of Wire Dia OD Length mm N
Foldout Ref. Spring Part No. Color Code Coils mm (in.) mm (in.) mm (in.) (in.) (lb)
10,A 35 Retarder Flow Valve 29515101 Green 16 3.78 36.58 106.68 73.66 133.4
(0.149) (1.440) (4.200) (2.900) (29.99)
10,A, C, E, 35, 25, 35, Retarder Flow Valve 29515692 No Code 11.4 4.12 36.17 114.3 91.1 213.3
and F 25 (0.162) (1.424) (4.500) (3.587) (47.95)

WEAR LIMITS AND SPRING DATA


10,A, C, E, 76, 56, 75, Exhaust Backfill 23049391 No Code 20.4 0.61 8.00 29.2 18.2 2.67
and F 63 (0.024) (0.315) (1.15) (0.716) (0.60)
10,A 81 Retarder Control 29510495 Silver 7.5 1.40 15.1 30.8 18.0 33
Copyright 2001 General Motors Corp.

(0.055) (0.594) (1.212) (0.71) (7.42)


10,A, C, E, 81, 65, 80, Retarder Control 29512792 Lt. Green 7.5 1.40 15.09 33.69 18.0 40
and F 68 (on end) (0.055) (0.594) (1.326) (0.71) (9.0)
10,A 81 Retarder Control 29510494 Orange 7 1.60 15.50 27.8 18.0 44
(0.063) (0.610) (1.09) (0.71) (9.9)
11,A and 101, 120, Solenoid Regulator 29502195 No Code 4 0.67 11.05 6.5 3.45 3
Fig. 531 152, 167 (0.026) (0.440) (0.26) (0.14) (0.7)
11,A 112 Accumulator Relay 29507455 Silver 12.8 1.28 11.68 43.6 20.0 49.8
(0.050) (0.460) (1.72) (0.79) (11.2)
11,A 112 Accumulator Relay 28537452 Dark Blue 12.8 1.275 11.68 43.6 20.0 49.8
(0.050) (0.460) (1.72) (0.79) (11.2)
11,A 127 Overdrive 23049332 Orange 12 0.76 7.75 26.6 12.5 12.0
(0.030) (0.305) (1.05) (0.49) (2.7)
11,B 134 Lockup 23049326 Yellow 10 1.37 14.1 42.1 17.0 49
(0.054) (0.555) (1.66) (0.67) (11.0)
11,B 138 Lube Regulator 23049327 Red 13 1.22 11.1 46.3 3.5 47
(0.048) (0.437) (1.82) (0.93) (10.6)
11,B 142 Main Regulator 29500963 Lt. Blue 15 2.87 22.00 98.5 54.6 305
(0.113) (0.866) (3.88) (2.15) (68.6)
77
Table 71. Spring Data (contd)
78

Length under load

4000 MH/HD 4000/B 500 SERIES ON-HIGHWAY SERVICE MANUAL


Approx.
Spring Free
No. of Wire Dia OD Length mm N
Foldout Ref. Spring Part No. Color Code Coils mm (in.) mm (in.) mm (in.) (in.) (lb)
11,B 146 Control Main 23049325 Orange 10 1.83 14.8 44.6 24.0 131
(0.072) (0.583) (1.76) (0.95) (29.5)
11,B 156 C2 Latch 29501071 Lt. Green 11 1.32 11.43 41.3 19.0 71.0
(0.052) (0.450) (1.63) (0.75) (16.0)
11,B 160 Exh. Back 23049391 No Code 17 0.61 7.80 29.2 18.2 2
(0.024) (0.307) (1.14) (0.72) (0.5)
11,B 164 C1 Latch 6885065 Blue 12 1.37 16.26 46.2 29.2 18
Copyright 2001 General Motors Corp.

(0.054) (0.640) (1.82) (1.15) (4.0)


11,B 168 Converter Regulator 29507456 Pink 10.2 1.53 11.00 30.3 22.8 54
(0.060) (0.433) (1.19) (0.90) (12.1)
Section 8 CUSTOMER SERVICE
81. OWNER ASSISTANCE Step Two If your problem cannot be readily
resolved at the distributor level without additional
The satisfaction and goodwill of the owners of Allison assistance, contact the Allison Transmission
transmissions are of primary concern to Allison Regional Office responsible for your local
Transmission Division (ATD), its distributors, and distributor (see maps in Warranty Manual). You will
their dealers. be assisted by a member of the Regional Service
Managers staff.
As an owner of an Allison transmission, you have
service locations throughout the world eager to meet For prompt assistance, please have the following
your parts and service needs with: information available:
Expert service by trained personnel
Name and location of authorized distributor or
Emergency service 24 hours a day in many dealer
areas
Type and make of equipment
Complete parts support
Transmission model number, serial number,
Sales teams to help determine your and assembly number if equipped with
transmission requirements electronic controls, also provide the ECU
Product information and literature assembly number
Refer to a current Worldwide Sales and Service Transmission delivery date and accumulated
Directory SA2229EN for a listing of Allison miles and/or hours of operation
Transmission authorized distributors and service Nature of problem
dealers. This directory is available from SGI, Inc.
Chronological summary of units history
Normally, any situation that arises in connection with Step Three If you contacted a regional office and
the sale, operation, or service of your transmission will you are still not satisfied, present the entire matter in
be handled by the distributor or dealer in your area. writing or by phone to the Home Office:
(Check the telephone directory for the Allison
Transmission service outlet nearest you.) Manager Warranty Administration PF9
Allison Transmission
We recognize, however, that despite the best intentions P. O. Box 894
of all concerned, misunderstandings may occur. To Indianapolis, Indiana 46206-0894
further assure your complete satisfaction, we have Phone: 1-800-524-2303
developed the following three-step procedure in the
event you have a problem that has not been handled The inclusion of all pertinent information will assist
satisfactorily. the Home Office in expediting the matter. If an
additional review by the Home Office of all the facts
Step One Discuss your problem with a member involved indicates that some further action can be
of management from the distributorship or taken, the Regional Office will be advised.
dealership. Complaints are frequently the result of a
breakdown in communication and can be quickly When contacting the Regional or Home Office, please
resolved by a member of management. If you have keep in mind that ultimately your problem will likely
already discussed the problem with the Sales or be resolved at the distributorship or dealership
Service Manager, contact the General Manager. All using their facilities, equipment, and personnel.
ATD dealers are associated with an ATD distributor. If Therefore, we suggest you follow the above steps, in
your problems originate with a dealer, explain the sequence, when experiencing a problem.
matter to a distributorship member of management
with whom the dealer has his service agreement. The Your purchase of an Allison Transmission product is
dealer will provide his ATD distributors name, greatly appreciated, and it is our sincere desire to
address, and telephone number on request. assure complete satisfaction.

Copyright 2001 General Motors Corp. 81


4000 MH/HD 4000/B 500 SERIES ON-HIGHWAY SERVICE MANUAL
82. SERVICE LITERATURE Table 81. 4000 MH/HD 4000/B 500 Series
(Table 81) Service Literature
Additional service literature is available. This service Publication Type 4000 MH HD/B 500
literature provides fully illustrated instructions for Automatic Transmission Fluid GN2055EN GN2055EN
operation, maintenance, service, overhaul, and parts Technicians Guide
support for your transmission. To ensure that you get Mechanics Tips (WTEC III)* MT3004EN MT3004EN
maximum performance and service life from your Mechanics Tips (WTEC II)* MT2159EN
transmission, you may order publications from: Operators Manual (WTEC III)* OM2995EN
SGI, Inc. Operators Manual (WTEC II)* OM2157EN
Attn: Allison Literature Fulfillment Desk Owners Manual* OM3349EN
8350 Allison Avenue Parts Catalog PC2456EN PC2456EN
Indianapolis, IN 46268 Parts Catalog CD-ROM CD2456EN CD2456EN
TOLL FREE: 888-666-5799 Principles of Operation PO2454EN PO2454EN
INTERNATIONAL: 317-471-4995 Retail Literature Catalog GN2978EN GN2978EN
Service Manual SM2457EN SM2457EN
Troubleshooting Manual TS2973EN TS2973EN
(WTEC III)
Troubleshooting Manual TS2470EN
(WTEC II)
Worldwide Sales SA2229EN SA2229EN
and Service Directory
* Also Available On The Internet At www.allisontransmission.com

82 Copyright 2001 General Motors Corp.


4000 MH/HD 4000/B 500 SERIES ON-HIGHWAY SERVICE MANUAL
Legend For Foldout 1

1 Lockup clutch/ damper


2 Converter turbine
3 Converter stator
4 Converter pump
5 Breather
6 Front support
7 Main housing
8 Main shaft
9 C3 clutch
10 C4 clutch
11 P2 sun gear
12 C5 clutch
13 P3 sun gear
14 Output shaft
15 Rear cover
16 C5 piston
17 P3 module
18 Oil level sensor
19 Control module
20 P2 module
21 P1 module
22 C2 clutch
23 C1 clutch
24 Turbine shaft
25 Ground sleeve
26 Converter housing module

Foldout 1 Copyright 2001 General Motors Corp.


