AED Drive Unit Service Manual SM 3602 200708

SM3602EN_Front_ATI_20#EEB57.
pdf
8/27/07
10:07:58 AM
leaders in advanced hybrid technology
CM
MY
ALLISON ELECTRIC DRIVES
EP 40/50 SYSTEMS
SERVICE MANUAL
CY
CMY
SM3602EN
CMY
CY
MY
CM
SM3602EN Spine Outline.pdf
10/2/06
1:37:
Service
Manual
2007 JANUARY
Rev. 1 2007 AUGUST
SM3602EN
Allison Transmission
Allison Electric Drives
EP 40/50 System
Allison Transmission, Inc.

P.O. Box 894, Indianapolis, Indiana 46206-0894
1-800-252-5283
www.allisontransmission.com
Printed in USA
Copyright 2007 Allison Transmission, Inc.
E P 40/50 SYSTEM SERVICE MANUAL

TRADEMARK USAGE
The following trademarks are the property of the companies indicated:
Allison DOC and Allison Diagnostic Optimized Connection are trademarks of General
Motors Corporation.
EV Drive, EP 40/50 System, and EP 40/50 Series Electric Drive Propulsion System are
trademarks of General Motors Corporation.
Spiralock is a registered trademark of Spiralock Corporation
Teflon is a registered trademark of the Dupont Corporation.
TranSynd is a trademark of Castrol Ltd.
Windows is a trademark of Microsoft Corporation.
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
TransmissionsTruck, Tractor, etc.
ii
IMPORTANT SAFETY NOTICE

IT IS YOUR RESPONSIBILITY to be completely familiar with the Warnings and
Cautions 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
equipment, 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.
Consequently, Allison Transmission has not undertaken any such broad evaluation.
Accordingly, 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
Service Manual are effective methods for performing service operations. Some of these
service 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.
iii
LIST OF WARNINGS
This manual contains the following Warnings
IT IS YOUR RESPONSIBILITY TO BE FAMILIAR WITH ALL OF THEM.
The Allison Electric Drives EP 40/50 System uses potentially hazardous electrical energy. All
hybrid propulsion components are identified with warning labels or symbols (see Figures 11, 12,
and 13). DO NOT attempt to service components containing potentially hazardous electrical
energy if you are not trained to do so.
Normal Operating Conditions
ESS Voltage Range:
432780 VDC
DPIM Voltage Range: 350 to +350 A
DO NOT rely solely on the HVIL System to de-energize the system. Always perform the
appropriate checks to make sure the system is discharged before servicing components.
DO NOT attempt to bypass any High Voltage Interlock for any reason. Tampering with the HVIL
may result in injury. Failure to follow proper safety procedures may result in serious personal
injury or death.
For vehicles containing the EV Drive, each time you park the vehicle or leave the operator's
station with the engine running, do the following.
Bring the vehicle to a complete stop using the service brake.
Put the EV Drive in N (Neutral).
Apply the emergency brake and/or parking brake, if present, and make sure it is
properly engaged.
If the operators station will be unoccupied with the engine running, chock the wheels
and take any other steps necessary to keep the vehicle from moving.
If this procedure is not followed, the vehicle can move suddenly and you or others could be injured.
Observe safety precautions during hydraulic pressure check procedures. All personnel must stand
clear of the vehicle. Take precautions against movement of the vehicle. Be sure that gauges (vacuum,
pressure, tachometer) have extended lines so that they can be read from inside the vehicle.
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.
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.
Chock wheels to prevent vehicle from moving when driveline is disconnected. This is not necessary
if all wheels are off the ground.
To help avoid personal injury, use an appropriate hoist and lifting devices to lift the input damper
assembly. The input damper assembly weighs approximately 23 kg (60 lbs).
To help avoid personal injury, use an appropriate hoist and lifting devices to lift the input housing.
The input housing weighs approximately 28 kg (75 lbs).
To help avoid personal injury or equipment damage, make sure the work table or other supporting
device can safely support Rotor A in a vertical position. Rotor A weighs approximately 90.9 kg (200
lbs), use care when maneuvering Rotor A.
iv
INTRODUCTION
Acronym List for Allison Electric Drive

AC
Alternating Current
AED
Allison Electric Drive
BIPD
Battery Pack Installation Protection Device
CAN
Control Area NetworkTwisted shielded pair of wires used to communicate J1939

messages between electronic controllers
DC
Direct Current
DIPD
DPIM Installation Protection Device
DOC
Allison Diagnostic Optimized ConnectionPC based diagnostic tool for troubleshooting
DPIM
Dual Power Inverter ModuleResponsible for ACDC conversion and motor controls in
the EP System.
DTC
Diagnostic Trouble Code
EP System
Allison Parallel hybrid system
EV 40/50
EV Drive for Parallel hybrid system
ESS
Energy Storage SystemBattery assembly that provides high voltage DC power to the
EP System
HVIL
High Voltage Interlock LoopSafety circuit that attempts to prevent exposure to

hazardous electrical energy
ID
Inside Diameter
IGBT
Insulated Gate Bipolar Transistor
OD
Outside Diameter
OEM
Original Equipment Manufacturer
OLS
Oil Level Sensor
PBSS
Pushbutton Shift Selector
SID
System IDIdentifies compatible calibrations at the system level. SID is identified on the
TCM, VCM, and DPIM calibration labels and is required when performing a service
recalibration of the system or individual component.
TCM
Transmission Control ModuleInterfaces with EV Drive
Volt
VCM
Vehicle Control ModuleInterfaces with vehicle systems

Page
SECTION 1. GENERAL INFORMATION
11. SCOPE OF MANUAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
a. Content and Organization . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
b. Illustrations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
c. Maintenance Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
d. Dual Power Inverter Module and Energy Storage System . . . . . . . . . . . . . . . . . . . . . . 11
12. SUPPLEMENTARY INFORMATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
13. ORDERING PARTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
a. Model Nomenclature . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
b. Ev Drive Nameplate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
c. ESS Nameplate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
d. DPIM Nameplate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
e. Parts Catalog . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
14. GENERAL DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
a. EP 40/50 System Design Features . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
15. TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
a. Before Performing Repairs. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
b. System Malfunction Indicator Lamps . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
c. Personal Computer (PC)-Based Diagnostic System . . . . . . . . . . . . . . . . . . . . . . . . . . 18
d. Troubleshooting When No Diagnostic Codes Are Present. . . . . . . . . . . . . . . . . . . . . . 19
e. Troubleshooting Intermittent Diagnostic Codes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
16. RECOVERY OF DEPLETED ENERGY STORAGE SYSTEM . . . . . . . . . . . . . . . . . . . . . 19
17. EV DRIVE STORAGE AND PRESERVATION REQUIREMENTS . . . . . . . . . . . . . . . . 110
a. Preservation Methods . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 110
b. One-Year Storage (Without Fluid) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 110
c. One-Year Storage (With Fluid) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 110
18. DPIM STORAGE AND PRESERVATION REQUIREMENTS . . . . . . . . . . . . . . . . . . . . . 111
a. Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 111
b. Storage (With Fluid) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 111
c. Storage (Without Fluid) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 111
d. Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 111
19. SEASONAL STORAGE OF EP 40/50 SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 111
a. Preparing the EP 40/50 System for Seasonal Storage. . . . . . . . . . . . . . . . . . . . . . 112
b. Maintaining the EP 40/50 System During Seasonal Storage . . . . . . . . . . . . . . . . . 112
c. Restoring the EP 40/50 System After Seasonal Storage . . . . . . . . . . . . . . . . . . . . 112
110. RESTORING EV DRIVE FOR SERVICE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 113
a. Ev Drive Exterior. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 113
b. Sealed Breather and Openings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 113
c. New Ev Drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 113
d. Stored Without Fluid. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 113
e. Stored With Fluid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 113
111. RESTORING ESS FOR SERVICE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 113
vi
INTRODUCTION
112.
113.
114.
Page
RESTORING DPIM FOR SERVICE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 113
OPERATING INSTRUCTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 114
SPECIFICATION AND DATA . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 114
SECTION 2. ELECTRICAL SAFETY

21. ELECTRIC SYSTEMS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
a. High Voltage Interlock Loop . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
b. Isolation Fault Detection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
c. General Electrical Safety Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
d. Electrical Disconnect Verification Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
e. Energy Storage Lockout . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
f. Electrical Safe Work Practices . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
21
21
22
22
22
24
24
SECTION 3. PREVENTIVE MAINTENANCE

31. SCOPE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
32. PERIODIC INSPECTIONS AND CARE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
a. Ev Drive Inspection. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
b. DPIM Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
c. ESS Inspection. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
d. Welding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
33. IMPORTANCE OF PROPER TRANSMISSION FLUID LEVELS . . . . . . . . . . . . . . . . . . .
34. TRANSMISSION FLUID CHECK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
a. Fluid Check Procedure. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
b. Invalid for Display Codes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
c. Exiting the Fluid Level Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
35. FLUID RECOMMENDATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
36. Ev DRIVE FLUID AND FILTER CHANGE INTERVALS . . . . . . . . . . . . . . . . . . . . . . . . . .
a. Fluid and Filter Change Intervals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
b. Abnormal Conditions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
c. Fluid Analysis . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
37. TRANSMISSION FLUID CONTAMINATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
a. Fluid Examination. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
b. Water . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
c. Metal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
38. Ev DRIVE FLUID AND FILTER CHANGE PROCEDURE . . . . . . . . . . . . . . . . . . . . . . .
a. Fluid and Filter Changed Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
b. Refill Ev Drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
c. Control Main Filter Change Procedure. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
d. Lube Circuit Filter Change Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
e. Sump Filter Change Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
39. BREATHER (OIL VENT) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
a. Location and Purpose . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
b. Maintenance. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
31
31
31
31
31
32
32
32
32
33
33
33
34
34
34
35
35
35
35
35
35
35
36
36
36
36
37
37
37
vii

310.
311.
Page
MAIN PRESSURE CHECK PROCEDURE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
FLUID LEAK DIAGNOSIS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
a. Finding the Leak. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
b. Powder Method . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
c. Black Light and Dye Method . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
d. Repairing the Leak . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
SECTION 4. GENERAL OVERHAUL INFORMATION

41. SCOPE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
42. TOOLS AND EQUIPMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
a. Improvised Tools and Equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
b. Special Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
c. Mechanics Tools and Shop Equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
43. REPLACEMENT PARTS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
44. CAREFUL HANDLING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48
45. CLEANING AND INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48
a. Dirt Causes Malfunction. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48
b. Cleaning Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48
c. Cleaning Bearings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48
d. Keeping Bearings Clean . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48
e. Inspecting Bearings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48
f. Inspecting Cast Parts and Machined Surfaces . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49
g. Inspecting Bushings and Thrust Washers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49
h. Inspecting Sealrings and Gaskets . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49
i. Inspecting Gears . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49
j. Inspecting Splined Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 410
k. Inspecting Threaded Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 410
l. Inspecting Retaining Rings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 410
m. Inspecting Springs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 410
n. Inspecting Clutch Plates. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 410
o. Inspecting Swaged And Interference-Fit Parts. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 410
p. Inspecting Sealing Surfaces. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 410
46. ASSEMBLY PROCEDURES. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 410
a. Parts Lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 410
b. Grease Used for Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 410
c. Sealing Compounds and Nonsoluble Greases . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 410
d. Clutch and Pistons . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 411
e. Threaded Plugs and Hydraulic Fittings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 411
f. Bearings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 411
g. Electrical Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 411
47. TORQUE SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 411
48. PRESSURE SCHEDULE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 411
viii
INTRODUCTION
Page
SECTION 5. EV DRIVE DISASSEMBLY
51. REMOVE THE Ev DRIVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51
a. Drain the Ev Drive. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51
b. Disconnect Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51
c. Uncouple From Driveline, Engine, and Vehicle. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53
d. Install Drive on Repair Stand . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55
52. REMOVE MOTOR SPEED SENSORS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55
a. Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56
b. Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56
53. REMOVE OUTPUT SPEED SENSORS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57
a. Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57
b. Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57
54. REMOVE CONTROL MAIN FILTER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58
55. REMOVE INPUT DAMPER. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58
56. REMOVE INPUT HOUSING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 510
57. REMOVE ROTOR A . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 512
58. REMOVE REAR COVER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 512
59. REMOVE ROTOR B / C1 CLUTCH HOUSING. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 514
510. REMOVE LUBE FILTER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 515
511. REMOVE OIL PAN . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 516
512. REMOVE SUCTION FILTER. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 516
SECTION 6. MODULE REBUILD
61. FLYWHEEL DAMPER ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61
a. Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61
b. Inspect Front Damper Cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63
c. Replace Front Damper Cover Dowel Pins . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64
d. Inspect Damper . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64
e. Inspect Damper Hub . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65
f. Inspect Rear Damper Cover. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66
g. Replace Rear Cover Bushing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67
h. Assemble Flywheel Damper Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68
62. INPUT HOUSING AND PUMP ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 611
a. Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 611
b. Inspect Plugs and Cooler Fittings. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 613
c. Inspect Input Housing. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 614
d. Front Support Pump Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 614
e. Remove and Inspect Main Regulator Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 616
f. Remove and Inspect Main Relief Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 617
g. Remove and Inspect Lube Regulator Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 618
h. Inspect Pump Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 619
ix
63.
64.
65.
66.
Page
i. Replace Pump Housing Bushing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 623
j. Inspect Front Support. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 624
k. Inspect and Replace Front Support Assembly Roller Bearing . . . . . . . . . . . . . . . . . . 624
l. Inspect and Replace Front Support Assembly Bushing. . . . . . . . . . . . . . . . . . . . . . . 625
m. Assemble Front Support/Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 626
ROTOR A . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 633
a. Remove Main Shaft/P2 Carrier . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 633
b. Remove P1 Planetary . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 635
c. Disassemble Input Shaft/P1 Ring Gear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 636
d. Replace Input Shaft Bushing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 638
e. Inspect P1 Ring Gear. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 640
f. Assemble P1 Ring Gear/Input Shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 640
g. Inspect P1 Sun Gear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 642
h. Disassemble and Inspect P1 Carrier . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 642
i. Assemble P1 Carrier . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 646
j. Disassemble Main Shaft/P2 Carrier . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 648
k. Replace P2 Carrier Bushing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 655
l. Assemble P2 Carrier . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 655
m. Inspect P2 Drive Hub Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 657
n. Replace P2 Drive Hub Bushing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 658
o. Inspect Main Shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 659
p. Inspect Rotor A Hub. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 661
q. Inspect Rotor A Hub Assembly P2 Ring Gear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 662
r. Replace Rotor A Flange Bearing Race . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 663
s. Assemble Main Shaft/P2 Carrier . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 664
t. Replace Speed Signal Wheel Roller Bearing Race . . . . . . . . . . . . . . . . . . . . . . . . . . 667
u. Assemble Rotor A . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 668
INSPECT C1 CLUTCH PACK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 671
C1 CLUTCH HOUSING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 673
a. Remove and Inspect C1 Clutch Hub . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 673
b. Inspect C1 Clutch Housing. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 674
c. Inspect C1 Clutch Housing Roller Bearing. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 675
d. Remove and Replace C1 Clutch Housing Roller Bearing . . . . . . . . . . . . . . . . . . . . . 676
DISASSEMBLE ROTOR B HUB ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 677
a. Replace P3 Carrier Flange Bushing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 681
b. Disassemble P3 Carrier . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 682
c. Assemble P3 Carrier . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 684
d. Disassemble P3 Ring Gear Flange . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 686
e. P3 Ring Gear Flange Bushing Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 688
f. Inspect P3 Ring Gear. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 689
g. Assemble P3 Ring Gear Flange and Ring Gear . . . . . . . . . . . . . . . . . . . . . . . . . . . . 690
INTRODUCTION
67.
68.
69.
610.
611.
612.
Page
h. Inspect Rotor B Hub Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 691
i. Remove and Install Rotor B Roller Bearing Race (Wheel Side) . . . . . . . . . . . . . . . . 693
j. Install Rotor B Roller Bearing Inner Race . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 693
k. Disassemble and Inspect Rotor B Flange Assembly . . . . . . . . . . . . . . . . . . . . . . . . . 694
l. Remove Roller Bearing Race, Rotor B Flange. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 695
m. Install Roller Bearing Race, Rotor B Flange. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 696
n. Assemble Rotor B . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 696
o. Install Selective C1 Housing Thrust Bearing Race. . . . . . . . . . . . . . . . . . . . . . . . . . 6100
REAR COVER. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6103
a. Remove Output Speed Sensors. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6103
b. Remove Output Yoke/Flange . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6103
c. Remove Output Seal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6104
d. Remove and Inspect Rear Cover Plugs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6105
REAR COVER DISASSEMBLY. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6105
a. Remove Output Shaft Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6105
b. Remove and Inspect Taper Bearing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6106
c. Remove and Inspect C1 Piston and Return Spring Assembly . . . . . . . . . . . . . . . . . 6106
d. Inspect Rear Cover. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6106
e. Remove Taper Bearing Race From Rear Cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6107
f. Install Taper Bearing Race Into Rear Cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6109
SELECTIVE TACHOGRAPH WHEEL MEASUREMENT AFTER
BEARING REPLACEMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6110
DISASSEMBLE AND INSPECT OUTPUT SHAFT . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6113
a. Remove and Inspect Tachograph Wheel, Output Shaft O-ring, and Seals. . . . . . . . 6113
b. Remove and Inspect C2 Clutch Backplate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6113
c. Remove and Inspect C2 Drive Hub . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6114
d. Remove and Inspect C2 Clutch Pack . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6115
e. Remove and Inspect C2 Clutch Return Spring Assembly . . . . . . . . . . . . . . . . . . . . 6116
f. Remove and Inspect C2 Piston . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6118
g. Remove and Install Output Shaft Taper Roller Bearing . . . . . . . . . . . . . . . . . . . . . . 6118
h. Inspect Output Shaft. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6119
i. Remove and Install Output Shaft Bushings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6119
OUTPUT SHAFT ASSEMBLY. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6121
a. Install C2 Piston . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6121
b. Install C2 Piston Return Spring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6121
c. Install C2 Clutch Pack, Tachograph Wheel, Sealrings . . . . . . . . . . . . . . . . . . . . . . . 6123
ASSEMBLE REAR COVER MODULE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6125
a. Install C1 Piston Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6125
b. Install Rear cover and Taper Bearing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6126
c. Install Output Seal and O-ring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6126
d. Install Output Yoke/Flange . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6127
e. Install Rear Cover Plugs and Seals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6127
xi

