2019 Allison DOC Transmission+GEN5 Diagnostic Software Installation Service
1. Remove the six PTO cover retaining bolts or the Power Take Off whichever it is equipped with, on the right hand side of the transmission as shown in Figure 43.
2. Install holding fixture similar to the one shown in Figure 43, onto the PTO surface, to be used with the bench fixture base.Caution: Because of the mass and the weight of this unit, we feel it necessary to use holding fixture shown in Figure 43, with the fixture base or in a suitable turn-over stand.
3. Using a suitable hoist, lift the transmission and install into bench fixture base, or the suitable turn-over stand.
4. With transmission assembly locked, in the pan facing down position, remove the converter by pulling it straight out (See Figure 44).Caution: This torque converter weighs about 60 pounds, so exercise extreme caution.
5. Remove the engine speed sensor, turbine speed sensor and output speed sensor, as shown in Figure 45.
Note: The engine speed sensor, if equipped, the turbine speed sensor, and the output speed sensor on 2WD models are all the same part number (See Figure 45).
6. Remove and discard the "O" rings from the 3 speed sensors (See Figure 45).
7. Remove the Neutral Start Back-Up switch from the side of case, as shown in Figure 45.Note: The NSBU Switch is exactly the same as the 4L60-E switch (See Figure 45).
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9. Remove the twelve bottom pan retaining bolts, using a 13 mm socket (See Figure 46).
10. Remove the bottom oil pan (See Figure 46).
11. Remove and discard the bottom pan gasket, as shown in Figure 46.
12. Remove and discard the bottom pan filter and filter seal, as shown in Figure 47. 13. Remove the inside detent roller and spring assembly retaining bolts, using an 8mm socket, as shown in Figure 48.
14. Remove the inside detent roller and spring assembly, as shown in Figure 48.
15. Remove the pass through case connector from the case bore using the Teckpakä GM harness removal tool, as shown in Figure 49.
16. Remove the 15 valve body to case retaining bolts, using an 8mm socket (See Figure 50).Note: Remove "Only" the valve body to case bolts that are shaded as shown in Figure 50
17. After the 15 valve body bolts are removed, you can remove the valve body, ensuring that you disengage the manual valve pin from the inside detent lever, as shown in Figure 51.
18. Set the complete valve body assembly aside for the component rebuild process.
19. Remove the external oil filter from the cooler manifold or the bell housing, depending on the design, as shown in Figure 52.
20. Remove the cooler manifold assembly retaining bolts, as shown in Figure 54.
21. Remove the cooler manifold assembly from the bell housing, as shown in Figure 54.
22. Remove and discard the 2 cooler manifold gaskets, as shown in Figure 54.
23. Rotate the transmission in the fixture so that the bell housing is facing
2019 Allison DOC Transmission Diagnostic Software Free Download
24. Remove 2 bell housing bolts from each side of the case that are not inside the bell housing, as shown in Figure 55. 25. Remove the bell housing to case bolts that are shaded, from inside the bell housing, as shown in Figure 56.Note: Remove the shaded bolts only, as shown in Figure 56. There will be 11 bolts that are 50mm long and 5 bolts that are 70mm long. The remaining bolts retain pump to bell.
26. Remove bell housing and oil pump assembly from the transmission case, by lifting straight up, as shown in Figure 55.
27. Remove and discard the pump spacer plate to case gasket (See Figure 55).
28. Set the bell housing and pump assembly aside for the component rebuild process.
29. Remove the C1/C2 clutch housing from the case by lifting straight up using the turbine, as shown in Figure 57.Note: Remove the sun gear/planetary carrier thrust bearing if it is not stuck to sun gear
30. Set C1/C2 clutch housing aside for component rebuild process that is covered later. 31. Rotate transmission case so that the extension housing is facing up as shown in Figure 58.
32. Remove the yoke from the transmission if it is equipped with one, as shown in Figure 58.Note: Some models are equipped with the parking brake as shown in Figure 58. Four Wheel Drive models will have neither.
33. Remove the 16 extension housing bolts, using a 15mm socket (See Figure 59).
34. Remove the extension housing assembly and set aside for the component rebuild process,as shown in Figure 59.
35. Remove and discard the extension housing gasket, as shown in Figure 59.
36. Grasp the output shaft splines and lift straight up, removing the output shaft and P3 planetary carrier as an assembly (See Figure 60).
37. Remove the P3 sun gear and the thrust bearing as shown in Figure 60.
38. Grasp the main shaft splines and lift straight up removing the main shaft, P2 sun gear and the sun gear spacer, as shown in Figure 62.
39. Remove the parking pawl shaft by pulling up and twisting motion at the same time. This will help in the removal as it is air locked in the case bore (See Figure 62). 40. Remove the parking pawl by slight twisting motion to disconnect from the parking pawl return.
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