F OLDOUT 1
1 2 3 4 5 6 7 8 9 10 11 12 13 14

26 25 24 23 22 21 20 19 18 17 16 15 V02535.01

Foldout 1. Model 4000 MH, HD 4060, B 500 (Close Ratio) Transmission Cross Section
4000 MH/HD 4000/B 500 SERIES ON-HIGHWAY SERVICE MANUAL
Legend For Foldout 2

1 Lockup clutch/damper
2 Converter turbine
3 Converter stator
4 Converter pump
5 Charging oil pump
6 Front support
7 Breather
8 Main housing
9 Main shaft
10 C3 clutch
11 C4 clutch
12 P2 sun gear
13 C5 clutch
14 Output shaft
15 Rear cover
16 C5 piston
17 P3 module
18 Oil level sensor
19 Control module
20 P2 module
21 P1 module
22 C2 clutch
23 C1 clutch
24 Turbine shaft
25 PTO drive gear
26 Ground sleeve
27 Converter housing module

Foldout 2 Copyright 2001 General Motors Corp.


F OLDOUT 2

1 2 3 4 5 6 7 8 9 10 11 12 13 14

27 26 25 24 23 22 21 20 19 18 17 16 15 V02536.01

Foldout 2. Model HD 4560 (Wide Ratio) Transmission With PTO Provision Cross Section
4000 MH/HD 4000/B 500 SERIES ON-HIGHWAY SERVICE MANUAL
Legend For Foldout 3

1 Lockup clutch/ damper


2 Converter turbine
3 Converter stator
4 Converter pump
5 Charging oil pump
6 Front support
7 Main housing
8 Main shaft
9 C3 clutch
10 C4 clutch
11 P2 sun gear
12 C5 clutch
13 P3 sun gear
14 Retarder stator
15 Retarder rotor
16 Retarder module
17 Retarder housing
18 P3 module
19 Oil level sensor
20 Control module
21 P2 module
22 P1 module
23 C2 clutch
24 C1 clutch
25 Turbine shaft
26 Ground sleeve
27 Converter housing module

Foldout 3 Copyright 2001 General Motors Corp.


F OLDOUT 3

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17

27 26 25 24 23 22 21 20 19 18 V02537.03

Foldout 3. Model 4000 MH, HD 4060, B 500 (Close Ratio) Transmission With Retarder Cross Section
4000 MH/HD 4000/B 500 SERIES ON-HIGHWAY SERVICE MANUAL
Legend For Foldout 3,A

1 Lockup clutch/damper
2 Converter turbine
3 Converter stator
4 Converter pump
5 Charging oil pump
6 Front support
7 Main housing
8 Main shaft
9 C3 clutch
10 C4 clutch
11 P2 sun gear
12 Shim
13 C5 clutch
14 P3 sun gear
15 C5 piston assembly
16 C6 adapter housing module
17 C6 clutch
18 P4 ring gear
19 Rear cover
20 Output shaft
21 C6 piston
22 P4 planetary
23 P4 sun gear
24 Selective shim
25 P4 shaft flange
26 P3 planetary
27 Control valve assembly
28 P2 planetary
29 P1 planetary
30 C2 clutch
31 C1 clutch
32 Turbine shaft
33 Converter ground sleeve
34 Converter housing

Foldout 3,A Copyright 2001 General Motors Corp.


;;;; ;;;;;;
F OLDOUT 3,A

;;;; ;;;;;; ;;;;


;; ;;;
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20

;;
; ;; ;; ;;
;; ; ;; ;

;;;; ;;;;;;; ;;;; ;;;


;;;;
; ;; ;;
;;;
;;; ;
;
;; ;;; ;;; ;;;;;
;;
;;;;;;;;;
; ;;; ;;;
;;
;
;; ;;
;;
;;;
;;
;;
;
;;
;;
; ;;; ;;;;;;; ;;;;
;; ;;;;;;;;; ; ; ;;
;;; ;;
;;
;; ;;;; ;;
;; ; ; ;;; ; ;;;;;;;;
; ; ;
;;;
;;;;;;;;;;;;;;;; ;;;; ;; ;;
;; ;;;;;;;;
;; ;; ; ;;;;;;;;;;
;;;
; ; ; ;;
; ;; ;;
; ;;;;;; ;;;;; ;; ;; ; ; ;
; ;
;;;; ;;;
;
;;
;;
;;; ;;
;
;;
;;;
;; ;;
;; ;;

;;;
;; ;;
;; ;; ;;
;;;;
;;;;
;;
;;
;; ;;;
;;
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;;;;;
;
;;;;
;;; ;; ;;;; ;;; ;
; ;;;

;;;; ;;; ;; ;;;;


; ;; ; ; ; ; ;;; ;

;;
; ;;;; ;;
;;; ; ; ;
;
;; ; ;; ;

;; ;;;;;
;;;;
;; ;; ; ; ;
; ;
;
;; ; ;; ;;
;;

;;;
;;
34

; 33 32

31
;;
; ;
; ;
30 29
;;
;; 28
; ;
; ; 27 26
25 24 23 22 21

V05265.01

Foldout 3,A. HD 4070/4076 Cross Section


4000 MH/HD 4000/B 500 SERIES ON-HIGHWAY SERVICE MANUAL
Legend For Foldout 3,B

1 Lockup clutch/damper
2 Converter turbine
3 Converter stator
4 Converter pump
5 Charging oil pump
6 Front support
7 Main housing
8 Main shaft
9 C3 clutch
10 C4 clutch
11 P2 sun gear
12 Shim
13 C5 clutch
14 P3 sun gear
15 C5 piston assembly
16 C6 adapter housing module
17 C6 clutch
18 P4 ring gear
19 Retarder stator
20 Retarder rotor
21 Retarder and output shaft module
22 Output shaft
23 C6 piston
24 P4 planetary
25 P4 sun gear
26 Selective shim
27 P4 shaft flange
28 P3 planetary
29 Control valve assembly
30 P2 planetary
31 P1 planetary
32 C2 clutch
33 C1 clutch
34 Turbine shaft
35 Converter ground sleeve
36 Converter housing

Foldout 3,B Copyright 2001 General Motors Corp.