613.
614.
615.
616.
617.
618.
619.
CONTROL MAIN VALVE BODY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

a. Remove Internal Harness . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
b. Control Main Valve Body Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
c. Control Main Valve Body Disassembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
d. Control Main Valve Body Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
e. Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
C1/C2 VALVE BODY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
a. C1/C2 Valve Body Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
b. Solenoid Filter Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
c. C1/C2 Valve Body Solenoid Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
d. C1/C2 Valve Body Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
e. C1/C2 Valve Body Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
f. C1/C2 Valve Body Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
C1/C2 RELAY VALVE BODY. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
a. C1/C2 Relay Valve Body Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
b. C1/C2 Relay Valve Body Disassembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
c. C1/C2 Relay Valve Body Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
d. C1/C2 Relay Valve Body Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
INSTALL INTERNAL HARNESS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
a. Install Oil Level Sensor. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
b. Install Internal Harness . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
DPIM BYPASS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
a. DPIM Bypass Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
b. DPIM Bypass Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
STATOR HOUSING. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
a. Preparation of Stator Housing for Cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
b. Inspect and Replace Stator Housing Roller Bearings . . . . . . . . . . . . . . . . . . . . . . .
INSTALL STATOR HOUSING EXTERNAL PARTS . . . . . . . . . . . . . . . . . . . . . . . . . . . .
a. Install Pressure Taps and Plugs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
b. Inspect and Install DPIM Bypass Valve Assembly . . . . . . . . . . . . . . . . . . . . . . . . . .
c. Install New Lug Box and Access Cover O-rings and Gaskets . . . . . . . . . . . . . . . . .
Page
6128
6128
6129
6129
6130
6131
6132
6132
6133
6133
6135
6137
6139
6139
6139
6140
6141
6142
6142
6142
6143
6143
6143
6144
6144
6144
6147
6148
6148
6149
6150
SECTION 7. EV DRIVE ASSEMBLY

71. INSTALL SUCTION FILTER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
72. INSTALL OIL PAN . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
73. INSTALL LUBE FILTER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
74. INSTALL ROTOR B / C1 CLUTCH HOUSING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
75. INSTALL REAR COVER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
76. INSTALL ROTOR A. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
77. INSTALL INPUT HOUSING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
78. INSTALL INPUT DAMPER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
79. INSTALL CONTROL MAIN FILTER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
xii
71
71
71
72
73
75
76
77
79
INTRODUCTION
710.
711.
712.
713.
Page
INSTALL OUTPUT SPEED SENSORS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 710
INSTALL MOTOR SPEED SENSORS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 710
a. Install Motor Speed Sensors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 711
INSTALL OUTPUT YOKE/FLANGE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 711
a. Remove Ev Drive From Repair Stand . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 712
INSTALL THE Ev DRIVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 712
a. Fill the Ev Drive. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 714
SECTION 8. WEAR LIMITS AND SPRING DATA

81. WEAR LIMITS DATA . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
a. Maximum Variations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
b. Maximum Relative Movement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
c. Cleaning and Inspection. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
82. SPRING DATA. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
a. Spring Replacement. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
b. Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
81
81
81
81
81
81
81
SECTION 9. CUSTOMER SERVICE

91. OWNER ASSISTANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 91
92. SERVICE LITERATURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 92
APPENDIX A. MATERIAL SAFETY DATA SHEET (MSDS)
APPENDIX B. STATOR HOUSING RE-USE REQUIRMENTS
APPENDIX C. EV DRIVE POST-OVERHAUL TESTING
APPENDIX D. BIPD AND DIPD TEST PROCEDURES
FOLDOUTS
Foldout 1.
Foldout 2.
Foldout 3.
Foldout 4.
Foldout 5.
Foldout 6.
Foldout 7.
Foldout 8.
Foldout 9.
Foldout 10.
Foldout 11.
Foldout 12.
Foldout 13.
Foldout 14.
Allison Electric Drives

Input Damper
Input Housing
Front Support/Pump
Rotor A
Rotor B
Stator Housing
Oil Pan and Filters
Control Module
C1 Housing
Output/Rear Cover
First and Reverse Range Hydraulic Schematic
Second Range Hydraulic Schematic
Neutral Range Hydraulic Schematic
xiii

NOTES
xiv
SECTION 1GENERAL INFORMATION

11.
SCOPE OF MANUAL
1. The organization or individual has the required

knowledge of the task through:
Formal instruction at Allison Transmission
a. Content and Organization
or a Distributor training facility.

On-the-job instruction by an Allison
Transmission Distributor representative.
Experience in performing the task.
This Service Manual describes the maintenance

procedures for the EV Drive of the EP 40/50
System.
Major components of the EV Drive are
described and their functions explained.

Detailed instructions are provided for
disassembly, rebuild, and re-assembly of the

the EV Drive.
2. The work environment is suitable to prevent

contamination or damage to the EV Drive
parts or assemblies.
3. The required tools and fixtures, listed in
Table 31, are available.
4. Reasonable and prudent maintenance practices are used.
b. Illustrations
1. The text is supported with line drawings, exploded, and cross-sectional views. Maintenance procedures are illustrated by line drawings. Cross-sections show the relationship of
assembled parts. Cross-sections and exploded
views are on foldout pages in the back of the
manual.
2. Illustrations show correct procedures for all
models.
c. Maintenance Information
Each task described in this manual has been successfully completed by service organizations and
individuals. Not every service organization or individual possesses the required special tooling,
training, or experience to perform all described
tasks. However, any task may be performed if the
following conditions are met.
NOTE:
Service organizations and individuals are encouraged to contact their local Allison Transmission Distributor for information and guidance on any task
outlined in this manual.
d. Dual Power Inverter Module
and Energy Storage System
Removal and installation of the Dual Power Inverter (DPIM) and the Energy Storage System
(ESS) are included in this manual. No other
DPIM or ESS service information is included.
Refer to SM4162EN for ESS service information.
12.
SUPPLEMENTARY
INFORMATION
Supplementary information will be issued, as required,

if any changes occur after publication of this manual.
Consult with your dealer or distributor to be sure you
have the latest information.
11
P3 SPEED SENSOR
P1 SPEED SENSOR
V10552.00.00
Figure 11. EV DriveRight Side
OIL TO COOLER PORT

HIGH VOLTAGE
LUG BOX
FOR MOTOR "A"
P2 MOTOR A
SPEED SENSOR
P4 MOTOR B
SPEED SENSOR
OIL FROM DPIM PORT
OIL TO DPIM PORT
NAMEPLATE
OIL FROM COOLER PORT
FILL TUBE PROVISION

MAIN PRESSURE TAP
Figure 12. EV DriveLeft Side
12
V07584.05.00
GENERAL INFORMATION
HV DC
INPUT/OUTPUT
INVERTER A
HV AC
INPUT/OUTPUT
V08073.01.00
INVERTER B
V08073.01.00
Figure 13. DPIMHigh Voltage Input/Output
OIL COOLING
PORTS
V08066.01.00
V08066.00.01
Figure 14. DPIMOil Cooling Ports
13
MAIN ESS CONNECTOR
ESS NAMEPLATE
HIGH VOLTAGE TERMINALS
V08657.00.01
Figure 15. ESSLeft-Front View
COOLING AIR
OUTLET
COOLING AIR
INLET
V08649.01.01
Figure 16. ESSLeft-Rear View
14
GENERAL INFORMATION
13.
ORDERING PARTS
d. DPIM Nameplate
a. Model Nomenclature
The elements in the nomenclature structure
indicating propulsion system series and drive unit
type are the letters P and V. The letter P
indicates the propulsion system is a Parallel
system operating in parallel, or in conjunction
with, an internal combustion engine. The letter
V is associated with Variable. This term
denotes variability relating to varying power
between engine torque and electric motor torque
within the EV Drive. It should also be noted that
the letter P refers to the complete propulsion
system of EV Drive, Dual Power Inverter
Module (DPIM), TCM and VCM, and Energy
Storage System (ESS). The V designator refers
specifically to the EV Drive.
b. EV Drive Nameplate
The DPIM nameplate (refer to Figure 19) is located on the Motor B side panel of the DPIM. The
nameplate is printed with the model, serial number, part number, and date of manufacture. Use all
of these numbers when ordering replacement
parts or requesting service information.
e. Parts Catalog
Replacement parts are listed in Parts Catalog
(PC3717EN). Do not order by the item numbers
used on exploded views in this manual. Use the
Parts Catalog to determine the correct part number.
Order all replacement parts from your distributor
or authorized dealer. Refer to the Yellow Pages for
your nearest authorized service outlet. Listings are
under TransmissionTruck, Tractor, etc.
14.
EV
The
Drive nameplate (refer to Figure 17) is
located on the left side of the EV Drive. The
nameplate is imprinted with the EV Drive
model, serial number, and date of manufacture.
Use all of these numbers when ordering replacement parts or requesting service information.
GENERAL DESCRIPTION
a. EP 40/50 System Design Features

The EP 40/50 System is fully automatic and
electronically controlled. The EV Drive has
three ranges: forward, neutral, and reverse. The
EV Drive incorporates a variety of standard design features.
c. ESS Nameplate
The ESS nameplate (refer to Figure 18) is located
on the connector side panel of the ESS. The nameplate is imprinted with the ESS assembly part
number and serial number. Use all of these numbers when ordering replacement parts or requesting
service information.
Made In Japan
29541231
EV-PP6R5R23B
7010000500
Panasonic EV Energy Co., Ltd.

V08651.00.00
Figure 18. ESS Nameplate
XXXX
XXXXXXXX
V08418.00.00
Figure 17. EV 40/50 Systems

Electric Drive Nameplate Components
V08434.00.01
Figure 19. DPIM Nameplate
15

1. EV Drive-to-Engine Coupling. The input
housing of the EV Drive mates directly to a
SAE No. 2 flywheel housing. Flexplate drive
provides engine-to-EV Drive torque transfer.
2. Planetary Gearing. The planetary gear train
includes three constant-mesh, helical gear
planetary sets.
3. Clutches. Two clutches (one rotating and one
stationary) direct the flow of torque through
the EV Drive. All clutches are hydraulicallyactuated and spring-released, with automatic
wear compensation. Clutches are cooled by
transmission fluid. The transmission electronic
control module (TCM) signals solenoid valves
to apply and release clutches based on speed
and power combinations.
4. Hydraulic System. A common hydraulic
system serves the EV Drive and DPIM.
Transmission fluid for all hydraulic operations,
lubrication, and cooling comes from the sump
and is supplied by the charging pump. Fluid
flow to the DPIM is regulated internally by the
EV Drive.
5. Transmission Fluid Filtration. Fluid filtration
is provided by three filter systems. A suction
filter, located in the EV Drive sump, provides
general protection to the entire hydraulic
system by filtering large particulates. A spin-on
filter provides full-time protection for the
control solenoids. The spin-on filter is
externally located in the stator housing at the
lower left front of the EV Drive. A canister
style lube filter provides protection for the
lubrication circuit. The lube filter is located
under the lube filter cover in the stator housing
at the lower right front of the EV Drive.
6. Remote Oil Cooler. The oil-to-cooler port (oil
out) is located at the top of the input housing.
Cooler return (oil in) is located on the lube
filter cover at the lower front right of the EV
Drive.
7. Output Yokes/Flanges. A variety of output
yokes or flanges are available to meet vehicle
driveline requirements. Yokes or flanges are
factory installed and are specified by the vehicle manufacturer.
16
8. Electronic Control Modules. Two microprocessors, a Transmission Control Module

(TCM), and a Vehicle Control Module (VCM)
control the EP 40/50 System. The TCM and
VCM monitor and control system components,
store system control calibrations, and perform
diagnostic functions. The TCM/VCM part
number is identified on the data label (refer to
Figure 110). Calibrations for the EP 40/50
System are loaded into the components at a
system level. The system calibration is
identified by a System ID (SID) number. The
SID is identified on the calibration labels (see
Figures 111 through 114). The system
calibration contains compatible software and
calibrations for the TCM, VCM, ESS, and
DPIM based on the software and hardware
compatibility of each component. The SID
number is required when recalibrating a TCM/
VCM, DPIM, or ESS.
EP 40/50
EP 40/50
EP 40/50
ECU-TCM, 12 VOLTS
29544007
MM - DD - YYYY
020285
466
MODEL : 29544007
10R-020284
S/N XXXXXXXXXXXXXXXX
V08070.03.00
Figure 110. TCM/VCM Identification Label
TCM_IIO
V08654.00.00
Figure 111. TCM Calibration Label
GENERAL INFORMATION
EPCU_B
V08653.00.00
Figure 112. DPIM Calibration Label (B)
10. Dual Power Inverter Module (DPIM). The

DPIM converts AC electricity to DC electricity
and DC electricity to AC electricity. During regenerative braking, AC electricity generated by
the EV Drive is converted to DC electricity
and stored in the ESS. DC energy drawn from
the ESS is converted to AC energy for the EV
Drive. The EV Drive then combines electric power with engine power, a process called
torque blending, to accelerate the vehicle.
11. Pushbutton Shift Selector (PBSS). The pushbutton shift selector (refer to Figure 115)
commands direction of operation rather than
selecting an operating range. The direction of
operation displays on the shift selector. Shift
selector directional buttons are:
VCM_IIO
DForward, commands
movement, F displays
V08656.00.00
Figure 113. VCM Calibration Label (A)
EPCU_A
V08652.00.00
Figure 114. DPIM Calibration Label (A)
9. Energy Storage System (ESS). The ESS stores

energy generated by the EV Drive and captured during regenerative braking. This energy
is available on demand to the EV Drive. The
energy storage unit never requires off-board
charging.
forward
vehicle
NNeutral, commands neutral, no vehicle

movement, N displays
RReverse, commands rearward vehicle
movement, R displays
Up and Down Arrow Buttons. Pressing the
(Down) arrow button while in Forward
operation commands the EP 40/50 System to
increase the regenerative braking effect.
Regenerative braking provides the same
braking function as does a hydraulic retarder.
The PBSS displays F or L to identify the level
of regenerative braking in use. Unlike a
transmission pre-select downshift, increasing
regenerative braking does not limit forward
speed to a particular range. The EP 40/50
System remains in the selected regenerative
braking mode until the vehicle ignition is
turned off, the (Up) or (Down) arrows are
used, or N (Neutral) is selected. When ignition
is turned on or N (Neutral) is selected, the
system will return to the default regenerative
braking level.
17

Transmission Control Module (TCM) as follows:
The EV Drive may continue to operate
with limited/de-rated operation.

Direction changes and shifts from neutral-
to-range may not occur.
MODE
Whenever a System Malfunction Indicator
Lamp is displayed, the TCM logs a

diagnostic code in memory. These
diagnostic codes can be accessed through
the PC-based Allison DOC For PC
Service Tool (AED).
V07611.00.00
Figure 115. Pushbutton Shift Selector
Simultaneously pressing and holding the

(Up) and (Down) arrow keys for five seconds, while in N (Neutral), starts the Oil Level
Sensor Mode (OLS). Simultaneously pressing
the (Up) and (Down) arrow keys again,
while in OLS Mode, starts the diagnostic mode
in which diagnostic codes can be viewed.
15.
TROUBLESHOOTING
NOTE:
Refer to the TS3715EN EP 40/50 System
Troubleshooting
Manual
for
in-depth
troubleshooting procedures.
a. Before Performing Repairs
Before attempting to repair the EV Drive, identify the faulty condition and its probable cause.
b. System Malfunction Indicator Lamps
1. The System Malfunction Indicator Lamps are
original equipment manufacturer (OEM)supplied and usually located on the vehicles
instrument panel.
2. The System Malfunction Indicator Lamps are
illuminated briefly during vehicle start-up as a
bulb test.
3. When a System Malfunction Indicator Lamp is
ON, operation may be restricted by the
18
NOTE:
Diagnostic codes can be logged without illuminating
the System Malfunction Indicator Lamps. This occurs when the TCM senses a problem that does not
require immediate service attention.
c. Personal Computer (PC)-Based
Diagnostic System
Control system diagnostics are performed using a
Windows PC operating system and interface/
software which is available through Allison
Transmission tool sources. The PC is a receiver/
transmitter/display medium that allows the service technician to communicate with the system.
Typical troubleshooting activities include installation checkout and diagnostic code retrieval.
1. Allison Diagnostic Optimized Connection
(Allison DOC) For PC (AED)Service Tool
provides tabular, graphical, and chart displays
of real-time and recorded system data. A Help
system is incorporated into the Allison DOC
For PC (AED)Service Tool software and a
printed User Guide is shipped with each Allison DOC For PC (AED)Service Tool Installation CD-ROM.
2. The User Guide and Users Manual contains
information for performing the following:
Display (retrieve) diagnostic trouble codes
(DTCs). For a complete list of codes and

more detailed information, refer to the
Electronic Troubleshooting Manual
(TS3715EN).
Clear diagnostic codes
GENERAL INFORMATION
Obtain EV Drive data such as input speed
Improperly mounted electronic control
or sump fluid temperature

A solenoid test
Clutch diagnostics
components
Poor connector seals (where applicable)
Exposed harness wires
d. Troubleshooting When No Diagnostic

Codes Are Present
EMI generating components and
accessories
Always start with the basics:
Loose ground connections
Make sure the shift selector is in the

appropriate range.
Determine the fluid level.
Make sure vehicle 12/24V batteries are
properly connected and charged.
Make sure electrical connections are
properly made.
Inspect support equipment for proper
installation and operation.
Refer to General Troubleshooting of
Performance Complaints section of the EP 40/
50 System Troubleshooting Manual
(TS3715EN).
These troubleshooting charts list a variety
of conditions that may or may not relate to
the TCM.
Some conditions and suggested test include
mechanical and hydraulic items.
If the troubleshooting charts refer you to a
system test, use the diagnostic code
troubleshooting information that best applies
to the situation.
e. Troubleshooting Intermittent
Diagnostic Codes
1. Intermittent codes are a result of conditions
which are not always present.
2. When conditions causing the code exist, the
code is logged in memory. The code stays in
memory until it is manually cleared or cycled
out by forty code-free warm-up cycles.
3. When intermittently occurring codes exist, inspect for the following items:
Dirty, damaged or corroded harness
connectors and terminals

Terminals not fully seated in connectors
Damaged harnesses (due to poor routing,
chafing, excessive heat, tight bends, etc.)
4. To help locate intermittents, it sometimes helps

to place the appropriate tester on the suspect
component or circuit and simulate operating
conditionswiggle, pull, bump, and bend
while watching the tester.
16.
RECOVERY OF DEPLETED
ENERGY STORAGE SYSTEM
If the ESS has been totally depleted (DTC 80-45 active

and cleared with Allison DOC still resulting in no
engine crank, refer to the Troubleshooting Manual,
TS3715EN) and cannot crank the engine, a 24V
engine starter must to be installed in order to start the
engine and allow the EP 40/50 System to charge the
depleted ESS.
1. Remove engine flywheel housing cover plate
and install a 24V engine starter and a method
of activating it.
2. Key-on the vehicle (the TCM will wake up the
engine) and wait for the engine grid heaters to
finish preheating the intake air.
3. Activate the engine starter (the WAIT-TOSTART lamp will remain illuminated) until the
engine has started. The 12V battery may need
to be charged (by charging the 24V supply system if appropriate) for the starter to operate
properly. The engine will go to low idle governed speed once it is running.
4. Use Allison DOC to clear any active/inactive
diagnostic codes. The engine control will
change from low idle governed to EV Drive
control. The engine will begin to charge the
ESS. This may take an extended period of
time, during which the vehicle may be moved.
A reduced amount of output power is available
at first because the EP 40/50 System
automatically reduces output power to
accommodate the ESS low state-of-charge
19

condition. Follow charge procedures for ESS
as outlined in the ESS Components Storage
and Preservation Requirements, Section 110
before returning vehicle to service.
17.
EV DRIVE STORAGE
AND PRESERVATION
REQUIREMENTS
VCI#10
Daubert Chemical
(Chicago, IL)
(708) 496-7353
Biobor JF
Hammonds Technical Services, Inc.

(Houston TX)
(800) 582-4224
c. One Year Storage (With Fluid)
a. Preservation Methods
When the EV Drive is stored, or is inactive for
an extended period of time (one or more years),
specific preservation methods are required to prevent damage from rust, corrosion, and organic
growth in the transmission fluid.
b. One Year Storage (Without Fluid)
1. Drain transmission fluid.
2. Seal all openings and the breather with
moisture-proof tape. A Service Kit is available
with all necessary plugs; refer to the EP 40/50
System Parts Catalog (PC3717EN).
3. Secure the damper assembly with retaining
brackets. A Service Kit is available with all
necessary hardware; refer to the EP 40/50
System Parts Catalog (PC3717EN).
1. Drain the fluid and replace the control main

and lube filter elements.
2. Fill the EV Drive to operating level with a
mixture of one part VCI#10 (or equivalent) to
30 parts TES-295 certified fluid or
TranSynd. Add 1 ml of Biobor JF (or
equivalent) for every 10 liters (14 teaspoon for
every 3 gallons) of fluid in the system.
NOTE:
When calculating the amount of Biobor JF required, use the total volume of the cooling system,
not just the amount required to fill the EV Drive.
Include external lines, filters, cooler, and DPIM.
3. Operate the EV Drive for approximately
10 minutes at engine idle in Neutral.
4. Coat all exposed, unpainted surfaces with corrosion preventative grease such as petrolatum
(MIL-C-11796, Class 2).
4. Operate the vehicle to a minimum road speed

of 30 mph.
5. Spray 30 ml (one ounce) of VCI#10 (or equivalent) into the EV Drive through the fill port
labeled OIL FILL.
5. Continue to operate the EV Drive until normal

operating temperature is reached6071C
(140160F).
6. If additional storage time is required, repeat

Step 5 at yearly intervals.
6. As soon as the EV Drive is cool enough to

touch, seal all openings and the breather with
moisture-proof tape.
NOTE:
Volatile Corrosion Inhibitor (VCI#10) is used to prevent corrosion on exposed metal surfaces during
storage. It is installed as a vapor and adheres to surfaces to prevent oxygen contact and subsequent rust.
Biobor JF is a biocide used to prevent any microbiological (bacterial/fungal) growth during storage.
110
Vendor Information:
7. Coat all exposed, unpainted surfaces with corrosion preventative grease such as petrolatum
(MIL-C-11796, Class 2).
8. If additional storage time is required, repeat
Steps 2 through 7 at yearly intervals. It is not
necessary to drain the transmission fluid each
year. Just add VCI#10 and Biobor JF (or
equivalents).
GENERAL INFORMATION
18.
DPIM STORAGE
AND PRESERVATION
REQUIREMENTS
d. Installation
1. Confirm vehicle low voltage wiring integrity
using DPIM Installation Protection Device.
a. Removal
CAUTION:
1. Place vehicle on level surface with parking

brake set or wheels chocked.
2. Perform electrical
procedure.
disconnect
If test fails DO NOT connect low voltage

connections to DPIM, damage may occur.
verification
3. Drain transmission fluid (refer to Draining

Fluid).
4. Disconnect inverter A and B 32 pin connectors.
5. Disconnect DC lugs
6. Remove wire pass-through assembly from lug
box assembly. Label +/- on each wire before
removal.
7. Repeat removal on AC lugs and pass-throughs.
If wiring is not labeled, label each wire with
phase A, B, or C.
8. Remove oil cooler lines.
Refer to Appendix D for DIPD operating

instructions, test procedures, and pass/fail
criteria.
2. Install DPIM housing to vehicle chassis.
Always use new isolation mounts or isolation
mounting kit P/N 29541507. Torque bolts to
30 lb ft max.
3. Install cooler lines.
4. Install high voltage cabling and wire passthrough assemblies. Ensure phasing and +/labels on DPIM correlate with marks made
during removal. Confirm that lug box housing
are clean and no debris or metal has entered the
enclosure.
5. Install 32-pin and 24-pin connectors.
NOTE:
A small amount of fluid will leak from DPIM and
cooler lines.
6. Reconnect components in reverse order made

during Electrical Disconnect Verification
Procedure (refer to Section 2).
9. Remove bolts and vibration isolation mounts

retaining DPIM housing to vehicle
(3 locations).
7. Refill EV Drive with approved transmission

fluid and perform fluid check procedure.
19.
b. Storage (With Fluid)

Follow procedures outlined in the One Year Storage (With Fluid) of the EV Drive Components
Storage and Preservation Requirements.
c. Storage (Without Fluid)
The DPIM should be stored in its original shipping container. The storage environment should
be clean and prevent exposure to moisture or condensation. All shipping plugs and lug housing
covers must be installed to prevent intrusive contamination. A Service Kit is available with all
necessary plugs; refer to the EP 40/50 System
Parts Catalog (PC3717EN).
SEASONAL STORAGE OF
EP 40/50 SYSTEM
Properties that use an EP 40/50 System equipped vehicle seasonally have need to store the vehicle during
the off-season. The following procedures describe the
steps to take to:
Prepare the EP 40/50 System for seasonal
storage.
Maintain the EP 40/50 System during
seasonal storage.
Restore the EP 40/50 System to operation
after seasonal storage.
111

a. Preparing the EP 40/50 System for Seasonal
Storage
Perform the following pre-storage tasks:
1. Using the Pushbutton Shift Selector (PBSS) or
Allison DOC for PC (AED)Service Tool,
determine if any diagnostic trouble codes are
present in the system. Using the EP 40/50
Troubleshooting Manual TS3715EN, take
appropriate action to resolve any codes.
2. Change EV Drive Control Main and Lube oil
filters (refer to Section 3 Preventive Maintenance). Refer to Service Information Letter,
10-TR-99 Rev. D, for additional information.
3. Inspect for damage and clean the ESS cooler
air inlet filter. Replace any damaged
components. Refer to SM4162EN ESS Service
Manual.
4. With the engine at idle, use the PBSS to determine the fluid level in the EV Drive. Adjust
the fluid level as necessary (refer to Section 3
Preventive Maintenance).
b. Maintaining the EP 40/50 System During
Seasonal Storage
Perform the following at approximately one
month intervals:
1. Start the vehicle and let the engine operate at
low idle while examining the dash for warning
lights.
2. Using the Pushbutton Shift Selector (PBSS) or
Allison DOC for PC (AED)Service Tool,
determine if any diagnostic trouble codes are
present in the system. Using the EP 40/50
Troubleshooting Manual TS3715EN, take
appropriate action to resolve any problems.
3. Activate the vehicle climate control system.
Select air conditioning, if possible.
4. After the engine has been operating at idle for
10 minutes depress the service brake and shift
into D, wait 30 seconds and shift back to N.
112
5. After the engine has been operating at idle for

15 minutes, slowly increase the throttle to full
throttle (2000 rpm). After one minute, allow
the engine to idle.
6. After the engine has been operating for 20
minutes, use the PBSS to check fluid level.
Add or drain fluid as necessary (refer to Section 3 Preventive Maintenance).
7. After 30 minutes of engine operation, shut
down and secure the vehicle.
c. Restoring the EP 40/50 System After
Seasonal Storage
Perform the following tasks before restoring an
EP 40/50 System equipped vehicle to service:
1. Start the engine and operate it at low idle.
2. Monitor the dash for warning lights. After the
engine has been running 5 minutes, depress the
service brake and shift into D. After 30 seconds, shift back to N.
3. With the vehicle in N, slowly increase the engine rpm to full throttle. Reduce the engine
rpm to idle.
4. After 2 minutes, take a sample of the EV
Drive Unit fluid using the proper equipment
and techniques as outlined in the Technicians
Guide to Automatic Transmission Fluid
Analysis, GN2055EN. Shut down and secure
the vehicle.
5. Submit the oil sample for oil analysis.
6. If the oil analysis indicates that the oil is within
Allison Transmission fluid limits, put the vehicle back into service (refer to Service Information Letter, 13-TR-90, for information on
Allison Transmission fluid limits). If the oil
analysis indicates that the oil has high moisture
content or other unacceptable results outside of
Allison Transmission fluid limits, change the
transmission fluid and both EV Drive Unit
filters before placing the vehicle into service.
GENERAL INFORMATION
110. RESTORING EV DRIVE
FOR SERVICE
111. RESTORING ESS FOR SERVICE
CAUTION:
a. Follow installation procedures outlined in ESS

Service Manual SM4162EN. Install auxiliary
cooling system if equipped. Allow engine to idle
in Neutral for a minimum of 1 hour.
Whenever an EV Drive is exchanged, the TCM

clutch fill and main boost adaptives must be
reset. This will erase previous adaptive
information and reset the TCM to its default
values. Use Allison DOC For PC (AED); select
Action Request, Reset Adaptives, checking
the boxes for C1, C2, and Main Boost adaptive
reset.
NOTE:
a. EV Drive Exterior
NOTE:
Wash all external grease from the EV Drive

with mineral spirits.
b. Sealed Breather and Openings
Remove all tape from openings and the breather.
c. New EV Drive
If the EV Drive is new, drain the residual preservative fluid. Refill the drive to the proper level
with TES-295 certified fluid or TranSynd.
d. Stored Without Fluid
If the EV Drive was prepared for storage
without fluid, drain the residual fluid and replace
the control main circuit and lube circuit filter
elements. Fill the drive to the proper level with
TES-295 certified fluid or TranSynd.
e. Stored With Fluid
If the EV Drive was prepared for storage with
fluid, it is not necessary to drain and refill the
drive with new fluid. Determine the proper fluid
level using the PBSS or Allison DOC for PC
(AED). Add or drain fluid as required to obtain
the proper level.
f. Follow installation procedures
Section 7 Paragraph 713.
outlined
in
During installation and removal, the ESS should

not be tilted in any direction more than 45 degrees.
Prior to installation, confirm low voltage wiring

integrity using the Battery Pack Installation
Protection Device (BIPD) Refer to Appendix D for
BIPD operating instructions, test procedures, and
pass/fail criteria.
b. Using Allison DOC For PC (AED), display any