;;;; F OLDOUT 3,B

;;;; ;;;;;; ;;;; ;; ;;


1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22

;;;; ;;;;;; ;;;; ;; ;; ;


; ; ;; ;;
;; ;; ;; ;
;;;;
;;; ;;;
; ;;
;;
;; ;
;
;;
;; ;;
;;;;
;;;;
;;
; ; ;;; ;
;;; ;;
;;;;
;;;;
;;;;

;;;; ; ;;;; ;;
;;
;;
;;; ;; ;;;;;;;;;
; ;;; ;;;
;;;; ;;
;
;
;;
;;
;;;;
;;
;; ;
;
;;;;;;;
; ;;
; ; ;; ;;;;
; ;;;;;
;;;;; ; ;; ; ;;
;;;; ;;
;;
;;; ;;
;;;; ;;
;;;;; ;; ;; ;; ;;;;;;;;;
;;

;;;
;;;
; ;;;;
; ;; ;;; ;; ;; ;;;;;;;;;
; ;; ; ;;
;; ;;

;;;;;;;;
;; ;;;; ;;
; ;;
;;;;;;; ;;
;; ; ;; ; ;;
;;;;; ; ;; ;;
;; ;;
;;
;;;;
;;
;;;; ;; ;;
;; ;
;;;; ;; ;; ;;
;;;; ; ;;; ;; ;;;; ;; ;;
;; ;; ;;;;
;
;; ;;;;; ;; ;;;;
;;
;;;;

;; ;;
;; ;;;;
;;
;;;;
;; ; ; ;;
;;;;
;;;;
;;
;;;;

;;;;; ;; ;;;;;;; ;; ;;; ;; ;;;; ;; ;;


;;;; ; ;;
;;
;;;;

; ; ;;;;;; ;;;
;; ; ;;;
; ; ; ; ; ;;;; ;;
;;;; ;;
; ; ;;
;;; ; ; ; ;; ;

;;;;;; ;;;;;;;;
;;;;
;
;
;
;; ; ;; ;;

;;;
;;
36

; 35 34

33
;;
; ;
; ;
32 31
;;
;; 30
; ;
; ; 29 28
27 26 25 24 23

V05266.01

Foldout 3,B. HD 4070/4076 With Retarder Cross Section


4000 MH/HD 4000/B 500 SERIES ON-HIGHWAY SERVICE MANUAL
Legend For Foldout 3,C

1 Lockup clutch/damper
2 Converter turbine
3 Converter stator
4 Converter pump
5 Charging oil pump
6 Front support
7 Oil vent assembly
8 Main housing
9 Main shaft
10 C3 clutch
11 C4 clutch
12 P2 sun gear
13 Shim
14 C5 clutch
15 P3 sun gear
16 C5 piston assembly
17 C6 adapter housing module
18 C6 clutch
19 P4 ring gear
20 Retarder stator
21 Retarder rotor
22 Retarder and output shaft module
23 Output shaft
24 C6 piston
25 P4 planetary
26 P4 sun gear
27 Selective shim
28 P4 shaft flange
29 P3 planetary
30 Control valve assembly
31 P2 planetary
32 P1 planetary
33 C2 clutch
34 C1 clutch
35 Turbine shaft
36 PTO drive gear
37 Converter ground sleeve
38 Converter housing

Foldout 3,C Copyright 2001 General Motors Corp.


F OLDOUT 3,C

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23

38 37 36 35 34 33 29 28 27 26 25 24
32 31 30 V05646.02

Foldout 3,C. HD 4070/4076 With Retarder and PTO Provision Cross Section
F OLDOUT 4,A
2 3
4
5
1 Crank hub adapter 23 Flexplate
6
2 Bolt, M8 x 1.25 x 20 (12), A 24 Flexplate
7 8
3 Flexplate assembly 25 Bolt, M8 x 1.25 x 25 (28), A
4 Bolt plate (6) 26 Flexplate adapter assembly 1 9
10
5 Flexplate 27 Ring gear
6 Flexplate (3) 28 Flexplate adapter
7 Bolt, M8 x 1.25 x 25 (28), A 29 Wear plate
13 11
8 Flexplate adapter assembly 30 Bolt, 58-18 x 2 (6), A 12
9 Ring gear 31 Bolt, M8 x 1.25 x 25 (12), A 14
15
10 Flexplate adapter 32 Flexplate assembly
16
11 Wear plate 33 Bolt plate (6)
12 Bolt, M8 x 1.25 x 45 (12), A 34 Flexplate 17
18
13 Ring gear assembly 35 Flexplate
14 Ring gear 36 Bolt, M8 x 1.25 x 25 (16 or 28), A
15 Flexplate 37 Flexplate adapter assembly
20 21 19
16 Flexplate (3) 38 Ring gear
22
17 Bolt, M8 x 1.25 x 25 (28), A 39 Flexplate adapter
23
18 Flexplate adapter 40 Wear plate 24
19 Wear plate 41 Bolt (2), A
25 26
20 Bolt, M8 x 1.25 x 25 (12), A 27
21 Flexplate assembly Torque Nm lb ft
28
22 Bolt plate (6) A 2429 1821
31 32
33
34 29
30
35

36
37
38
39

40
41

L00182

Foldout 4,A. Flexplate And Adapter Exploded View


F OLDOUT 4,B

1
1 Retaining ring 22 Converter stator assembly (complete) 2 8
2 Converter end plug 23 Retaining ring 3 9
3 O-Ring 24 Stator thrust plate assembly
4 Converter end plug, A 25 LH stator thrust washer
10 11
7
5 Torque converter module 26 Stator race
4 12
6 Nut (36), B 27 Stator spring (13)
7 Torque converter cover assembly 28 Stator roller (13) 5
13
(complete) 29 Stator and cam assembly 6
8 Converter cover assembly 30 Shim, 0.27 mm (0.010 inch) 14
9 Converter cover 30 Shim, 0.48 mm (0.019 inch)
10 Bushing 30 Shim, 0.711 mm (0.028 inch) 18 15
19
11 Lockup piston sealring 31 Thrust bearing race
12 Lockup piston assembly 32 Pump thrust bearing assembly 17
13 Lockup piston sealring 20
33 O-Ring 21
14 Damper assembly 34 Thrust bearing race 23
15 Lockup clutch backplate 24
35 Converter pump assembly (complete)
16 Bolt, M8 x 1.25 (44), B 25
36 Converter pump assembly 26
17 Thrust bearing assembly 37 T-head bolt (36) 28
18 Turbine assembly 29 16
19 Turbine hub sealring
Torque Nm lb ft 30
20 Thrust bearing assembly
A 5060 3744 31
21 Star plate
27 32
B 3035 2226
22 33

34

36
37
35

V06850

Foldout 4,B. Torque Converter Module Exploded View


4000 MH/HD 4000/B 500 SERIES ON-HIGHWAY SERVICE MANUAL
Legend For Foldout 5

A 10 PTO gear assembly


1 Converter housing module 11 Ball bearing (2)
2 Oil vent assembly, M12 x 1.5, A 12 PTO gear
3 Converter housing 13 Oil pump drive hub
4 Speed sensor assembly 14 Sealring
5 O-Ring 15 Speed sensor assembly
6 Speed sensor retainer 16 O-Ring
7 Bolt, M8 x 1.25 x 20, B 17 Speed sensor retainer
8 Sensor shipping cover 18 Bolt, M8 x 1.25 x 20, B
9 Converter housing gasket 19 Converter housing
10 Bolt, M10 x 1.5 x 35 (25), C 20 Oil vent assembly, M12 x 1.5, C
21 Bolt, M10 x 1.5 x 35 (25), A
Torque Nm lb ft
22 Converter housing gasket
A 1216 912 23 Sensor shipping cover
B 2429 1821 24 Bolt, M10 x 1.5 x 25 (10), A
C 5161 3845 25 PTO cover
26 PTO cover gasket
B 27 Bolt, M10 x 1.5 x 25 (10), A
1 Converter housing module 28 PTO cover
2 Bolt, M10 x 1.5 x 35 (11), A 29 PTO cover gasket
3 Bearing retainer assembly
Torque Nm lb ft
4 Oil seal assembly
A 5161 3845
5 Bearing retainer/bushing assembly
6 Bushing B 2429 1821

7 Bearing retainer C 1216 912


8 Sealring
9 Piston sealring

Foldout 5 Copyright 2001 General Motors Corp.