ESS SPN FMI diagnostic trouble codes.
c. Using Allison DOC For PC (AED), make sure
that ESS operating temperature is within
acceptable limits: 23 to 52C (10 to 125F).
112. RESTORING DPIM

FOR SERVICE
a. Remove all shipping/storage plugs from DPIM.
Follow installation procedures outlined in
Section 52.
NOTE:
Before installation, confirm low voltage wiring integrity using DPIM Installation Protection Device
(DIPD).
g. Using Allison DOC For PC (AED)Service

Tool, display any diagnostic trouble codes.
b. Using Allison DOC For PC (AED)Service

Tool, display any diagnostic trouble codes.
h. Using Allison DOC For PC (AED)Service

Tool, make sure that sump and motor operating
temperatures are within acceptable limits. Refer
to Table 13.
c. Using Allison DOC For PC (AED)Service

Tool, make sure that DPIM IGBT operating
temperatures are within acceptable limits: 23 to
95C (10 to 203F).
113

113. OPERATING INSTRUCTIONS
114. SPECIFICATIONS AND DATA
Detailed EV Drive operation information is in the

EP 40/50 System Operators Manual (OM3491EN).
Refer to the latest edition.
The following tables provide a quick reference to the

major characteristics of the EV Drive. More detailed
information may be obtained from Tech Data Book
(SA3541EN).
Table 11. Input/Output Rating

Parameter
EV 40
EV 50
Unit
Maximum Input Speed
2300
2300
rpm
Maximum Gross Input Power
209 (280)
246 (330)
kW (hp)
Input Torque
Maximum Gross
1234 (910)
1424 (1050)
Nm (lb ft)
Output Torque*
Forward Operation
Regenerative Braking/reverse Operation
4745 (3500)
2983 (2200)
5423 (4000)
2984 (2200)
Nm (lb ft)
Nm (lb ft)
3000
3300
rpm
3000
450
3300
450
rpm
rpm
18 182 (40,000)
31 818 (70,000)
kg (lb)
Maximum Output Shaft Speed

Maximumforward
Maximumreverse
Gross Vehicle Weight (GVW)
* Output torque ratings are peak transient, not continuous.
Table 12. Hydraulic System

Fluid Type
TES-295, TranSynd (refer to Section 25 for fluid recommendations)
Filters
Control circuit; external spin-on, lube circuit; internal cartridge
Cooler
OEM supplied, oil-to-air

Table 13. Temperatures
Parameters
Value
Unit
Minimum Start-up, TranSynd
30 (22)
C (F)
Sump, Minimum Continuous
40 (104)
C (F)
Sump, Typical Continuous
80 (176)
C (F)
Sump, Maximum Intermittent
121 (250)
C (F)
Table 14. Dry Weights

Drive Unit
EV Drive
114
Configuration
Nominal Value
Unit
417 (919)
kg (lbs)
SECTION 2ELECTRICAL SAFETY

21.
ELECTRICAL SYSTEMS
a. High Voltage Interlock Loop
WARNING!
The Allison Electric Drive EP 40/50 System uses
potentially hazardous electrical energy. All EP 40/50
System components are identified with warning labels or symbols (see Figure 21, Figure 22,
and Figure 23). DO NOT attempt to service
components containing potentially hazardous
electrical energy if you are not trained to do so.
All persons working with potentially hazardous
electric energy should familiarize themselves
with safe electrical work practices. References to
publicly available documentation that can assist
a technician in developing the safe electrical
work practices required to service the EP 40/50
System electrical system are at the end of this
section.
EP 40/50 System Normal Operating Conditions:
ESS Voltage Range:
432780 VDC
DPIM Voltage Range: 350 to +350A
CAUTION
HIGH VOLTAGE
To help avoid serious personal injury from electrical shock:
Do not remove covers

Electrical connectors to be removed only by qualified service technician
No servicable components. Return to designated service center for repair
V10323.00.00
16268915
The Allison EP 40/50 System uses a High

Voltage Interlock Loop (HVIL) to attempt to
prevent access to energized potentially hazardous
electrical circuits. The HVIL is comprised of a
12V control circuit routed to switches on cover
plates located on all hybrid components where
potentially hazardous electrical energy may exist.
When a switch is open the HVIL circuit is open,
and is described as invalid.
An open HVIL circuit detected during ignition
key-on will prohibit the pre-charge sequence
from occurring (ESS relays will remain open).
Diagnostic code 80 22 (HVIL Invalid
Shutdown) will be logged and the STOP
SYSTEM lamp will illuminate. Engine cranking
will not occur.
An open HVIL circuit detected during forward or
reverse operation will log DTC 80 21 (HVIL
Invalid). DTC 80 21 is not displayed on the PBSS
and does not result in an active system shutdown.
If DTC 80 21 remains active when N (Neutral) is
selected and output speed is zero, DTC 80 22 will
be logged.With DTC 80 22 active, the STOP
SYSTEM lamp will illuminate and an active
system shutdown will occur.
PRINTED IN U.S.A.
V10323.00.00
V10324.0.00
Figure 21. DPIM Warning Label
DANGER
High Voltage Inside / Alkaline Electrolyte

T o a vo id in j u r i e s , b u r n s o r e l e c t r i c s h o c k s :
N e ve r d isa s s e m b l e t h i s b a t t e r y u n i t o r r e m o v e i ts c o v e r s .
- Service by Qualified Technician. -
V10322.00.00
A v o i d c o n t a c t a l k a l i ne el ectr o l yte wi th eyes, ski n o r cl o th es. I n even t o f accide nt , f lus h w it h

w a t e r a n d g e t m e d ical h el p i mmed i atel y.
K e e p c h i l d r e n a w a y fr o m th i s
u n i t.
D o n o t p u n c t u r e o r i mp act o n th i s u n i t wh en o p er ati n g fo r kl i ft o r exp o se to ope n f la me or
i n c i n e r a t e a s e x c e s si ve h eat may g en er ate fi r e an d el ectr o l i te my l eak o u t.
T o t h e q u a li f i e d E V T e c h n i c i a n s :
Be
sure
to
read
the
Repair
Manual
when
servicing
or
replacing
the
battery.
MADE IN JAPAN
V10324.00.00
V10322.00.00
Figure 22. ESS Warning Label
Figure 23. EV Drive Warning

(Lug Box)
21

ALLISON ENERGY
STORAGE SYSTEM
HV DC
MOTOR A
HV AC
Ev DRIVE
A
DPIM
600V DC
MOTOR B
Refer to the EP 40/50 System Troubleshooting

Manual (TS3715EN) for troubleshooting procedures.
LOW
VOLTAGE
= HVIL LOCATIONS
VEHICLE
IGNITION
SWITCH
HYBRID
ECU
c. General Electrical Safety Precautions

V08188.00.00
Figure 24. HVIL Locations
Always treat electrical systems as if they are
powered ON.
Make sure vehicle ignition is OFF.
Always follow the Electrical Disconnect
WARNING!
DO NOT rely on the HVIL or control systems to
de-energize the system. Always perform the appropriate tests to be sure the system is discharged
before servicing components.
may result in injury. Failure to follow proper
safety procedures may result in serious personal
injury or death.
NOTE:
Refer to the EP 40/50 System Troubleshooting
Manual (TS3715EN) for troubleshooting procedures.
b. Isolation Fault Detection
The Allison EP 40/50 System uses Isolation
Fault Detection to identify a high voltage circuit
short to the vehicle chassis.
Diagnostic Trouble Codes 73 90 (Inverter A
isolation faultCaution) and 74 90 (Inverter B
isolation faultCaution) are logged when the
isolation resistance between the high voltage
circuit and the chassis ground is measured at less
than 50 Mega Ohms (M). This code is not
displayed on the PBSS and does not illuminate a
dash lamp.
Diagnostic Trouble Codes 73 91 (Inverter A
isolation faultShutdown) and 74 91 (Inverter B
isolation faultShutdown) is logged when the
isolation resistance between the high voltage
circuit and chassis ground is less than 1 Mega
Ohm (M) The STOP SYSTEM lamp is
illuminated and an active system shutdown
occurs. The engine cannot be restarted while
73 91 and 74 91 diagnostic codes are active.
22
NOTE:
Verification Procedure before servicing a

component where potentially hazardous
voltages may exist.
d. Electrical Disconnect Verification Procedure
Before beginning any repair on the EV Drive,
DPIM, or ESS you must perform the following
Electrical Disconnect Verification Procedure:
1. Vehicle ignition must be turned OFF.
2. If the vehicle is so equipped, place the switch
for the +24V/+12V battery disconnect in the
OFF position. Use a lockout device to prevent
unauthorized access to the +24V/+12V battery
switch.
3. Remove connector PI120 (the low voltage
24-pin connector) from the DPIM (Figure 25).
4. Remove the main ESS connector (31-pin Deutsch) from the ESS.
5. Remove the DPIM DC bus access cover.
6. Use an approved voltmeter (UL Listed E59794
and CSA Certified LR44340, IEC-1010-1
1000V Cat III input protection), such as a
Fluke 87 and proper personal protective equipment (Class 0 isolation gloves), to measure the
following voltages:
Measure the DC voltage between DC+
and DC
Measure DC (+) to DPIM chassis
Measure DC () to DPIM chassis
All voltage measurements must read less than
3 VDC before proceeding to the next step. If
measurements are not less than 3 VDC, replace
the access cover and allow the DPIM to dissipate residual energy.
SECTION 2ELECTRICAL SAFETY

32-PIN
CONNECTOR
H08194.00.00
32-PIN
CONNECTOR
V08674.00.00
24-PIN
CONNECTOR
V08674.00.00
Figure 25. DPIM Low Voltage Disconnect Points
Figure 27. Measure Voltage Between Each

DPIM DC HV Terminal and Ground
H08193.00.00
H08190.00.00
Figure 26. Measure Voltage Between

DPIM DC Terminals
7. Remove both HVIL covers on the ESS

(Figure 28).
8. Using proper personal protective equipment
(Class 0 isolation gloves), remove the
positive (+) and negative () connectors
from the ESS (Figure 28). Use a lockout
device to prevent unauthorized reinstallation
(Figure 210).
Figure 28. ESS HVIL Cover Removal, Disconnect

Electrical Connector
9. Remove AC lug access covers on the DPIM.

Use an approved voltmeter (UL Listed E59794
and CSA Certified LR44340, IEC-1010-1
1000V Cat III input protection), such as a
Fluke 87 and proper personal protective
23

equipment (Class 0 isolation gloves), to
measure the following voltages:
AC Phase to Phase; AB, AC, CB
Each AC Phase to Chassis ground
(Figure 29).
10. Before proceeding to the next step, all measurements must be read less than 3 VDC. If
measurements are not less than 3 VDC, replace
access lid cover and allow DPIM to dissipate
residual energy.
11. Work can now be performed on the High Voltage circuit and EP System components.
e. Energy Storage Lockout

To prevent installation of the ESS DC connectors
during service, use lockout devices commercially
available from electrical safety suppliers
(Figure 210).
f. Electrical Safe Work Practices
More information for establishing safe electrical
work practices can be found at the following
sources:
www.OSHA.gov, 29CFR 1910 Subpart S
www.NFPA.org, NFPA 70E-2004
H08196.00.00
Figure 29. Measure Voltage Between Each

DPIM AC Phase and Ground
24
Figure 210. Lockout Devices
SECTION 3PREVENTIVE MAINTENANCE

31.
SCOPE
b. DPIM Inspection
Proper care and regular maintenance enables the

EP 40/50 System to meet its duty requirements.
Perform the maintenance procedures described in
this section on a regular basis to prevent premature
EP 40/50 System or support equipment failure. The
Allison EP 40/50 System is manufactured to provide
long term, efficient service in its designed
applications.
Clean and inspect the exterior of the DPIM at

regular intervals. Location of the DPIM and
operating conditions determine the frequency of
inspections. Inspect the DPIM for:
Loose boltsmounting components and
grounding straps.
Loose, worn, or frayed electrical components.
32.
PERIODIC INSPECTIONS
AND CARE
Improperly routed vehicle electrical harness.

Damaged or loose hoses.
a. EV Drive Inspection
Fluid leaks.
CAUTION:
When cleaning the EV Drive, do not spray
steam, water, or cleaning solution directly at the
breather (oil vent). Spraying steam, water, or
cleaning solution at the breather can force the
water or cleaning solution into the EV Drive
and contaminate the transmission fluid.
DO NOT spray water or cleaning solution directly at system control components.
DO NOT spray water or cleaning solution directly at EP 40/50 System components when
they are not properly installed in the vehicle.
Clean and inspect the exterior of the EV Drive
at regular intervals. Severity of service and operating conditions determine the frequency of these
inspections. Inspect the EV Drive for:
An internal cooling circuit removes heat from the

DPIM. COOLER IN and COOLER OUT ports
are on the front of the DPIM. The DPIM cooling
system uses transmission fluid from the
EV Drive to remove heat.
c. ESS Inspection
Clean and inspect the exterior of the ESS at
regular intervals. Location of the component and
operating conditions determine the frequency of
inspections. Inspect the ESS for:
Loose boltsmounting components,
grounding straps, and ESS cover.

Loose, worn, or frayed electrical components.
Loose boltsEV Drive and mounting
components.
Improperly routed vehicle electrical harness.
Fluid leaksrepair immediately.
Damage to the housing.
Damaged or loose hoses.

Worn, frayed, or improperly routed electrical
harnesses.
Worn or frayed electrical connections.
Dented, worn, or out-of-phase driveline
U-joints and slip fittings.
Dirt and debris collection in inlet filter (Figures
31 and 32).
Damage to and torque retention in the HVIL
cover.
Damage to and torque retention in low voltage
Clogged or dirty air breather (oil vent).
connector.
31

33.
INLET FILTER
V08660.00.00
Figure 31. Air Inlet Filter
IMPORTANCE OF PROPER
TRANSMISSION FLUID LEVEL
Proper transmission fluid level is important to the

performance, reliability, and durability of the
EV Drive. The transmission fluid cools the
EV Drive and DPIM, lubricates moving parts, and
transmits hydraulic power. Low fluid level can result
in inadequate cooling, poor clutch apply, and
overheating. High fluid level can cause fluid aeration
due to churning and the formation of air bubbles in the
fluid. Aeration increases fluid oxidation rates and
reduces fluid life. Aeration can also cause overheating
due to increased friction. Fluid may be expelled
through the breather when the fluid level is too high.
34.
TRANSMISSION FLUID CHECK
INLET FILTER
ELEMENT
WARNING!
V08659.00.00
Figure 32. Air Inlet Filter Element
For vehicles containing the EV Drive, each time

you park the vehicle or leave the operators station
with the engine running, do the following.
Bring the vehicle to a complete stop using the
service brake.
Put the EV Drive in N (Neutral).
d. Welding
Apply the emergency brake and/or parking

brake, if present, and make sure it is properly
engaged.
CAUTION:
When welding on the vehicle:
DO NOT WELD on the vehicle without disconnecting all control system wiring harness
connectors from the TCM and VCM.
DO NOT WELD on any system components
including the DPIM, ESS, and EV Drive.
DO NOT CONNECT welding cables to any
control components.
If the operators station will be unoccupied

with the engine running, chock the wheels and
take any other steps necessary to keep the vehicle from moving.
If this procedure is not followed, the vehicle can
move suddenly and you or others could be injured.
a. Fluid Check Procedure

A label describing on-vehicle welding
precautions is available from your authorized
Allison service dealer and should be installed in a
conspicuous place. A vehicle used in a vocation
that requires frequent modifications or repairs
involving welding must have an on-vehicle
welding label (ST2067EN).
32
The EV Drive is equipped with an electronic

Oil Level Sensor (OLS). The OLS provides a
means to check the drive unit fluid level. To display fluid level, simultaneously press the (Up)
and (Down) arrow keys on the pushbutton shift
selector for five seconds.
PREVENTIVE MAINTENANCE
As soon as fluid level information is requested,
the TCM determines that if conditions are right to
allow a fluid level check. Certain operating conditions must have been met for a period of two minutes before fluid level is checked. These operating
conditions are:
Engine at idle (625850 rpm)
Sump fluid at operating temperature of 2080C
(68176F)
EV Drive output shaft stopped
EV Drive in N (Neutral)
Oil level sensor functioning properly
If the two-minute period has elapsed before the

fluid level check request, information is displayed
immediately. However, if the two-minute period
has not elapsed, a countdown displays before
fluid level information displays. The countdown
display flashes constantly. The countdown starts
at 8 and decreases sequentially to 1 during the
two-minute period.
When a fluid level check is requested, and the
two-minute countdown is in process, the flashing
display shows the number corresponding to the
countdown progress. For example, if the fluid
level check were requested in the middle of the
two-minute countdown period, the display would
flash a 5 or a 4 and decrease to 1.
Table 31. Invalid for Display Codes

Display
Sequence
Interpretation of Display
o,L,5,0
Engine rpm too low, below 750 rpm
o,L,5,9
Engine rpm too high, above 850 rpm
o,L,6,5
Neutral not selected
o,L,7,0
Sump fluid temperature too low
o,L,7,9
Sump fluid temperature too high
o,L,8,9
Output shaft rotation
o,L,9,5
Sensor failure*
* Report sensor failure to a distributor or dealer in your area.