F OLDOUT 5
A B

2
1
4

3
24
2 25
5 26
3
6
7

8
4 9

20
6 15
10
16 17 18
5 11
10 9
7 12

21 13

11
14
23
19

8 22

29
28
27

V03918.02
V05395

Foldout 5,A. Converter Housing Module Exploded View Foldout 5,B. Converter Housing Module With PTO Provision Exploded View
4000 MH/HD 4000/B 500 SERIES ON-HIGHWAY SERVICE MANUAL
Legend For Foldout 6

A 7 Turbine shaft (PTO)


1 Bolt, M10 x 1.5 x 65 (7), A 8 Sealring (3)
2 Bolt, M10 x 1.5 x 35 (7), A 9 Rotating clutch drum
3 Front support module 10 Thrust bearing
4 O-Ring 11 Rotating clutch hub assembly (complete)
5 Oil seal assembly 12 Rotating clutch hub bushing
6 Bolt, M10 x 1.5 x 65 (8), A 13 Rotating clutch hub assembly
7 Pump housing assembly 14 Thrust bearing
8 Bushing 15 Turbine shaft retaining ring
9 Pump housing 16 C2 piston sealring
10 Pump housing (PTO) 17 C1 piston sealring
11 Pump gear set 18 External sealring
12 Bushing 19 C2 piston
13 Wear plate 20 C2 spring assembly
14 Bolt, M10 x 1.5 x 25 (14), A 21 C2 spring plate
15 Front support assembly (complete) 22 Internal retaining ring
16 Ground sleeve (PTO) 23 C1 sealring
17 Ground sleeve 24 C1 piston
18 Front support assembly 25 C1 spring assembly
19 Dowel pin, 10 x 32 (2) 26 Rotating clutch balance piston
20 Front support 27 Rotating clutch balance piston sealring
21 Front support sleeve 28 Balance piston retaining ring
22 Spring 29 C1 clutch apply plate
23 Ball 30 C1 friction plate (7)
24 Dowel pin 31 C1 reaction plate (6)
25 Sealring (3) 32 C1 clutch backplate
26 Roller bearing assembly 33 External retaining ring
34 C1 drive hub
Torque Nm lb ft
35 Thrust bearing (2)
A 5161 3845 36 C2 drive hub
37 C2 reaction plate (7)
B 38 C2 friction plate (7)
1 Rotating clutch module 39 C2 clutch backplate
2 O-Ring 40 Internal retaining ring
3 Turbine shaft assembly 41 Sun gear assembly (complete)
4 Turbine shaft 42 Thrust bearing
5 Turbine shaft bushing 43 Internal retaining ring
6 Turbine shaft assembly (PTO)

Foldout 6 Copyright 2001 General Motors Corp.


F OLDOUT 6
A B

2
3
4
8
2
5 9
7

1
7 11
8 6 10
4
12 13
5 9
3
21

14
22 15
1 16
17
23 18
10
24 19
11
6 25
12 13 16 20
15 26
27
28
33 29
14 18
17 30
20 34 31
19
35

36
21
35

25 37
38 32

26
23 22

24

39

40
41

42

V02818.01 43 V06870

Foldout 6,A. Front Support and Oil Pump Module Exploded View Foldout 6,B. Rotating Clutch Module Exploded View
F OLDOUT 7

3
1 C3/C4 clutch assembly 29 C5 clutch friction plate (8)
2 Bolt, M10 x 1.5 x 90 (14), A 30 C5 clutch reaction plate 6

3 C3 backplate assembly (complete) 31 Bolt, M5 x 8 x 20 (2) B,


4 Clutch backplate assembly prior to model year 1995 2
5 P1 ring thrust plate (4) 32 Connector shipping cover
33 Feedthrough connector assembly, 4 1
6 Rivet (3 OD x 6) (12) 5 10
prior to model year 1995 7
7 P1 ring gear
34 24-way internal seal 8
8 C3 clutch friction plate (5) 9
35 Bolt, M10 x 1.5 x 35 (14), A
9 C3 clutch reaction plate (4) 22
36 Identification plate
10 Return spring assembly (4)
37 Rivet
11 Piston return plate
38 Bolt, M8 x 1.25 x 20, C 20 11
12 Spring retainer assembly 21 17 16
12
39 Speed sensor assembly
13 Sealring 13
40 O-Ring 14
14 Sealring
41 Speed sensor bracket 42 15
15 C3 clutch piston
42 Sensor shipping cover
16 C3 clutch housing assembly 23 18
43 Main housing 39 24
(complete)
44 Fill tube seal 40 25
17 Rivet (3 OD x 6) (12) 19
26
18 P1 ring thrust plate (4) 45 Oil fill tube 48
46 Tapping screw, M8 x 25, C 27
19 C3 clutch housing 38
45
20 C4 clutch reaction plate (5) 47 Oil fill tube bracket 41
46 28
21 C4 clutch friction plate (5) 48 Oil level indicator 49
49 Tapping screw, M8 x 25, C 50
22 Return spring assembly (4) 47
23 Piston return plate 50 Wiring harness clamp 44
24 Spring retainer assembly 31
Torque Nm lb ft 36
25 Sealring 37
32
A 5161 3845 43
26 Sealring
27 C4 clutch piston B 2.02.8 1825 lb in. 33
28 C4 clutch housing C 2429 1821 34

35 30
29

V06851

Foldout 7. Main Housing Module Exploded View


F OLDOUT 8

WIDE RATIO
4
1
5
2
6

1 Shim (non-selective) HD 4070 only 3


1 Shim (selective) all except HD 4070, 0.2450.295 mm (0.00970.0116 inch) (marked with 1 slot)
1 Shim (selective) all except HD 4070, 0.5150.565 mm (0.021030.0222 inch) (marked with 2 slots)
1 Shim (selective) all except HD 4070, 0.7850.835 mm (0.03100.0328 inch) (marked with 3 slots)
1 Shim (selective) all except HD 4070, 1.0551.105 mm (0.04160.0435 inch) (marked with 4 slots)
1 Shim (selective) all except HD 4070, 1.3251.375 mm (0.05220.0541 inch) (marked with 5 slots)
1 Shim (selective) all except HD 4070, 1.5951.645 mm (0.06280.0647 inch) (marked with 6 slots) 7
1 Shim (selective) all except HD 4070, 1.8651.915 mm (0.07350.0753 inch) (not marked with slots)
2 Thrust bearing

Wide Ratio Close Ratio


3 Main shaft module 3 Main shaft module
4 External retaining ring (spiral) 4 External retaining ring (spiral) CLOSE RATIO
5 P2 sun gear 5 P2 sun gear 4
6 Bearing spacer 6 Bearing spacer 1
7 Main shaft 7 P3 sun gear 5
2
8 Main shaft 6

V06878

Foldout 8. Main Shaft Module Exploded View


4000 MH/HD 4000/B 500 SERIES ON-HIGHWAY SERVICE MANUAL
Legend For Foldout 9

A B
1 P1 planetary module 1 P2 planetary module
2 Internal retaining ring 2 Retaining ring
3 P1 planetary carrier assembly 3 P2 planetary carrier assembly
4 Retaining ring 4 Internal retaining ring
5 P1 indexing ring 5 P2 indexing ring
6 P1 pinion spindle (6) 6 Carrier and bushing assembly
7 P1 planetary carrier/bushing assembly 7 P2 planetary carrier
8 P1 planetary carrier 8 Bushing
9 P1 carrier bushing 9 Thrust washer (4)
10 P1 thrust washer (6) 10 Roller bearing (8)
11 P1 pinion gear (6) 11 P2 pinion gear (4)
12 Roller bearing assembly (12) 12 Thrust washer (4)
13 P1 thrust washer (6) 13 P2 pinion spindle (4)
14 Thrust bearing assembly 14 Thrust bearing assembly
15 P2 ring gear 15 P3 planetary ring gear

Foldout 9 Copyright 2001 General Motors Corp.