Consult the telephone directory for the Allison
Transmission distributor or dealer near you.
Fluid level information is displayed one character

at a time as follows (see Table 32):
Table 32. Fluid Shift Selector Display
Display
Sequence
Display Meaning
o,L,o,K
Fluid level is correct
o,L,L,o,0,1
Fluid level is 1 quart low
o,L,H,I,0,1
Fluid level is 1 quart high
c. Exiting The Fluid Level Mode

To exit the Fluid Level mode, press the
N (Neutral) button once.
b. Invalid For Display Codes

An Invalid for Display Code is returned when a
fluid level check is requested, but an operational
condition has not been met. The shift selector displays invalid for display codes one character at a
time. The Invalid for Display condition interrupts the two-minute countdown (momentary increase in engine speed does not affect the countdown).
Refer to Table 31 for Invalid for display codes
and their meaning.
The countdown is restarted when the condition
causing the invalid for display code is corrected.
The countdown is not restarted if there is a momentary increase in engine rpm that may generate
a diagnostic code 59.
35.
FLUID RECOMMENDATIONS
The fluid used in the EV Drive has an important influence on performance, reliability, and durability. Use
ONLY a TES-295 certified fluid, such as TranSynd.
Disregarding this recommendation can result in reduced EV Drive life.
NOTE:
A dipstick/fill tube label is available from you local
Allison dealer (SA3316EN).
33

36.
EV DRIVE FLUID AND FILTER
CHANGE INTERVALS
Table 34. Recommended Fluid and Filter Change

Interval* (TranSynd/TES-295 Fluid)
Filters
CAUTION:
Fluid
Transmission fluid and filter change frequency is

determined by the severity of EV Drive service.
More frequent changes may be necessary than
recommended in the general guidelines when operating conditions create high levels of contamination or overheating.
a. Fluid and Filter Change Intervals
Table 33 is a general guide for fluid fill capacity.
Determine change intervals by severity of service.
More frequent fluid and filter changes may be
necessary if operating conditions create high levels of contamination or overheating. If there is
any question as to the severity of your duty cycle,
perform an oil analysis to determine proper
change interval. Refer to GN2055EN for established fluid wear limits.
Table 34 is given only as a general guide for fluid
and filter change interval. Recommendations are
based upon the EV Drive containing 100 percent
TransSynd. Lube filter change interval is only
valid with the use of Allison Transmission Gold
series filters. Flushing machines are not recommended or recognized due to variation and inconsistencies with removal of 100 percent of the used
fluid. Refer to the latest revision of SIL 10-TR-99
for more information regarding fluid and filter
change intervals.
When performing the initial control main filter change
or changing Control Main Filter and Lube Filter Kit
at recommended intervals, approximate fluid lost
for each filter is as follows:
Control Main Filter1 quart (0.94 liters)
Lube Filter3 quarts (2.84 liters)
Table 33. Fluid Capacity

Drive Unit Model
Fluid Capacity*
EV Drive
16 qts. (15.1 l)
* Fluid capacity will vary based on location of DPIM and

the size of the oil-to-air heat exchanger.
Control
Main
Lube
Sump/
Internal
100,000 miles 50,000 miles 100,000 miles

(160,000 km) (80 000 km) (160,000 km) Overhaul
48 months
24 months
48 months
* Change control main filter after the first 5000 miles
(8000 km) of service. Thereafter, change fluid/filters after
recommended mileage, or months have elapsed, whichever
occurs first.
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. EV Drive protection and fluid
change intervals can be optimized by using fluid
analysis. Filters must be changed at or before
recommended intervals.
b. Abnormal Conditions
Use fluid analysis for an EV Drive used in high
cycle rate applications to be certain that a proper
fluid change interval is established. Transmission
fluid must be changed whenever there is evidence
of dirt or a high temperature condition. A high
temperature condition is indicated by the
transmission fluid being discolored or having a
strong odor, or by fluid analysis. Local
conditions, severity of operation, or duty cycle
may require more or less frequent fluid or filter
change intervals.
Table 35 lists the minimum fluid temperatures at
which the EV Drive may be safely operated
without preheating the fluid. Preheat with auxiliary heating equipment or by running the equipment or vehicle with the EV Drive in
N (Neutral) for a minimum of 20 minutes before
attempting range operation.
Table 35. Transmission Fluid Operating
Temperature Requirements
Viscosity Grade
TranSynd
Ambient Temperature Below

Which Preheat is Required
Celsius
Fahrenheit
30
22
(Ref. SIL 13-TR-90)
34
c. Fluid Analysis
b. Water
EV Drive protection and fluid change intervals

can be optimized by monitoring fluid oxidation
according to the tests and limits shown in
Table 36. Fluid oxidation can be monitored
through a fluid analysis firm or by using an oil
analysis kit.
Fluid analysis firmsConsult your local
telephone directory for fluid analysis firms. For

consistent and accurate fluid analysis, use only
one fluid analysis firm. Refer to the
Technicians Guide for Automatic
Transmission Fluid (GN2055EN) for
additional information.
Oil analysis kits (P/N 29537805) are available
through your normal Allison Transmission
parts source.
Refer to the Technicians Guide for Automatic
Transmission Fluid (GN2055EN) for additional
information.
Table 36. Fluid Oxidation Measurement Limits
Test
Limit
Viscosity
25% change from new fluid
Total Acid Number +3.0* change from new fluid
Water
0.2% by volume maximum
* mg of KOH required to neutralize a gram of fluid.
37.
TRANSMISSION FLUID
CONTAMINATION
a. Fluid Examination
Prevent foreign material from entering the EV
Drive by using clean containers, fillers, etc.
Obvious water contamination of the transmission

fluid indicates water ingestion through the
breather. Determine how the water contamination
occurred and perform a fluid change.
c. Metal
It is normal to find a small number of metal particles in the fluid and filter. Large pieces or a large
number of particles may indicate internal
EV Drive damage. If large particles are found in
the sump, do not operate the EV Drive or vehicle and notify your Allison representative. Metal
contamination requires complete EV Drive disassembly.
Clean the cooler, the internal and external hydraulic circuits, the DPIM, and all other areas where
metal particles could lodge.
After flushing the cooler, be sure to test for external cooler circuit restriction. If circuit pressure
drop is above specification, the cooler has an excessive number of trapped particles and must be
replaced.
When equipment to flush the oil cooler is not
available, install a filter in the cooler line between
the oil cooler and the EV Drive from cooler
port. The cooler circuit pressure drop specifications must still be met (refer to AS64-071 or
AS64-072 in the Allison Tech Data book
SA3541EN).
The filter may require frequent changes as debris
is flushed out of the oil cooler circuit. Closely
monitor changes in cooler circuit pressure drop to
indicate when a filter change is needed.
38.
CAUTION:
NEVER USE containers or fillers for transmission fluid that have been used for antifreeze solution or engine coolant. Antifreeze and coolant
solutions contain ethylene glycol which, if put
into the EV Drive, can cause the clutch plates to
fail.
At each fluid change, examine the drained fluid
for evidence of dirt or water. During operation a
normal amount of condensation will collect in the
fluid.
EV DRIVE FLUID AND FILTER

CHANGE PROCEDURE
a. Fluid and Filter Change Procedure

1. Bring the vehicle to a complete stop on a level
surface using the service brake and put the vehicle in N (Neutral).
2. Set parking brake and chock the wheels to
make sure that the vehicle cannot move.
3. Remove the drain plug at the rear of the oil pan
using a 38 inch square-drive wrench.
35

4. Allow all fluid to drain.
2. Remove lube filter cover and O-ring.
5. Install the drain plug and tighten to 2532 Nm

(1824 lb ft).
3. Remove the lube filter.
6. Using a funnel, fill the EV Drive with 15 liters (16 quarts) of approved fluid (refer to 35
Fluid Recommendations).
4. Lubricate the O-ring on the new filter with

transmission fluid.
7. Start the engine and determine fluid level. Add

or drain fluid as necessary.
b. Refill EV Drive
The amount of refill fluid is less than the amount
used for the initial fill. Fluid remains in the external
circuits and EV Drive cavities after draining the
drive. After refill, determine the fluid level using the
procedure described in Paragraph 34.
Table 37. EV Drive Fluid Fill Capacity
Drive Unit Model
EV Drive
Fluid Capacity*
16 qts (15.1 l)
* Fluid capacity will vary based on location of DPIM and

the size of the oil-to-air heat exchanger.
5. Install the filter over the filter pilot in the stator

housing.
6. Install a new O-ring on the filter cover. Install
the filter cover, torque four bolts to 2429 Nm
(3239 lb ft).
e. Sump Filter Change Procedure
1. Bring the vehicle to a complete stop on a level
surface using the service brake and put the vehicle in N (Neutral).
2. Set parking brake and chock the wheels to
make sure that the vehicle cannot move.
3. Remove the drain plug at the rear of the oil pan
using a 38 inch square-drive wrench.
c. Control Main Filter Change Procedure

1. Remove the control main filter by rotating it in
the counter-clockwise direction. Use special
tool J 45023 or standard strap-type filter
wrench.
4. Allow all the fluid to drain.
2. Remove the magnet from the filter attachment

tube or from the top of the filter element.
3. Clean any metal debris from the magnet.
6. Loosen the two bolts retaining the filter retention tabs. Rotate the retention tabs clear of the
filter and remove the filter and seal assembly
from the housing.
4. Reinstall the magnet onto the filter attachment

tube.
7. If seal remains in housing, carefully remove it,

making sure not to score the housing.
5. Lubricate the gasket on the new control main

filter with transmission fluid.
8. Install new seal and filter, make sure that filter

seats completely against housing. Install retention tabs on filter.
6. Install the control main filter, by hand, until the

gasket on the control main filter touches the
stator housing.
7. Turn the filter ONE FULL TURN ONLY
after gasket contact.
d. Lube Circuit Filter Change Procedure
1. Remove the four bolts retaining the lube filter
cover located on the front, lower-left side of
the EV Drive.
36
5. Remove the lube filter cover, oil pan, and oil

pan gasket.
9. Install oil pan gasket, oil pan, and lube filter

cover. Install drain plug and tighten to 2532 Nm
(1824 lb ft).
10. Using a funnel, fill the EV Drive with
16 quarts of approved fluid.
11. Start the engine and allow to idle for a minimum of two minutes. Determine fluid level,
add or drain fluid as necessary.
39.
BREATHER (OIL VENT)
a. Location and Purpose

The breather is located on top and toward the rear
of the stator housing. The breather prevents air
pressure buildup within the EV Drive. The
breather passage must be kept clean and open.
The amount of dust and dirt encountered will determine the frequency of breather cleaning.
CAUTION:
2. Connect a 0350 psi (02070 kPa),

0.4375-20 UNF-2B inch series oil pressure
gauge at the main pressure tap. Use Allison
DOC for PC (AED) to check engine rpm. See
Table 38 for main pressure levels.
Table 38. Main Pressure Schedule
Range
In Range
Neutral
Main Pressure
8621422 kPa (125320 psi)
862 kPa (125 psi)
3. Disconnect the driveshaft.
When cleaning the EV Drive, do not spray

steam, water, or cleaning solution directly at the
breather (oil vent). Spraying steam, water, or
cleaning solution directly at the breather can
force the water or cleaning solution into the EV
Drive and contaminate the transmission fluid.
b. Maintenance
Always use a correctly sized wrench to remove or
replace the breather. Using pliers or a pipe wrench
can crush or damage the breather stem and produce
metal particles that could enter the EV Drive.
Tighten the breather to 1216 Nm (912 lb ft).
310. MAIN PRESSURE CHECK

PROCEDURE
Checking main pressures helps to determine if a
EV Drive malfunction is due to a mechanical or an
electrical problem. Properly making these pressure
checks requires EV Drive and vehicle (or test stand)
preparation, recording of data, and comparing
recorded data against specifications provided.
WARNING!
Observe safety precautions during hydraulic
pressure check procedures. All personnel must
stand clear of the vehicle. Take precautions
against movement of the vehicle. Be sure that
gauges (vacuum, pressure, tachometer) have extended lines so that they can be read from inside
the vehicle.
1. All transmission fluid level and pressure
checks must be made at normal operating
temperatures 2080C (68176F) sump.
Check transmission fluid level.
4. With brakes applied, determine main pressure

with the engine running at 2100 rpm and
600 rpm.
5. Using Allison DOC for PC (AED), determine main boost pressure by commanding the
main boost solenoid to 100 percent full boost.
311. FLUID LEAK DIAGNOSIS

a. Finding the Leak
1. Identify the fluid. Determine whether the fluid
is engine oil, automatic transmission fluid, or
hydraulic fluid from a specific vehicle system.
2. Operate the vehicle to reach normal operating
temperature and park the vehicle.
3. Inspect the vehicle to identify the source of the
leak. Refer to the following list for possible
points of fluid leaks and their causes.
EV Drive mating surfaces:
Attaching bolts not correctly tightened

Improperly installed or damaged gasket
Mating surface(s) damaged
Stator housing leak:
Fill tube or plug seal damaged or

missing
Fill tube bracket dislocated
Oil cooler connector fittings loose or
damaged
Output shaft seals worn-out or damaged
Pressure port plugs loose
Porous casting
37

Leak at damper end:
Direct the black light toward the suspected
Damper O-ring damaged
area. The dyed fluid will appear as a brightly

colored path leading to the source.
Porous casting
Fluid comes out of fill tube:
d. Repairing the Leak
Plugged breather
Once the leak has been traced back to its source,

inspect the leaking part for the following conditions, and repair the leaking part.
Water or coolant in fluid increasing fluid

levelfluid appears milky
Gaskets:
Overfilled
Drain-back holes plugged

4. Visually inspect the suspected area. Inspect all
the gasket mating surfaces for leaks.
5. If the leak still cannot be identified, then clean
the suspected area with a degreaser, steam, or
spray solvent. Clean and dry the area. Operate
the vehicle for several miles at varying speeds.
Re-inspect the vehicle for leaks.
b. Powder Method
Fluid level/pressure is too high

Plugged breather or drain-back holes
Improperly tightened fasteners or dirty/
damaged threads
Warped flanges or sealing surfaces
Scratches, burrs, or other damage to a
sealing surface
Damaged or worn-out gasket
Clean the suspected area.