F OLDOUT 9,A,B
A B

1
2

14

15
3 4 3

4
5
5

6
7
7
8 15
8

9
14
6

9
13
10
10
11 11
12
13 12

V06852
V03630.01

Foldout 9,A. P1 Planetary Module Exploded View Foldout 9,B. P2 Planetary Module Exploded View
F OLDOUT 9,C

2 12 16 14
1 P3 carrier module 24 Pressure tap plug
3 17 15
2 Internal retaining ring, 219 OD 25 O-ring, 8.92 ID
4 1 18
3 P3 indexing ring 26 Ball bearing assembly
4 P3 planetary carrier 27 C6 reaction plate (9) 5
19
5 P4 shaft flange 28 C6 friction plate (8) 7 6
8
6 Shim locating ring 29 C6 backplate 9 20
13
7 P3 planetary spindle 30 P4 sun gear 10
8
8 P3 thrust washer (8) 31 Thrust bearing
9 P3 pinion gear (4) 32 P4 carrier assembly
10 Roller bearing assembly (8) 33 Internal retaining ring 11
11 Flange head bolt, M12 x 1.75 x 45 (14), A 34 Internal retaining ring, 235 OD
12 Shim, (selective), 0.27 mm 35 Indexing ring
Shim, (selective), 0.54 mm 36 P4 carrier and bushing assembly
Shim, (selective), 0.81 mm
37 P4 carrier
Shim, (selective), 1.08 mm 22 26
Shim, (selective), 1.35 mm 38 P4 carrier bushing 21 27
28
Shim, (selective), 1.62 mm 39 P4 planetary spindle (6)
Shim, (selective), 1.89 mm 40 P4 planetary thrust washer (12)
Shim, (selective), 2.16 mm 23
41 P4 pinion gear (6)
Shim, (selective), 2.43 mm 25
42 Caged needle bearing (12) 24
13 Adapter housing gasket
43 C6 clutch drum hub 23 25
14 C6 adapter housing module
44 Thrust bearing assembly 24
15 Piston assembly 30 29
45 P4 ring gear and hub assembly
16 External retaining ring 31
46 P4 ring gear
17 Piston return spring assembly 32
47 P4 ring gear hub
18 Piston
48 Retaining ring
19 Piston OD sealring 43
49 Star tolerance ring (11)
20 Piston ID lip-type sealring
Torque Nm lb ft 44
21 Adapter housing assembly
46 45
22 Adapter housing A 100120 7488
23 Plug assembly (2), B B 1013 710
33 47
34 37 49
38 36 48
35 39

41
42

40
V06854

Foldout 9,C. P3 Planetary Module and C6 Adapter Housing Module (HD 4070/4076 Models Only) Exploded View
4000 MH/HD 4000/B 500 SERIES ON-HIGHWAY SERVICE MANUAL
Legend For Foldout 10,A
1 Retarder housing gasket 53 Bolt, M8 x 1.25 x 25 (3), C
2 Retarder and P3 planetary module 54 Speed sensor assembly
3 P3 planetary carrier assembly 55 O-Ring
4 Output shaft assembly 56 Speed sensor retainer
5 Bushing 57 Bolt, M8 x 1.25 x 20, B
6 Output shaft 58 Cone and roller bearing assembly
7 Internal retaining ring 59 Locknut retainer
8 P3 indexing ring 60 Bearing retainer locknut, D
9 P3 planetary carrier 61 Oil seal assembly
10 Thrust washer 62 Sensor shipping cover
11 External retaining ring 63 Bolt, M12 x 1.75 x 55 (12), E
12 P3 planetary spindle (4) 64 Bolt, M8 x 1.25 x 100 (9), B
13 P3 thrust washer (4) 65 Retarder control body assembly
14 P3 pinion gear (4) 66 Bolt, M8 x 1.25 x 55 (5), B
15 Roller bearing assembly (4 groups of 2) 67 Shipping cover
16 P3 thrust washer (4) 68 Solenoid connector
17 Cone and roller bearing assembly 69 Modulating solenoid cover
18 Retarder stator assembly 70 Solenoid cover gasket
19 External retaining ring 71 Solenoid
20 Spring and retainer assembly 72 O-Ring
21 C5 clutch piston 73 O-Ring
22 C5 piston outer sealring 74 Retarder control valve
23 C5 piston inner sealring 75 Valve stop
24 Roller bearing cup 76 Spring, 7.8 OD x 29.2
25 Retarder stator 77 Exhaust backfill valve
26 O-Ring 78 Retarder control body
27 Retarder sealring 79 Retaining pin, 2.5 OD x 40
28 Retarder housing gasket 80 Retaining pin, 3 OD x 43
29 Rotor assembly 81 Spring
30 Retarder sealring 82 O-Ring
31 Retarder housing assembly 83 Plug
32 Retaining ring 84 Retaining ring
33 Valve plug 85 Pressure tap plug assembly
34 O-Ring 86 O-Ring
35 Valve spring 87 Pressure tap plug, F
36 Retarder valve 88 Separator plate gasket (2)
37 Spring pin 89 Solenoid separator plate
38 Tachograph plug, A if used with brass 90 Channel plate
washer 42; B if used with O-Ring 42 91 Channel plate gasket
39 Brass washer (later models); 92 Bolt, M12 x 1.75 x 165 (4), E
O-Ring (earlier models) 93 Bolt, M12 x 1.75 x 105 (2), E
40 Retarder housing 94 Bolt, M10 x 1.5 x 160 (7), G
41 Temperature sensor assembly (TID2) 95 Shipping cover
42 O-Ring
Torque Nm lb ft
43 Retainer A 6067 4549
44 Bolt, M8 x 1.25 x 20, B B 2429 1821
45 Temperature sensor assembly (TID1) C 1215 911
46 O-Ring D * *
47 Connector E 100120 7488
48 Retainer F 1013 710
49 Bolt, M8 x 1.25 x 20, B G 5161 3845
50 Valve plug
51 Retaining ring * Before module is installed 193207 Nm (143152 lb ft);
52 Roller bearing cup After Module is installed 7488 Nm (5564 lb ft)

Foldout 10,A Copyright 2001 General Motors Corp.


F OLDOUT 10,A
1

17
19
20
21
18
22
3
2
4 23
5 24
25
6
7
8
26
9

10
11
12

13
14 65 95
15 67
16 66 68
64 69
71 70

53 44 72 75
43 63 73 76
27 41 74 77
42 49
48 47 62 78
45
79
28 46
80 87
86
29 30 55 56 57 85
54 81
40 82
51 52
50 83
39 84
38 88 88
37 91 90 89
58
59
31 60
61
35 36
33 92
32 94
34 93
V06855

Foldout 10,A. Retarder And P3 Planetary, Retarder Valve Body Module (Units Prior to S/N 6610066447) Exploded View
F OLDOUT 10,B

1 Rear cover gasket 25 Internal sealring


2 Bolt, M12 x 1.7 x 45 (19), A 26 Roller bearing cup
3 Washer 27 Rear cover assembly
4 Rear cover and P3 planetary module 28 Brass washer (later models);
19
O-Ring (earlier models)
5 P3 planetary carrier assembly 21
29 Plug, 34-16 straight thread, B 1
6 Output shaft assembly 22
29 Tachograph plug, C if used with brass
7 Bushing
washer 28; B if used with O-Ring 28 3
8 Output shaft 23 4 2
30 Rear cover 5
20
9 Internal retaining ring 24
31 Dowel pin (2)
10 P3 indexing ring 35
32 Speed sensor assembly 25 32
11 P3 planetary carrier
33 O-Ring 26 41
34
12 Thrust washer 6
34 Speed sensor retainer 7 27 33
13 External retaining ring 30
35 Bolt, M8 x 1.25 x 20, C 9
14 P3 planetary spindle (4) 8
36 Roller bearing cup 10
15 P3 thrust washer (4) 31
37 Cone and roller bearing assembly
16 P3 pinion gear (4) 11
38 Locknut retainer
17 Roller bearing assembly (4 groups of 2) 29
39 Bearing retainer locknut, D 12 28
18 P3 thrust washer (4) 13
40 Output seal assembly
19 Cone and roller bearing assembly 31
41 Speed sensor shipping cover
20 Rear cover assembly
36
21 External retaining ring Torque Nm lb ft 14
A 100120 7488
22 Spring and retainer assembly
B 2429 1821
23 C5 clutch piston C 6067 4549
24 Piston sealring D 7488 5565 15
16 37