Apply an aerosol-type white powder.
Cracked or porous casting adjacent to the

gasket
Operate the vehicle under normal operating
Improper sealant used (where applicable)
conditions.
Visually inspect the suspected area and trace
the leak path over the white powder surface to

the source.
Seals:
Fluid level/pressure is too high

Plugged breather or drain-back holes
Damaged seal bore
NOTE:
Dye and black light kits are available for finding
leaks. Refer to the manufacturers directions when
using the kits. See kit directions for the color of the
fluid dye mix.
c. Black Light and Dye Method

Pour the specified amount of dye into the
EV Drive fill tube.
38
Improper installation
Cracks in component
Output shaft surface scratched, nicked, or
damaged
Loose or worn-out bearing causing excess
seal wear
Sealing Flange:
Operate the vehicle in normal operating condi-
tions.
Damaged or worn-out seal
Inspect the sealing flange for bends;

replace the part with the damaged flange.
SECTION 4GENERAL OVERHAUL INFORMATION

41.
SCOPE
This section provides general information for

EV Drive maintenance. The information provided
includes:
42.
Tools and equipment required

Replacement parts information
Cleanliness and careful handling
Cleaning and inspection of components
Assembly procedures
EV Drive, DPIM, ESS removal and
installation
Locating torque specifications for plugs, bolts,
and nuts
TOOLS AND EQUIPMENT
a. Improvised Tools and Equipment

The following items may be improvised.
Work Table500 kg (1000 lb) capacity

(Figure 41)
48 in.
(120 cm)
Stator Housing FixtureJ 46701 or equivalent

(Table 41)
b. Special Tools
Special tools are illustrated and identified in
Table 41.
c. Mechanics Tools and Shop Equipment
The following tools, in addition to the common
tools ordinarily required, should be available.
Common hand tools, metric where required
Metric wrench set (sockets, box-end

wrenches, and Allen wrenches)
Snapring pliers
Micrometer (metric preferred)
Depth micrometer (metric preferred)
Dial indicator set (metric preferred)
78 in.
(200 cm)
TRANSMISSION FLUID DRAIN
STEEL TOP
24 in.
(60 cm)
4 x 4 in. LEGS
(10 x 10 cm)
TRANSMISSION
FLUID DRAIN
(BOTH SIDES)
HOLE FOR
SHAFT CLEARANCE
APPROXIMATELY
3 in. (76 mm)
LOCATE WHERE
CONVENIENT
TROUGH
16-GAUGE SHEET STEEL
1 12 in. (35 mm) DEEP
1 12 in. (35 mm) WIDE
2 x 6 in. BOARD
(5 x 15 cm)
FOR TOP FRAME
AND LEG BRACKETS
V02733.01.00
Figure 41. Work Table
41
42
Metric headless guide bolts set
M10 eye bolt
M16 eye bolt
Suitable hoist500 kg (1000 lb) capacity
A 12 Nm (100 lb inch) torque wrench
WARNING!
A 350 Nm (250 lb ft) torque wrench
Use appropriate safety equipment such as safety

glasses, safety shoes, and gloves.
A press for disassembly and assembly of

spring-loaded clutches and interference-fit
parts
CAUTION:
Caustic cleaning compounds will damage some
EV Drive parts. Use only mineral spirits to
clean drive parts.
Clean, lint-free shop cloths (do not use waste

cloths)
Containers for parts
Supply of wood blocks
Petrolatum
Container of mineral spirits for cleaning parts
43.
REPLACEMENT PARTS
Refer to the latest version of Parts Catalog

(PC3717EN) for parts information. Do not order replacement parts using the reference numbers in this
service manual.
WARNING!
Do not burn discarded Teflon seals; toxic gases
are produced by burning Teflon.
GENERAL OVERHAUL INFORMATION

Table 41. Special Tools and Equipment*
Illustration
Tool No./ Description
Illustration
J 38548
Damper Assembly End
Play Gauge
(3000/4000 Torque
Converter End Play Gauge)
J 46706
Relay and CM
Valve Installer
J 46706
J 38548
J 46701
Stator Housing
FixtureLifting/Turnover
Stand
J 46699
Front Support Seal Installer
J-46701
J 46703
Output Spanner Nut Socket
J 46702
Output Seal Installer
J 46703
J 46702
J 46702
J 46705
C1/C2 Trim/Blocking
Valve Installer
J 8092
Universal Driver
J 8092
J 46705
43

Table 41. Special Tools and Equipment* (contd)
Illustration
Illustration
J 45023
Control Main
Filter Wrench
J 48125
Bearing Race Remover
J 45023
J 48122
Front Support
Bushing Installer
J 48129
Pump Assembly
Spring Compressor
J 48130
Input/Output Shaft
Bushing Remover
J 48123
Pump Assembly
Bushing Installer
J 48131
Input/Output Shaft
Bushing Installer
J 48124
Damper Assembly
Bushing Installer
44
J 48132
P2 Drive Hub Assembly
Bushing Installer

Illustration
Illustration
J 48341
C1 Housing Inner
Race Installer
J 48133
P2 Carrier Bushing Installer
J 48138
Inner Bearing
Race Installer
J 48344
Selective Shim
Measurement Tool
(Rear Cover)
J 48344
J 48139
Bearing Installer
J 48141
P3 Carrier Flange
Bushing Installer
J 48141
J 48142
P3 Ring Gear Flange
Bushing Installer
J 48149
Stator Protector
J 48347
C1 Housing Roller
Bearing Installer
J 48361
Tapered Bearing Installer
J 48365
Bearing Race
Installer/Remover
J 48530
C2 Snapring Removal Tool
45

Illustration
Illustration
J 46708
Digital Multi-Meter
J 48612
Taper Bearing Remover
J 46708.00.00
D-00002
Battery Protection
Installation Device (BPID)
mp
La t
Tes
t
Tesult
Res
up
Setition)
(Ign
er
Powuits
Circ
ply
Sup ts
Vol
All
ck
tte
ry
low
ure M
ens DPI
ly to age
ous
tinu not dam
con
lit e can
t be rfac
inte
mus
ps ng
lam wiri
n Pr
otec
volt
age
tio
n De
vic
450
EXIT
STORE
DATA
REC
TEST
HOLD
TIMER
REC
INTV
AMB-45 Amprobe
(Megger)
1000V
500V
250V
tio
alla
ZERO
Inst
Pa
Ba
OFF
COM
AMB - 45
M
V
V08430.00.00
J 33163
Valve Tray Set
D-00001
DPIM Protection
Installation Device (DPID)
V08431.00.00
00002-03300L
HV Gloves, Class 00
(Large)
V08429.00.00
46

Illustration
Illustration
J 46995-A
Allison DOC For PC
(AED) Software
J 46709
Power Adapter for TCM/
VCM/DPIM/ESS
J 44950
J 46709
N 00001
Softing CANcard2 and
Adapter Cable
J 46710
CAN Adapter to 9-Pin
Deutsch
J 46710
J 46713
ESS Removal/Installation
Fixture
J 46711
Harness Assembly TCM/
DPIM/VCM
J 46713.01.00
* We believe this source and its tools to be reliable. These tools may be
available from other manufacturers. Allison Transmission, Inc. 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, 28635 Mound Road,
Warren, Michigan 48092
1-800-328-6657 US
1-507-455-7223 International
J 46711
J 46712
Harness Assembly Drive
Unit/ESS
J 46712
47

44.
CAREFUL HANDLING
Handle parts and subassemblies carefully to prevent

nicking, scratching, and denting. Parts that fit together
closely and have a specific operating clearance can
bind if damaged. Parts that depend upon smooth surfaces for sealing may leak if scratched. Control valve
body assembly parts are especially susceptible to leaking if scratched. Valves, when dry, must move freely
by their own weight. Handle these parts carefully and
protect them during removal, cleaning, inspection, and
installation. Keep control valve body assembly parts in
clean containers until installation.
45.
CLEANING AND INSPECTION
a. Dirt Causes Malfunction

All parts must be clean to permit effective inspection. Do not allow dirt or foreign material to enter
the EV Drive during assembly. Even minute
particles can cause close-fit parts, such as valves,
to malfunction.
2. Soak particularly dirty bearings or ones filled

with hardened grease in mineral spirits before
trying to clean them.
WARNING!
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.
3. Before inspection, lubricate the bearings with
transmission fluid.
d. Keeping Bearings Clean
Ball or roller bearing failures are usually caused
by dirt or grit in the bearing. Keep bearings clean
during removal and installation. Observe the following rules for maximum bearing life:
Do not unwrap new bearings until they are to

be installed.
Do not remove the grease in which new

bearings are packed until they are to be
installed.
Do not lay bearings on a dirty bench. Place

bearings on clean paper or lint-free cloth.
If a bearing is not installed immediately, wrap

or cover the lubricated bearing with clean
paper or lint-free cloth to keep out dust.
b. Cleaning Parts
1. Clean all metallic EV Drive parts, except
bearings and friction-faced clutch plates, by
steam-cleaning or with volatile mineral spirits.
Do not use caustic soda solution for steamcleaning. Clean friction-faced clutch plates and
bearings with mineral spirits only.
2. Dry all parts, except bearing assemblies, with
compressed air. To prevent rust, lubricate
steam-cleaned parts as soon as they are dry.
3. Clean fluid passages by working a piece of soft
wire through the passages and flushing them
with mineral spirits. Dry the passages with
compressed air.
4. Examine parts, especially fluid passages, after
cleaning to make certain they are entirely
clean. Re-clean parts if necessary.
c. Cleaning Bearings
1. Bearings that have been in service should be
thoroughly cleaned in volatile mineral spirits.
48
e. Inspecting Bearings
1. Inspect bearings for rough or uneven rotation.
Replace a bearing if its rotation is still rough or
uneven after cleaning and lubrication.
2. Inspect bearings for scored, pitted, scratched,
cracked, or chipped races, and for excessive
roller or ball wear. Replace the bearing if any
defects are found.
3. Inspect a defective bearings bore and mating
shaft for grooved, burred, or galled conditions
that indicate the bearing has been turning in the
bore or on the shaft. If the damage cannot be
repaired with crocus cloth, replace the defective part.

4. When removing a bearing, do not apply pressure across the balls. This can cause brinelling
and bearing failure.
5. If a bearing must be removed or installed without the proper tool, press 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 hammer.
f. Inspecting Cast Parts and Machined Surfaces
1. Inspect bores for wear, scratches, grooves, and
dirt. Remove scratches and burrs with a crocus
cloth. Clean the part. Replace parts that are
deeply scratched or grooved.
2. Inspect all fluid passages for obstructions. If an
obstruction is found, remove it with compressed air, or by working a soft wire back and
forth through the passage and flushing it out
with mineral spirits.
3. Inspect mounting faces for nicks, burrs,
scratches, and foreign matter. Remove any defects with crocus cloth or a soft stone. Clean
the part. If scratches are deep, replace the defective part.
4. Inspect threaded openings for damaged
threads. Clean damaged threads with the correct size tap.
5. Inspect the ribs inside the C1 housing for
reaction plate wear grooves in the side of the
ribs.
6. Replace housings or other cast parts that are
cracked.
7. Inspect all machined surfaces for damage that
could cause fluid leakage or other malfunction.
Rework or replace defective parts.
8. Inspect the oil tracks of the valve bodies and
main housing for porosity, broken lands,
cracks, dirt, and land surface imperfections.
These imperfections will cause severe fluid
leakage leading to EV Drive failure.
g. Inspecting Bushings and Thrust Washers
1. Inspect bushings for scores, burrs, sharp edges,
and evidence of overheating. Remove scores
with a crocus cloth. Remove burrs and sharp
edges with a scraper or knife blade. Before
reinstalling, carefully examine bushings for

signs of distress.
CAUTION:
When removing a defective bushing do not
damage the bushing bore.
2. Replace bushings that are out-of-round, deeply
scored, or excessively worn. Inspect parts
mated to bushings to make sure they are not
damaged or worn beyond use.
3. Inspect thrust washers for distortion, scores,
burrs, and wear. Replace a thrust washer if defective or worn.
h. Inspecting Sealrings and Gaskets
1. Inspect piston sealrings and lip-type seals for
nicks, cuts, tears, splits, and pattern damage. A
damaged seal can indicate rough or sharp
edges in piston grooves or on a mating surface
that could damage a new seal.
2. Inspect clutch housing sealing surfaces for
nicks, burrs, dents, or displaced metal that
could interfere with mating parts or damage
the piston seal. Remove raised metal, sharp
edges, burrs, or nicks with a soft stone and crocus cloth. Thoroughly clean all residue from
the housing before assembly.
i. Inspecting Gears
1. Inspect gears for scuffed, nicked, burred, or
broken teeth. If a defect cannot be removed
with a soft stone, replace the gear.
2. Inspect gear teeth for wear that has changed
the original tooth shape. If this condition is
found, replace the gear.
3. Inspect the thrust face of gears for scores,
scratches, and burrs. Remove such defects with
a soft stone. If scratches and scores cannot be
removed with a soft stone, replace the gear.
4. Inspect gears for load pattern and signs of distress. Any sign of distress indicates that a gear
failure during operation is possible. Reusing
distressed gears is an individual customer decision based on experience. Backlash cannot be
used to establish critical gear wear. Backlash
tolerances are of such nature that a gear usually
49

tangs. Remove burrs and minor surface
irregularities using a soft stone. Replace plates
which have any defects.
pits, scuffs, scores, or galls long before gear

wear becomes critical.
j. Inspecting Splined Parts
1. Inspect splined parts for stripped, twisted,
chipped, or burred splines. Remove burrs with a
soft stone. Replace the part if other defects are
found. Spline wear is not considered harmful except where it affects the fit of the splined parts.
2. Spline wear is determined by comparing feeler
gauge thickness with the thickness of the worn
area on the spline. Replace parts having
excessive spline wear.
3. Backlash cannot be used to establish critical
spline wear. Accurate backlash measurement
requires the mating parts to be concentrically
located.
k. Inspecting Threaded Parts
Inspect threaded parts for burred or damaged
threads. Remove burrs with a soft stone or fine
file. Replace damaged parts.
l. Inspecting Retaining Rings
Inspect all retaining rings for nicks, distortion, or
excessive wear. Replace the retaining ring if any
defects are found. The retaining ring must snap
tightly into its groove to function properly.
o. Inspecting Swaged and Interference-Fit Parts

If there is evidence of looseness, the assembly
should be replaced.
p. Inspecting Sealing Surfaces
1. Inspect surfaces in contact with hook-type,
scarf-cut, and butt-joint sealrings for stepwear, nicks, scratches, and scoring. Use a soft
stone or crocus cloth to remove only the raised
metal portion of these defects. Polishing the
area to remove a defect is neither necessary nor
desirable. If the defects are too severe to correct, replace the defective part.
2. Inspect surfaces in contact with spring-loaded,
lip-type seals for nicks, scratches, roughness,
or other surface irregularities. Inspect for embedded particles, step-wear, and dirt on flanges
or other components exposed to external contamination. Remove the defects and restore the
finish. Replace the part if scores or scratches
permit fluid leakage.
46.
ASSEMBLY PROCEDURES
a. Parts Lubrication
m. Inspecting Springs
Inspect springs for signs of overheating, permanent set, or wear due to rubbing adjacent parts.
n. Inspecting Clutch Plates
1. Inspect friction-faced clutch plates (C1 clutch
plates are externally tanged; C2 clutch plates
are internally splined) for burrs, embedded
metal particles, severely pitted faces, loose
faces, excessive wear, cone, cracks, distortion,
shallow oil groove depth, or damaged spline
teeth. Remove burrs using a soft honing stone.
Replace plates which have any defects.
2. Inspect steel plates (C1 clutch plates are
internally splined; all other clutch plates are
externally tanged) for burrs, scoring, excessive
wear, excessive cone, distortion, imbedded
metal, galling, cracks, breaks, or damaged
410
During EV Drive final assembly, lubricate all

moving parts with transmission fluid. The fluid
will help protect friction surfaces and ferrous
metals until the unit is in service.
b. Grease Used for Assembly
During EV Drive assembly use oil-soluble
grease with a low melting point (petrolatum) to
temporarily retain parts, butt-joint sealrings, scarfcut sealrings, and hook-type sealrings.
c. Sealing Compounds and Nonsoluble Greases
Do not use gasket-type sealing compounds,
fibrous greases, or nonsoluble vegetable-base
cooking compounds inside the EV Drive or
where they could be flushed into the EV Drive
hydraulic system.