17 38
18 39

40

V06856

Foldout 10,B. Rear Cover And P3 Planetary Module Exploded View


F OLDOUT 10,C
1
Stator housing gasket 45 Speed sensor retainer
2
Retarder module 46 Self-locking bolt, M8 x 1.25 x 20, C
3
Output shaft assembly 47 Flange hd bolt, M12 x 1.75 x 55 (12), E 1
4
Bushing, 28 ID 48 Flange hd bolt, M8 x 1.25 x 100 (9), C
5
Output shaft 49 Retarder control valve body assembly 4
3
6
Cone and roller bearing assembly 50 Flange hd bolt, M8 x 1.25 x 55 (5), C
7
Retarder stator assembly 51 Shipping retarder connector cover
5
8
External retaining ring, 181 ID 52 Solenoid connector
9
C5 piston return spring and retainer assembly 53 Solenoid cover
10
C5 clutch piston 54 Solenoid cover gasket 6
8
11
External sealring, 315.17 ID 55 Valve stop 9
12
Internal lip-type sealring, 214.06 OD 56 Spring, 7.8 OD x 29.2 2 10 7
13
Roller bearing cup 57 Exhaust backfill valve
11
14
Retarder stator housing 58 Solenoid, N/C
15
O-Ring, 11.48 ID 59 O-Ring
16
Rotating sealring, 146 OD 60 O-Ring 12
61 Retarder control valve 13
17
Retarder housing gasket 14
18
Rotor assembly 62 Retarder control valve body
19
Rotating sealring, 146 OD 63 Dowel pin, 2.5 x 40
20
Flange hd bolt, M8 x 1.25 x 25 (3), A 64 Dowel pin, 3 x 43
15
21
Retarder Housing Assembly 65 Spring
22
Internal retaining ring, 45.82 OD 66 O-Ring, 21.9 ID
23
Valve plug 67 Valve plug
24
O-Ring, 34.6 ID 68 Internal retaining ring
25
Valve spring, 36.17 OD x 114.3 69 Pressure tap plug assembly 49
26
Retarder valve 70 O-Ring, 8.92 ID 51
27
Spring pin, 5 x 45 71 Pressure tap plug, 716-20, F 50 52
28
Plug and retarder housing assembly 72 Separator plate gasket 48 53
29
Tachograph plug, M18 x 1.5, B 73 Separator solenoid plate 58 54
30
Washer, M18 74 Separator plate gasket
20 34 59 55
31
Retarder housing 75 Channel plate 60
33 47 56
32
Temperature sensor assembly 76 Channel plate gasket 16 32 61 57
33
Thermistor protection bracket 77 Flange hd bolt, M12 x 1.75 x 350 (4), E
35
34
Self-locking bolt, M8 x 1.25 x 20, C 78 Flange hd bolt, M12 x 1.75 x 105 (2), E 62
79 Flange hd bolt, M10 x 1.5 x 345 (7), G 63
35
Sensor cover 17
64 71
36
Valve plug 70
Torque Nm lb ft 19 44 45 46 69
37
Internal retaining ring, 45.82 OD 18
A 1215 911 36 37
28 43 65
38
Roller bearing cup B 6067 4549 31 38 66
39
Roller bearing assembly C 2429 1821 67
30 72 68
D * * 29 74
40
Locknut retainer 27 76 75 73
41
Bearing retainer locknut E 100120 7488 39
F 1013 710 40
(output speed sensor nut), D 41
21
42 Oil seal assembly 25 26 42
* Before module is installed 193207 Nm (143152 lb ft); 23
43 Speed sensor assembly After Module is installed 7488 Nm (5564 lb ft) 22 75
44 O-Ring, 15.37 ID 24 77 76
V06857

Foldout 10C. Retarder and Output Shaft Module (HD 4070/4076 Models Prior to S/N 6610066447) Exploded View
F OLDOUT 10,D

1 Rear cover gasket


2
2 Bolt, M12 x 1.75 x 45 (14), A
3 Bracket
3
4 Bolt, M12 x 1.75 x 222.5 (5), A
5 Rear cover module
6 Output shaft assembly
1
7 Bushing
8 Output shaft
9 Roller bearing assembly 7 4
6 5
10 Rear cover assembly
11 External retaining ring
8
12 C5 piston spring return retainer assembly 9
13 C5 clutch piston 11

14 External sealring 12
15 Internal lip-type sealring
16 Roller bearing cup 13
10
17 Rear cover assembly 14
23
18 Rear cover 15 22
19 Tachograph plug, B 16 26
24
20 Washer 17 25
18
21 Roller bearing cup
22 Speed sensor assembly
23 Self-locking bolt, M8 x 1.25 x 20, C
27
24 Speed sensor retainer
25 O-Ring 28 19 20
26 Sensor shipping cover 29
27 Roller bearing assembly
30
28 Locknut retainer
21
29 Output speed sensor nut
30 Output seal assembly

Torque Nm lb ft
A 100120 7488
B 6067 4450
C 2429 1821

V06858

Foldout 10D. Rear Cover and Output Shaft Module (HD 4070/4076 Models Only) Exploded View
4000 MH/HD 4000/B 500 SERIES ON-HIGHWAY SERVICE MANUAL
Legend For Foldout 10,E

1 Retarder housing gasket 31 Retarder housing assembly


2 Retarder and P3 planetary module 32 Retaining ring
3 P3 planetary carrier assembly 33 Valve plug
4 Output shaft assembly 34 O-Ring
5 Bushing 35 Valve spring
6 Output shaft 36 Retarder valve
7 Internal retaining ring 37 Spring pin
8 P3 indexing ring 38 Retarder housing subassembly
9 P3 planetary carrier 39 Tachograph plug, A if used with brass
washer 40; B if used with O-Ring 40
10 Thrust washer
40 Brass washer (later models);
11 External retaining ring O-Ring (earlier models)
12 P3 planetary spindle (4) 41 Retarder housing
13 P3 thrust washer (4) 42 Gasket
14 P3 pinion gear (4) 43 Cover
15 Roller bearing assembly (4 groups of 2) 44 Bolt, M8 x 1.25 x 25 (9), B
16 P3 thrust washer (4) 45 Temperature sensor assembly (TID2)
17 Cone and roller bearing assembly 46 O-Ring
18 Retarder stator assembly 47 Retainer
19 External retaining ring 48 Bolt, M8 x 1.25 x 20, B
20 Spring and retainer assembly 49 Valve plug
21 C5 clutch piston 50 Retaining ring
22 C5 piston outer sealring 51 Roller bearing cup
23 C5 piston inner sealring 52 Bolt, M8 x 1.25 x 25 (3), C
24 Roller bearing cup 53 Speed sensor assembly
25 Retarder stator 54 O-Ring
26 O-Ring 55 Speed sensor retainer
27 Retarder sealring 56 Bolt, M8 x 1.25 x 20, B
28 Retarder housing gasket 57 Cone and roller bearing assembly
29 Rotor assembly 58 Locknut retainer
30 Retarder sealring 59 Bearing retainer locknut, D

Copyright 2001 General Motors Corp. Foldout 10,E


4000 MH/HD 4000/B 500 SERIES ON-HIGHWAY SERVICE MANUAL
Legend For Foldout 10,E (contd)

60 Oil seal assembly 85 O-Ring


61 Sensor shipping cover 86 Pressure tap plug, F
62 Bolt, M12 x 1.75 x 55 (12), E 87 Separator plate gasket (2)
63 Bolt, M8 x 1.25 x 100 (9), B 88 Solenoid separator plate
64 Retarder control body assembly
89 Channel plate
65 Bolt, M8 x 1.25 x 55 (5), B
90 Channel plate gasket
66 Connector shipping cover
91 Bolt, M12 x 1.75 x 165 (4), E
67 Solenoid connector
92 Bolt, M12 x 1.75 x 105 (2), E
68 Modulating solenoid cover
69 Solenoid cover gasket 93 Bolt, M10 x 1.5 x 160 (4), G

70 Solenoid 94 Gasket
71 O-Ring 95 Jumper manifold
72 O-Ring 96 Bolt, M10 x 1.5 x 30, G
73 Retarder control valve 97 Remote side manifold
74 Valve stop 98 Bolt, M10 x 1.5 x 160 (3), G
75 Spring, 7.8 OD x 29.2
99 Connector shipping cover
76 Exhaust backfill valve
77 Retarder control body Torque Nm lb ft
78 Retaining pin, 2.5 OD x 40 A 6067 4549
B 2429 1821
79 Retaining pin, 3 OD x 43 C 1215 911
80 Spring D * *
81 O-Ring E 100120 7488
F 1013 710
82 Plug
G 5161 3845
83 Retaining ring
* Before module is installed 193207 Nm (143152 lb ft);
84 Pressure tap plug assembly After Module is installed 7488 Nm (5564 lb ft)

Foldout 10,E Copyright 2001 General Motors Corp.


F OLDOUT 10,E
1

17
19
20
21
18
22
3
2
4 23
5 24 25
6
7
8
26
9

10
11
12

13
14 64 99
15 66
16 65 67
63 68
70 69

52 48 71 74
47 62 72 75
27 45 73 76
46
61 77
78
28
79 86
85
29 30 54 55 56 84
38 53 80
41 81
50
49 51 82
40 83
39 87 87
37 90 89 88
57
58
31 59
35 36 60
33 42
32 43
34 44

91 97
93
92 94 98
95
96
V06859

Foldout 10,E. Retarder And P3 Module (Units Starting With S/N 6610066447) Exploded View
F OLDOUT 10,F
1
Stator housing gasket 48 Speed sensor retainer
2
Retarder module 49 Self-locking bolt, M8 x 1.25 x 20, D 1
3
Output shaft assembly 50 Sensor cover 4
3
4
Bushing, 28 ID 51 Flange head bolt, M12 x 1.75 x 55 (12), E
5
Output shaft 52 Flange head bolt, M8 x 1.25 x 100 (9), D
6
Roller bearing assembly 53 Retarder control valve body assembly 5
7
Retarder stator assembly 54 Flange head bolt, M8 x 1.25 x 55 (5), D
8 6
8
External retaining ring, 181 ID 55 Solenoid connector 9
9
C5 piston return spring and retainer assembly 56 Solenoid cover
10
C5 clutch piston 57 Solenoid cover gasket 10
7
11
External sealring, 315.17 ID 58 Solenoid, N/C 11
12
Internal lip-type sealring, 214.06 OD 59 O-Ring
2
13
Roller bearing cup 60 O-Ring
14
Retarder stator housing 61 Retarder control valve 12
15
O-Ring, 11.48 ID 62 Valve stop 13
16
Rotating sealring, 146 OD 63 Spring, 7.8 OD x 29.2
17
Retarder housing gasket 64 Exhaust backfill valve
18
Rotor assembly 65 Retarder control valve body 14
19
Rotating sealring, 146 OD 66 Dowel pin, 2.5 x 40 15
20
Flange head bolt, M8 x 1.25 x 25 (3), A 67 Dowel pin, 3 x 43
21
Retarder Housing Assembly 68 Spring
22
Internal retaining ring, 45.82 OD 69 O-Ring, 21.9 ID
23
Valve plug 70 Valve plug 79
24
O-Ring, 34.6 ID 71 Internal retaining ring 53
25
Valve spring, 36.17 OD x 114.3 72 Pressure tap plug assembly
26
Retarder valve 73 O-Ring, 8.92 ID
27
Spring pin, 5 x 45 74 Pressure tap plug, 716-20, F 54 55
28
Plug and retarder housing assembly 75 Separator plate gasket (2) 52 56
29
Tachograph plug, M18 x 1.5, B 76 Separator solenoid plate 58 57
30
Washer, M18 77 Channel plate
31
Retarder housing 78 Channel plate gasket 38 59 62
20
32
Gasket 79 Retarder connector shipping cover 51 60 63
16 37
35 61
33
Cover 80 Gasket 64
34
Bolt, M8 x 1.25 x 25 (9), D 81 Jumper manifold
36
35
Temperature sensor assembly 82 Bolt, M10 x 1.5 x 30 50 65
66
36
O-Ring 83 Remote side manifold 17 74
37
Thermistor protection bracket 84 Bolt, M10 x 1.5 x 354 (3) 67 73
38
Self-locking bolt, M8 x 1.25 x 20, D 85 Flange head bolt, M10 x 1.5 x 345 (7), G 18 19 47 48 49 72
39
Valve plug 86 Flange head bolt, M12 x 1.75 x 350 (4), E 28 46 68
40
Internal retaining ring, 45.82 OD 87 Flange head bolt, M12 x 1.75 x 105 (2), E 31 69
40 70
30 39 41
41
Roller bearing cup 29
75 71
Torque Nm lb ft 75
42
Cone and roller bearing assembly 78 77 76
A 1215 911 27
43
Locknut retainer 42
44
Bearing retainer locknut B 6067 4549 43
C * * 21 44
(output speed sensor nut), C
D 2429 1821 25 26 45
45 Oil seal assembly 23 32
46 Speed sensor assembly E 100120 7488 22
F 1013 710 33
47 O-Ring, 15.37 ID 24 34 86
G 5161 3845
85
83
* Before module is installed 193207 Nm (143152 lb ft); 80
After Module is installed 7488 Nm (5564 lb ft) 87 81
84
82

V06860

Foldout 10F. Retarder and Output Shaft Module (HD 4070/4076 Models Starting With S/N 6610066447) Exploded View
4000 MH/HD 4000/B 500 SERIES ON-HIGHWAY SERVICE MANUAL
Legend For Foldout 11,A

1 Control valve assembly 34 Secondary lock (2)


2 Suction filter gasket 35 Cable tie
3 Suction filter 36 Temperature sensor
4 Sump scavenge suction-filter housing 37 Connector
5 Bolt, M6 x 1.0 x 60, A 38 Terminal
6 Face seal 39 Secondary lock
7 Bolt, M6 x 1.0 x 95 (2), A 40 Spiral wrap
8 Bolt, M6 x 1.0 x 95 (4), A 41 Solenoid connector
9 Wiring harness cover plate 42 Female terminal
10 Bolt, M6 x 1.0 x 30, A 43 Female terminal
11 Face seal 44 Spiral wrap
12 Suction filter assembly 45 Connector
13 Gasket 46 Male terminal (2)
14 Electronic connector shoulder bolt (3), B 47 Solenoid connector
15 Control harness assembly 48 Female terminal
16 Harness channel plate 49 Female terminal
17 Standoff 50 Solenoid connector
18 Warning tag 51 Female terminal (2)
19 Spring clip 52 Solenoid connector
20 O-Ring 53 Female terminal
21 Seal 54 Female terminal
22 Grommet 55 Solenoid connector
23 Cavity plug (14) 56 Female terminal (2)
24 Grommet (2) 57 Solenoid connector
25 Backshell follower (2) 58 Female terminal (2)
26 Backshell housing (2) 59 Solenoid connector
27 Convolute conduit 60 Female terminal (2)
28 Terminal (17) 61 Control harness assembly
29 Connector plug 62 Standoff
30 Lockwasher 63 Spacer
31 Panel nut 64 Female terminal (20)
32 4-way connector 65 Internal connector
33 Female terminal (3) 66 Standoff bolt

Copyright 2001 General Motors Corp. Foldout 11,A


4000 MH/HD 4000/B 500 SERIES ON-HIGHWAY SERVICE MANUAL
Legend For Foldout 11,A (contd)

67 4-way connector 102 Solenoid regulator valve (3)


68 Female terminal (3) 103 N/O solenoid (2)
69 Secondary lock (2)
104 O-Ring
70 Cable tie
105 O-Ring
71 Temperature sensor
106 N/C solenoid
72 Spiral wrap
73 Solenoid connector 107 O-Ring
74 Female terminal 108 O-Ring
75 Female terminal 109 Retention pin (3)
76 Spiral wrap 110 Rotating clutch solenoid body
77 Connector
111 A/R valve
78 Male terminal (2)
112 A/R valve spring
79 Solenoid connector
80 Female terminal 113 A/R valve stop

81 Female terminal 114 Pin


82 Female terminal (2) 115 Bolt, M6 x 1.0 x 95 (8), A
83 Solenoid connector 116 Face seal (2)
84 Solenoid connector
117 Stationary clutch solenoid body assembly
85 Female terminal
118 Stationary clutch solenoid body
86 Female terminal
87 Female terminal (2) 119 Retention pin (3)

88 Solenoid connector 120 Spring (11.05 OD x 6.48) (3)


89 Solenoid connector 121 Solenoid regulator valve (3)
90 Female terminal (2) 122 Retention pin
91 Female terminal (2)
123 N/C solenoid (3)
92 Solenoid connector
124 O-Ring
93 Bolt, M6 x 1.0 x 95 (3), A
125 O-Ring
94 Face seal
95 Rotating clutch solenoid body assembly 126 Valve stop
96 Bolt, Allen-Head, M5 x 0.8 x 12 (2), C 127 Overdrive valve spring
97 Pressure switch 128 Overdrive valve
98 Female terminal (2)
Torque Nm lb ft/lb in.*
99 Solenoid connector
A 1013 710
100 O-Ring B 23 1826*
101 Solenoid regulator spring (3) C 58 4471*

Foldout 11,A Copyright 2001 General Motors Corp.