d. Clutches and Pistons
1. Soak each friction-faced clutch plate (twominute minimum) in transmission fluid before
final assembly.
2. Apply a generous amount of transmission fluid
to the piston cavity before final assembly.
3. Assemble clutch plates so that the cone of each
plate faces the same direction.
e. Threaded Plugs and Hydraulic Fittings
CAUTION:
Do not use Teflon tape on threaded parts.
Slivers can cause the EV Drive to
malfunction.
Improperly installed plugs or fittings can
cause leakage and cracked housings.
Tighten all pipe plugs to the specified torque in the
assembly procedure and on the exploded views.
Tighten other fittings sufficiently to prevent
leakage.
f. Bearings
If a bearing must be removed or installed without
an installation sleeve, drive or press 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 hammer, driving against the supported race.

g. Electrical Components
For inspection and repair of electrical components, refer to the Allison Transmission EP 40/50
System Series Troubleshooting Manual
(TS3715EN).
47.
TORQUE SPECIFICATIONS
Assembly procedures in Sections 6 and 7 specify the

torque requirements for all plugs, bolts, and nuts.
Torque values are also presented with the foldout
illustrations in the back of this manual. Torque values
specified are for dry assembly, except when otherwise
noted. Bolts and washers should be washed and dried
before assembly. As a general reference, GM500M
(10.9) torque values are presented in Table 42.
As a general practice; when tightening plugs, bolts, or
nuts, snugly tighten plugs and fasteners before tightening them to the specified torque. Use a criss-cross pattern to evenly tighten multiple fasteners retaining a
component.
48.
PRESSURE SCHEDULE
Refer to Table 43 for the hydraulic pressure schedule

at various engine rpm.
411

Table 42. GM500M (10.9) Bolt and Nut Torque Values
Torque Values
Nominal Thread
Diameter mm
Nm
Min
1.0
2.5
5
10
24
51
90
130
228
325
447
M3
M4
M5
M6
M8
M10
M12
M14
M16
M18
M20
lb ft
Max
2.5
5.0
8
13
29
61
110
163
266
377
513
Min
0.7
2
4
7
18
38
66
96
168
240
330
Max
1.8
4
6
10
21
45
81
120
196
278
378
Table 43. Pressure Schedule (Minimum Allowable)

Engine
Input
Speed
(rpm)
Applied
Range Clutch
Full
Boost
Main
Pressure
kPa (psi)
Low
Main
Pressure
kPa (psi)
Control
Main
Pressure
kPa (psi)
C1
Pressure
kPa (psi)
C2
Pressure
kPa (psi)
Lube
Pressure
kPa (psi)
755795
2030 (294)
770 (112)
495 (72)
8 (1)
8 (1)
30 (4)
755795
F1
C1
2030 (294)
770 (112)
495 (72)
Main
70 (10)
8 (1)
30 (4)
755795
F2
C2
2030 (294)
770 (112)
495 (72)
8 (1)
Main
70 (10)
30 (4)
755795
C1
2030 (294)
770 (112)
495 (72)
Main
70 (10)
Main
70 (10)
30 (4)
412
SECTION 5E V DRIVE DISASSEMBLY

51.
REMOVE THE EV DRIVE
CAUTION:
Whenever an EV Drive is exchanged, or has
undergone repairs, the TCM must have the C1
and C2 clutch and main boost pressure adaptives
reset. This will cause the TCM to erase previous
adaptive information and begin to adapt from
the base calibration. Use Allison DOC For PC
(AED)Service Tool to reset the TCM. Refer to
the user guide for instructions (GN3727EN).
Drain the transmission fluid before removing the

EV Drive from the vehicle.
a. Drain the EV Drive
WARNING!
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.
1. Remove the drain plug from the oil pan.
Examine the drained fluid for evidence of
contamination
(refer
to
Section
3,
Paragraph 37). Reinstall the drain plug.
EV Drive
2. Remove the
fill tube if it interferes
with drive removal. Plug the fill tube hole in
the stator housing to keep dirt from entering
the EV Drive.
OPTIONAL
REAR SUPPORT
BRACKET
BREATHER
MOUNTING
PAD
HIGH VOLTAGE
LUG BOX FOR
MOTOR B
P1 MOTOR A
SPEED SENSOR
V07608.04.01
OUTPUT
SPEED
SENSOR
FLYWHEEL
P3 MOTOR B
SPEED SENSOR
b. Disconnect Controls
OIL PAN
OIL DRAIN PLUG
WARNING!
FILL TUBE PROVISION

V07608.04.01
The Allison Electric Drives EP 40/50 System

uses potentially hazardous electrical energy. All
hybrid propulsion components are identified
with warning labels or symbols. DO NOT
attempt to service components containing
potentially hazardous electrical energy if you are
not trained to do so.
Normal Operating Conditions:
ESS Voltage Range:
432780 VDC
DPIM Current Range:
350 to +350 A
51

WARNING!
DO NOT rely solely on the HVIL to de-energize
the system. Always perform the appropriate
checks to make sure the system is discharged before servicing components.
WARNING!
may result in injury. Failure to follow proper
safety procedures may result in serious personal
injury or death.
OPTIONAL
REAR SUPPORT
BRACKET
1. Perform electrical disconnect verification procedure (refer to Section 2).

BREATHER
MOUNTING
PAD
HIGH VOLTAGE
LUG BOX FOR
MOTOR B
OUTPUT
SPEED
SENSOR
P1 MOTOR A
SPEED SENSOR
4-1-2
FLYWHEEL
P3 MOTOR B
SPEED SENSOR
2. Disconnect the external wiring harness from

the EV Drive internal harness 31-way connector.
3. Disconnect the external wiring harness from
four motor speed sensors in the stator housing.
Label each speed sensor wire.
OIL PAN
OIL DRAIN PLUG
FILL TUBE PROVISION

V07608.04.01
4. Disconnect the external harness from two output speed sensors in the rear cover. Label each
speed sensor wire.
5. Disconnect the external harness from the two
HVIL connectors attached to Motor A and Motor B lug boxes.
6. Remove four M8 x 70 mm bolts from each lug
box cover and remove the covers.
7. Remove the top nut from each of three high
voltage studs in each lug box.
8. Remove the external harness from each lug
box.
9. Install shipping covers over all detached connectors to prevent dirt or moisture from entering a disconnected connector.
10. Position the wiring harness so it does not interfere with EV Drive removal.
52
E V DRIVE DISASSEMBLY
NOTE:
A significant amount of fluid may drain from the
hydraulic lines when they are disconnected from the
EV Drive.
11. Disconnect all hydraulic lines from the
EV Drive. Remove the lines from the vehicle
if they interfere with drive removal.
12. Plug all openings to keep dirt from entering the
hydraulic system.
OIL TO COOLER PORT

HIGH VOLTAGE
LUG BOX
FOR MOTOR "A"
P2 MOTOR A
SPEED SENSOR
P4 MOTOR B
SPEED SENSOR
c. Uncouple From Driveline, Engine, and Vehicle

OIL TO DPIM PORT
WARNING!
OIL FROM DPIM PORT
V07584.03.01
NAMEPLATE
FILL TUBE PROVISION
Chock wheels to prevent vehicle from moving

when driveline is disconnected. This is not
necessary if all wheels are off the ground.
1. Disconnect the vehicle drive shaft from the
EV Drive output flange or yoke. Position the
disconnected shaft to avoid interference when
removing the EV Drive.
MAIN PRESSURE TAP

V07584.03.00
EV DRIVE
2. If EV Drive mountings support the rear of the

engine, place a jack or other support under the
engine.
3. Securely support the EV Drive with a hoist,
jack, or other suitable removal equipment.
DRIVESHAFT
4-1-4
V10651.00.00
NOTE:
It may be necessary to remove an engine flywheel
housing access cover to remove flexplate or
flexplate adapter bolts. This is the engine to
EV Drive connection.
53

4. Remove all bolts, nuts, washers, spacers, and
supports that attach the EV Drive to the vehicle and the engine.
RING GEAR
FLEXPLATE ADAPTER
FLEXPLATE
modified
WEAR PLATE
V07596.00.00
HUB ADAPTER
V07586.01.00
5. Remove ten bolts retaining the flexplate

adapter to the flywheel damper assembly.
6. Remove the flexplate adapter.
V09873.00.00(5-1-1)
DIVISION
OF
GENERAL
INDIANAP
OLIS, MOTORS
INDIANA
XX
54
CORP.
d. Install Drive on Repair Stand
Special Tools Required:
J 46701
Stator Housing FixtureLifting/

Turnover Stand
1. Position the drive on the work table so that the

oil pan is facing down.
2. Using eight M14 x 2.0-6G bolts with minimum
of 1.0 inch thread engagement, attach lifting fixture (J 46701) to stator housing mounting pads.
3. Make sure the adapter plate is mounted to the
turnover stand.
J 46701
4. Lift drive and align lifting fixture with adapter

plate. Install four bolts attaching lifting fixture
to adapter plate.
52.
J-46701
REMOVE MOTOR
SPEED SENSORS
The EV Drive uses directional Hall-effect speed

sensors for Motors A and B. The following procedure applies to both the Motor A and the Motor B
speed sensors. Each motor has two speed sensors.
Motor speed sensors are labeled on the stator
housing (Foldout 7) P1P4. P1 and P2 are for
Motor A. P3 and P4 are for Motor B.
V07608.04.00
P3
SPEED SENSOR
P1
SPEED SENSOR
V07608.04.00
55

a. Removal
1. Remove the M6 bolt retaining the speed sensor
to the housing.
2. Remove the speed sensor bracket.
3. Carefully work the speed sensor free of the
housing.
V07584.04.00
P2
SPEED SENSOR
P4
SPEED SENSOR
V07584.04.00
b. Inspection
1. Inspect the speed sensors for external damage.
2. Inspect the speed sensor electrical pin condition.
3. Inspect the speed sensor O-ring for cuts or
damage.
V09588.00.00
4. Replace any damaged speed sensors or

O-rings.
V09588.00.00
56
53.
REMOVE OUTPUT
SPEED SENSORS
P6 OUTPUT
SPEED
SENSOR
P7 OUTPUT
SPEED SENSOR
The output speed sensors are variable reluctance devices mounted in the rear cover (Foldout 11). Each
sensor consists of a wire coil wrapped around a pole
piece that is adjacent to a permanent magnet. Output
speed sensors are on the rear cover labeled P6 and P7.
a. Removal
1. Remove the M8 bolt retaining the speed sensor
to the housing.
housing.
b. Inspection
V08672.00.00
NOTE:
Refer to parts catalog PC3717EN or CD3717EN for
additional information regarding the output speed
sensors.
1. For former design speed sensors, inspect the
speed sensors for external damage. Measure
speed sensor resistance. Resistance should
measure 300 25 Ohms at 20C (68F). Refer
to TS3715EN for additional component troubleshooting.
2. For current design speed sensors, inspect the
speed sensors for external damage. Measure
speed sensor resistance. Resistance should
measure 340 25 Ohms at 20C (68F). Refer
to TS3715EN for additional component troubleshooting.
V09589.00.00
FORMER
V09589.00.00
3. Replace any damaged speed sensors or

O-rings.
CURRENT
V10655.00.00
57

54.
REMOVE CONTROL
MAIN FILTER

J 45023 Control Main Filter Wrench
1. Using J 45023 or a strap-type filter wrench, rotate the control main filter counter-clockwise
and remove control main filter 1.
2. Remove magnet 2 from the filter attachment

tube or from the bottom of the filter element.
3. Clean any metal debris from the magnet.
4-5-1
4. Reinstall the magnet onto the filter attachment

tube.
5. Lubricate the gasket on the control main filter
with transmission fluid.
V10479.00.00
6. By hand, install the control main filter until the

gasket contacts the stator housing.
CAUTION:
Turning the control main filter more than ONE
FULL TURN after gasket contact will damage
the filter.
7. Using J 45023 or by hand, turn the filter ONE
FULL TURN after gasket contact.
55.
REMOVE INPUT DAMPER
1. Position the EV Drive so that the front of the

EV Drive is facing up.
11
2. If installed, remove any shipping brackets 1

that prevent damper movement.
4-6-1
4-6-1
4-6-1
4-6-1
V10539.00.00
58
3. Remove threaded plug and O-ring 1 using a
34 inch Allen wrench.
11
4-6-2
4-6-2
4-6-2
4-6-2
V10488.00.00
NOTE:
The starter ring gear may need to be installed to
provide sufficient leverage to remove the input
bolt retaining the damper assembly to the input
shaft.
4. Insert a heel bar into an input housing bolt
hole. Insert two bolts into adjacent flexplate
adapter bolt holes. Place a heel bar between the
bolts and the heel bar so as prevent the input
damper from rotating.
4-6-3
4-6-3
4-6-3
4-6-3
V10475.01.00
59

5. Remove bolt 1 and shim 2 located below
threaded plug.
1
4-6-4
V10424.01.00
464
6. Attach a sling to damper assembly 1.
1
7. Attach a hoist to the sling and raise damper assembly 1 from input housing 2. Using
M8 x 1.25 bolts to attach the sling to the
damper. If the starter ring gear is installed, use
M10 x 1.25 bolts of sufficient length.
1
2
4-6-5
8. Place the damper assembly on the work table

and remove the sling.
4-6-5
4-6-5
V10577.00.00
56.
1
REMOVE INPUT HOUSING
1. Remove twenty-nine M10 x 1.50 x 35 mm 1

bolts from input housing.
1
4-7-1
4-7-1
4-6-6
V10660.01.00
510
2. Attach a sling to the input housing.
3. Attach a hoist to the sling.
4-7-3
4. Remove the input housing.

5. Place the input housing on table.
6. Remove the sling.
4-7-3
4-7-3
V10578.00.00
7. Remove and discard the stator housing/input

housing gasket.
1
4-7-4
4-6-9
4-6-9
4-7-4
V10376.00.00.(4-7-4)
8. Remove thrust bearing 1 (72 mm ID).

1
X X X X X X X X TIDO
XXXXX
XXXX
DIVISION OF GENERAL MOTORS CORP.

INDIANAPOLIS, INDIANA
4-7-5
4-7-5
4-6-10
V10371.00.00(4-7-5)
511

57.
REMOVE ROTOR A
1. Screw an M16 x 2 eye into input shaft 1.

1
2. Attach a hoist.
3. Slowly lift Rotor A from the stator housing.
XXXXX
XXXX
4-8-1
CAUTION:
4-8-1
4-8-1
V10372.00.00
Use care when positioning Rotor A on the work

surface so as not to damage the speed signal
wheel.
4. Set Rotor A on work surface with the input
shaft through the clearance hole in work table
or support Rotor A on wood blocks high
enough to allow the input shaft to clear the
work surface.
4-8-2
5. Remove hoist.
6. Remove eye hook.
4-8-2
4-8-2
V10386.00.00(4-9-1)
58.
REMOVE REAR COVER
4-9-1
512
XXXXX
XXXX

1. Position the EV Drive with the rear cover

facing up.
V10374.00.00
2. Remove M10 x 50 mm bolt 1 from the rear
cover.
4-9-2
4-9-2
V10378.00.00.(4-9-2)
3. Remove eight M10 x 75 mm bolts 1 from the

rear cover.
4-9-3
1
1
4-9-4
14-9-3
4. Remove two M12 x 100 mm bolts 1 from the

rear cover.
V10379.00.00
XXXXX
XXXX
4-9-4
V10377.00.00.(4-9-5)
5. Remove eighteen M12 x 55 mm bolts 1 from

the rear cover bolt circle.
1
1
1
1
4-9-5
1
1
4-9-6
4-9-6
495
1
1
1
V10380.00.00(4-9-5)
513

6. Attach a hook to the yoke assembly.
7. Attach a hoist to the hook and raise rear cover
assembly from stator housing.
8. Place rear cover assembly on the work table.
XXXXX
XXXX
4-9-6
4-9-7
V10545.00.00
9. Remove gasket 1 between the rear cover assembly and the C1 clutch housing.
1
4-9-7
4-9-7
4-9-8
4-9-8
V10581.00.00
59.
REMOVE ROTOR B / C1 CLUTCH

HOUSING
1. Remove C1 clutch pack 1 from C1 clutch

housing 2.
4-10-1
V10373.00.00(4-10-1)
514
2. Remove fifteen M12 x 45 mm bolts 1 from the
C1 clutch housing assembly.
XXXXX
XXXX

4-10-2
4-10-2
V10375.00.00.(4-10-2)
3. Arrange two wood blocks on the work surface

to receive Rotor B. Make sure the P3 sun shaft
will be clear of the work surface.
4. Install three bolts, equally spaced to provide a
balanced lift, in the threaded holes of the C1
clutch housing.
4-10-3
5. Attach a sling to C1 clutch housing assembly.