F OLDOUT 11,A
7
6 8 10
5
9
11

12
4

31
30 26 13
3
29
50
36
70

1 25
29
23 24
24 23
2 28 22
61 14
25 21 19
DE
18
26
TA
BE CH
FO CO

66
CO RE NNEC
NT DR
RO OP TOR
L MO PING
DU

20
LE

65 27
64 15
14 17
63
91 69 56 34
90 68 67 57 33 32
62
16
89 92 58 55
88 72 59 40
87 72 70 60 40 39
38
37
35 36
86 71 73 36 41
54
85 72 53 40
84 76 52 44
83 79 74 51 47 42
77 45
78 75 46 43
82 81 80 50 49 48

116
93
115 94
95

96
99 98 97
117
103
100
105
104
118 114 106
113 102
112 101
128 107
108
127 119
126 102
120 101
111 109
121
125
124
122
123 110

V06861

Foldout 11,A. Control Module Exploded View


F OLDOUT 11,B
129 Solenoid separator plate 178 Male terminal
130 Bolt, M6 x 1.0 x 95 (2), A 179 Secondary lock 181
131 Main valve body assembly 180 Four-way connector receptacle 1 (cont'd.)
182
132 Retaining pin, 5.0 OD x 43 181 Bolt (2), A
133 Lockup valve 182 Oil level sensor assembly 131 135 170
134 Lockup spring 183 Oil level sensor bracket 129 134 183
135 Lockup stop 184 O-Ring 132 133
136 139 171 174
136 Retaining pin, 3.0 OD x 43 185 Oil level sensor 162
137 Lube regulator valve 186 Spacer 138 172 184
166 158 140
138 Lube regulator spring 187 Base plate 137 143
130 144 175 185
139 Lube regulator stop 188 Separator plate 154 142
148 176
140 Retaining pin, 5.0 OD x 43 189 Channel plate gasket 141 177
147 173
141 Main regulator valve 190 Channel plate assembly (2 inch sump)
146 178
142 Main regulator spring 191 Dowel pin (2) 179 186
143 Main regulator stop 192 Oil transfer channel plate 145 180
173 187
144 Retaining pin, 3.0 OD x 43 193 Oil drain plug assembly, B 149
145 Control main valve 194 O-Ring (2 inch sump) 167 151
146 Control main spring 195 Pressure tap plug assembly (8) 168 150
147 Control main stop 196 O-Ring (8) 169 163
148 Retaining pin, 2.5 OD x 40 197 Pressure tap plug (8), C 164 152
149 Solenoid assembly 198 Channel plate assembly (4 inch sump) 165 159
150 O-Ring 199 Dowel pin (2)
160 153
151 O-Ring 200 Oil transfer channel plate 214
161 155
152 Control valve body 201 Plug assembly, B
153 Retaining pin, 5.0 x 55 202 O-Ring 156
154 Retaining pin, 5.0 OD x 43 203 Pressure tap plug assembly (8), C 157
155 C2 latch valve 204 O-Ring (8)
188
156 C2 latch spring 205 Pressure tap plug (8), C
198 189
157 C2 latch stop 206 Filter cover (2)
158 Retaining pin, 3.0 x 43 207 Filter cover gasket ** 199 190
159 Exhaust back valve 208 Square-cut seal * 210
160 Exhaust back spring 208 O-Ring (2) ** 200 191
161 Exhaust back stop 209 O-Ring (2)
209
162 Retaining pin, 5.0 OD x 43 210 Oil filter (2) 192
163 C1 latching valve 211 Bolt, M10 x 1.5 x 100 (34) 208
164 C1 latching spring (4 inch sump), D
165 C1 latching stop 212 Bolt, M10 x 1.5 x 55 (9), D 207
166 Retaining pin, 3.0 x 43 213 Bolt, M10 x 1.5 x 55 (34)
167 Converter regulator valve (2 inch sump), D
206
168 Spring 214 Case gasket
169 Valve stop 201
203 202
170 Sensor assembly kit 204
Torque Nm lb ft 193
171 Shoulder bolt, M6 x 1 x 45, A 205 195 196 194
A 1013 710
172 Oil level sensor assembly 197
173 Viton ferrule B 2532 1824
174 Oil level sensor harness adapter C 1013 710
175 Connector D 5161 3845
176 Secondary lock 212 213
177 Female terminal * Prior to S/N 661009730 211
V06863
** Starting With S/N 661009730

Foldout 11,B. Control Module Exploded View


4000 MH/HD 4000/B 500 SERIES ON-HIGHWAY SERVICE MANUAL
Legend For Foldout 12

A 11 Temperature gauge kit


1 Output flange 12 Temperature sender adapter
2 Output flange 13 Shipping plug (2)
3 O-Ring 14 Straight fitting
4 O-Ring (2) 15 Shipping plug assembly
5 Retaining plate 16 Cooler port plug (2)
6 Locktab 17 Pilot screw (2)
7 Bolt, M10 x 1.5 x 30 (2), A 18 PTO gasket
8 Output yoke 19 Bolt, M10 x 1.5 x 35 (8), A
9 Output shipping cover 20 Clutched drive PTO assembly
21 Hose assembly
Torque Nm lb ft 22 90 degree hose fitting
A 5161 3845 23 Pilot screw (2)
24 PTO gasket
25 Bolt, M10 x 1.5 x 25 (8), A
B
26 Clutch drive PTO assembly
1 Converter shipping bracket (3)
27 Hose assembly
2 Bolt, M10 x 1.5 x 25 (3), A
28 90 degree fitting
3 Rear support bracket (front)
29 Accumulator
4 Rear support bracket (rear)
30 Accumulator bracket
5 Remote mount cooler
31 Fitting plug
5 Retarder oil cooler
32 A/R solenoid
6 Remote mount gasket
7 Remote mount manifold
Torque Nm lb ft
8 Cooler port cover
A 5161 3845
9 Bolt, M10 x 1.5 x 28 (6), A
10 90 degree fitting

Foldout 12 Copyright 2001 General Motors Corp.


F OLDOUT 12
A B 3

4
1
5

13
14
15
16

11
8 10
12
2 120
150
0
12 250 C
300
F

0
10
TRANS
OIL
TEMP

3
4 6
29
7 20
5 30 9

6 19
31 17
7 32
18
8

21
22

1 2

9
1
2
24
25

26

28
23 27

V00439.01

V00201

Foldout 12,A. Output Flange And Yoke Exploded View Foldout 12,B. Support Equipment Exploded View
F OLDOUT 13

HD HYDRAULIC SCHEMATIC NEUTRAL


Torque
Converter Lube
Lube
Filter

CONVERTER IN Cooler
Conv
Regulator Lube Lube
CONVERTER OUT

Overdrive Conv
Knockdown Flow
Lockup

EX Lube
Regulator

F A B C D E
LU C1 C2 C3 C4 C5
N/C N/O N/O N/C N/C N/C EX

Ctl. Main
G FWD Main Filter
N/C Reg.
ONOFF

EX Main

Exhaust Pump
Main
C2 Backfill
Main
C4 C5 Regulator
Suction
C1 Filter
C1 C2 C3 C4 C5

Sump

Accumulator/
Relay Valve SOLENOIDS ENERGIZED A B E
CLUTCH APPLIED C5
C1 C3
Latch MAIN COOLER/LUBE
CONTROL MAIN EX. BACKFILL
C3 Pressure EXHAUST CONVERTER
C2 EX
Switch SUCTION C5
Latch V00330.03

Foldout 13. 4000 MH, HD 4000, B 500 Hydraulic Schematic Neutral


SM2457EN 200102 www.allisontransmission.com Printed in U.S.A. 200105

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