6. Attach a hoist to the sling and slowly lift the
C1 clutch housing/Rotor B assembly from the
stator housing 2.
7. Place C1 clutch housing/Rotor B assembly on
the work table and remove the sling.
4-10-3
4-10-3
V10579.00.00
8. Remove the gasket.
510. REMOVE LUBE FILTER

1. Remove four M8 bolts 3 from the lube filter
cover 2 and remove the cover.
2. Remove lube filter 1.

2
3. Replace the lube filter and the O-ring in lube

filter cover 2.
4-11-1
4-11-1
4-11-1
V10392.00.00
515

511. REMOVE OIL PAN
CAUTION:
To reduce the possibility of dropping small parts
between the stator housing and the stator
winding, which may be impossible to remove,
position the EV Drive vertically when
removing components such as the oil pan, valve
bodies, solenoid filter screens, etc.
1. Remove thirty-two M8 x 30 mm bolts 1 and

four M8 x 70 mm bolts 2 from the perimeter of
the oil pan.
2. Remove the oil pan 3 and gasket 4.

4-12-1
3
4
V10662.00.00
512. REMOVE SUCTION FILTER

1. Remove two bolts and two clips retaining the
suction filter to the control deck.
1
2. Remove the suction filter. At overhaul replace

the suction filter and O-ring 1.
4-13-1
V10656.00.00
516
SECTION 6MODULE REBUILD

61.
FLYWHEEL DAMPER
ASSEMBLY
WARNING!
To help avoid personal injury, use an appropriate
hoist and lifting devices to lift the input damper
assembly. The input damper assembly weighs
approximately 23 kg (60 lbs).
a. Disassembly
1. If not already marked, scribe a balance mark
across the OD of the front damper cover and
the damper rear cover. Using balance marks
prevents changing the balance characteristics
during re-assembly.
V09874.00.00
ALIGNMENT MARK
V09874.00.00(5-1-2)
2. Remove twenty-four M8 x 1.25 x 20 mm

bolts 1 retaining the rear cover assembly to
front damper assembly 2.
1
2
V09872.00.00
5-1-3
V09872.00.00(5-1-3)
3. Install two M8 x 1.25 jack bolts (1), 180 degrees apart, in blind threaded holes in the rear
cover assembly.
4. Separate the front damper assembly and rear
cover assembly by tightening the jack bolts until the rear cover assembly is free of front
damper assembly 2.
V09871.00.00
5. Remove the rear cover assembly.

6. Remove the jackbolts.
5-1-4
5-1-4
V09871.00.00
61

7. Remove O-ring 1 from the rear cover assembly.
1
8. Discard O-ring 1.
1
V09870.00.00
V09870.00.00(5-1-3)
9. Remove thrust bearing 1 from the rear cover

assembly.
10. Discard thrust bearing 1 if the races are damaged or if the thrust bearing exhibits uneven
movement or wear.
V09869.00.00
5-1-6
V09869.00.00(5-1-2)
11. Remove the damper hub from the front damper

assembly.
V09868.00.00
V09868.00.00
12. Remove eight bolts 3 retaining damper assembly 1 to damper front cover 2.
V09867.00.00
V09867.00.00
62
MODULE REBUILD
13. Remove damper 1 from front cover 2.
5-1-8A
V10419.00.00(5-1-8A)
14. Remove thrust bearing 1 from inside of the

front cover.
15. Discard thrust bearing 1 if the races are damaged or if the thrust bearing exhibits uneven
movement or wear.
V09866.00.00
V09866.00.00
b. Inspect Front Damper Cover

1. Inspect the front damper cover for obvious
damage such as galling. Replace the front
cover if thrust bearing surface 1 is damaged.
2. Inspect the twenty-four M8 x 1.25 threaded
holes for thread damage. Use a M8 x 1.25 tap
to correct thread damage.
1
2
2
3. Replace the front damper cover if the threads

cannot be repaired.
4. Inspect dowel pins 2 for damage. Replace
damaged dowel pins.
V09858.00.00
2
V09858.00.00
63

c. Replace Front Damper Cover Dowel Pins
1. Remove a damaged dowel pin 1 from the front
damper cover.
1
1
2. Press new dowel pin to a height of 10.95

11.55 mm (0.4310.455 inch) above the face.
CAUTION:
V09855.00.00
1
2
Do not use a standard tap in the ten M8 x 1.25

threaded holes on the front face of the front
damper cover. A standard tap will damage the
Spiralock threads in these holes. Do not repair
the Spiralock threads with inserts or by
oversize drilling and tapping. Do not use the
front damper cover if the Spiralock threads
were damaged by using a standard M8 x 1.25 tap
to clean and repair threads
3. Inspect ten M8 x 1.25 Spiralock threaded
holes 2 on the front face of front damper cover.
Clean any damaged threads with an M8 x 1.25
Spiralock tap.
4. Inspect the internal threads of pilot 1. Clean
damaged threads with a 1.625 inch x 12 tap.
2
V09859.00.00
1
V09859.00.00
5. Inspect pilot 1 for damage or excessive wear.

Maximum pilot diameter is 50.893 mm
(2.004 inch). Minimum pilot diameter is
50.823 mm (2.001 inch).
6. Replace the front cover if it is damaged, if the
pilot does not meet specification, or any
threads cannot be repaired with a tap.
d. Inspect Damper
1. Inspect the damper for battered, cracked, or
broken:
Housings
Springs
Rivet holes
V09860.00.00
Rivets
Loose rivets
Bolt holes
V09860.00.00
Bolts
Dowel pin holes
64
MODULE REBUILD
2. Inspect for spline wear between the damper
and the damper hub.
3. Replace the damper if any damage is found or
splines are deformed.
e. Inspect Damper Hub
1. Inspect the damper hub. Replace the hub if any
of the following conditions are found:
Damage to internal or external splines.

Damage to either thrust bearing surfaces 1
and 2 on either side of the damper hub.
5-1-1new
2
V10665.00.00
2. Inspect damper hub bushing journal 1 on the

rear cover side.
3. Replace the damper hub if the bushing journal

is damaged or the bushing has spun in the
bushing bore of the rear cover.
4. Measure the OD of bushing journal 1. Minimum OD is 56.93 mm (2.241 inch). Replace
the damper hub if specifications are not met.
V09861.00.00(5-1-1)
65

f. Inspect Rear Damper Cover
1
1. Inspect rear damper cover thrust bearing surfaces 1 on either side of the rear cover. If damage to either thrust bearing surface is found, replace the rear damper cover.
2. Inspect the O-ring groove for sharp edges or
burrs that might cut the O-ring. Remove sharp
edges or burrs with a soft stone or crocus cloth.
5-1-2new
V10663.00.00
3. Measure the ID of rear damper cover

bushing 1. Maximum ID is 73.20 mm
(2.882 inch). Inspect the rear damper cover
bushing for bronze material exposed by wear
on the orange coating. Replace the rear damper
cover bushing if bronze material is exposed or
the ID of the bushing does not meet the ID
specification.
5-1-new4
V09857.00.00(5-1-4)
66
4. Inspect the general condition of the rear

damper cover. Replace the rear damper cover if
it is cracked or the bushing has spun in its bore.
MODULE REBUILD
g. Replace Rear Cover Bushing
Replace the rear cover bushing if the bushing
does not meet specifications or is worn or damaged.
Special Tools Required
J 48124Damper Assembly Bushing Installer
J 8092Universal Driver
1. Position the rear cover, O-ring side up, on two

wooden blocks high enough above the work
surface to allow the bushing to be removed.
2. Drive bushing 1 from the back housing towards

the work surface using a hammer and punch.
3. Clean the bushing bore of residue. Parts must
be dry before installing a new bushing.
1
V09857.00.00
V09857.00.00(5-1-4)
4. Position back housing 2, O-ring side down, on

two wooden blocks.
5. Install bushing 1 on J 48124.
J 8092
1
6. Press or drive J 48124 until it seats against the

bushing bore, 6.206.40 mm (0.2440.252 inch)
below the top of the bushing bore.
J 48124
1
V09856.00.00
2
V09856.00.00
67

h. Assemble Flywheel Damper Assembly
1. Place front damper cover on the work surface
flexplate side down.
V09854.00.00
CAUTION:
Installing the thrust bearing upside down will
cause the thrust bearing to fail, resulting in
progressive damage to the EV Drive.
V09854.00.00
2. Install thrust bearing 1 (74 mm ID) onto the

bearing pilot inside the front damper cover so
that the rounded outer edge of the bearing race
is up. The thrust bearing inner race tangs retain
the thrust bearing to the bearing pilot.
ROUNDED EDGE
1
V09853.00.00
1
V09853.00.00
3. Position the damper over the front damper

cover so that the stepped side of the damper is
down and damper dowel pin holes align with
the flywheel dowel pins.
4. Install damper into the flywheel.

NOTE:
Inner springs float inside damper.
V09850.00.00
V09850.00.00
5. Retain damper 1 to flywheel 2 with eight

bolts 3 (M8 x 1.25 x 20 mm).
6. Tighten eight bolts to 3541 Nm (2630 lb ft).
5-1-24
1
V09867.00.00
68
MODULE REBUILD
7. Install damper hub into front cover.
5-1-24A
V09868.00.00
8. Place rear damper cover on the work surface

with the O-ring side up. Install a new O-ring 1
(330 mm free diameter) onto rear cover 2.
V09851.00.00
1
2
CAUTION:
V09851.00.00
9. Install thrust bearing 1, 105 mm (4.134 inch)

ID, so that the outer rounded edge of the bearing race is up.
1
V09852.00.00
V09852.00.00(5-1-26)
69

10. Install back damper cover 1 into front damper
cover 2 so that the scribed alignment marks
align.
5-1-26
1
2
ALIGNMENT MARK
V09874.00.00(5-1-2)
11. Install twenty-four (M8 x 1.25 x 20 mm)

bolts 1 that retain the back damper cover to
front damper cover 2.
12. Tighten bolts 1 to 3541 Nm (2630 lb ft).

5-1-27
V09872.00.00(5-1-3)
13. Position the damper assembly so the rear

damper cover is against the work surface. Install the flexplate adapter.
14. Install ten M8 x 1.25 x 25 mm bolts 1. Tighten

bolts to 3239 Nm (2429 lb ft).
5-1-new5
1
5-1-new5
610
V10666.01.00
MODULE REBUILD
62.
INPUT HOUSING AND

PUMP ASSEMBLY
a. Disassembly
WARNING!
To help avoid personal injury, use an appropriate
hoist and lifting devices to lift the input housing.
The input housing weighs approximately 28 kg
(75 lbs).
Special Tool Required
J 24171-ASeal Remover
1. Position input housing assembly on work surface with the input seal 1 up.
2. Using J 24171-A, remove input seal 1. Discard
the seal.
1
1
V10529.00.00
3. Position input housing assembly on work surface with the seal side down.
4
2
3
NOTE:
Leave two loosened bolts on the inner bolt circle in
order to remove the pump assembly from the front
support.
4. Loosen but do not remove two M10 x 1.5 x 45 mm
bolts located 180 degrees apart on inner bolt
circle 1 of pump assembly 2.
V10228.00.00
1
V10228.01.00
5. Remove the remaining M10 x 1.5 x 75 mm

bolts retaining front support assembly 2 to the
input housing.
611

6. Support the input housing assembly, front support down, on wooden blocks high enough
above the work surface and spaced so that the
front support can be removed from beneath the
input housing.
7. Using a soft-faced hammer, drive the front support out of input housing.
1
2
V10478.00.00
8. Remove SAE #16 to-cooler fitting 2 (or a shipping plug if the fitting is not installed) from input housing 1.
9. Remove O-ring 3 from SAE #16 fitting 2.
1
V10258.00.00
1
V10258.00.00
11. Remove SAE #4 plug and O-ring 2 from input

housing 1.
1
1
V10257.00.00
V10257.00.00
612
MODULE REBUILD
12. Remove two O-rings 1 and O-ring gasket (triple O-ring) 2 from the input housing.
2
1
13. Discard the O-rings.

1
V10230.00.00
NOTE:
There is moderate spring force behind the cooler
bypass plug. After removing the retaining pin exercise care so that the parts are removed in a controlled manner.
V10230.00.00
14. Thread an M6 x 1 bolt approximately 8 mm

(516 inch) deep into cooler bypass plug 1 to aid
in removing the plug.
15. Press in on cooler bypass plug 1 to compress
the cooler bypass spring until retaining pin 2 is
loose.
16. Remove pin 2 by pushing it towards the machined surface.
V10256.00.00
1
1
V10256.00.00
17. Pull cooler bypass plug 1 from the input housing.
18. Remove ball 2, spring 3, and stop 4.

19. Replace the O-ring on bypass plug 1.
3
2
1
20. Inspect plug 1, ball 2, and stop 4 for damage.

Replace a damaged component.
21. Inspect bypass spring 3 for wear or sagging.
Measure the bypass spring free length. Spring
free length is approximately 34.50 mm
(1.358 inch). Spring force is 54.58 5.19 N at
25.70 mm (12.3 1.2 lb at 1.012 inch).
2
3
1
V10255.00.00
V10255.00.00
22. Replace spring 3 if specifications are not met.

b. Inspect Plugs and Cooler Fittings
1. Inspect all plugs and cooler fittings for thread
damage or other defects.
2. Replace fittings as required. Replace all
O-rings.
613

c. Inspect Input Housing
1. Inspect the input housing for visible defects.
2. Replace the input housing if the housing is deformed or cracked.
3. Use crocus cloth or a soft stone to remove high
spots on sealing surfaces or in the cooler bypass bore.
4. Inspect all valve bores and other passages for
debris. Remove any debris found.
5. Inspect all threaded holes for thread damage. If
thread damage cannot be corrected with a tap,
replace the input housing. Use the following
taps to correct thread damage:
Bolt holesM10 x 1.5 standard tap
SAE #4 plugsSAE #4 tap
Cooler fittingsSAE #16 tap
d. Front Support Pump Disassembly

1. Place front support/pump assembly on the
work table, bolt side down.
2. Remove O-ring 2 from pump hub 1.
V10254.00.00
2
V10254.00.00
3. Remove and discard thrust bearing 1.
V10253.00.00
V10253.00.00(5-2-11)
614
MODULE REBUILD
4. Place front support/pump assembly on work
surface bolt side up.
5. Remove the remaining M10 x 1.5 x 45 bolts.
5-2-12
1
V10252.01.00
6. Remove the front support assembly.
V10251.00.00
V10251.00.00
7. Remove the separator plate.
V10250.00.00
V10250.00.00
615

8. Remove the Gerotor gear set from the pump
body.
CAUTION:
To help avoid EV Drive damage always use the
spring compressors designed for a particular
valve. There are high spring forces behind the
valve retaining pins. After removing the retaining pin, exercise care so that the parts are removed in a controlled manner.
V10249.00.00
V10249.00.00
e. Remove and Inspect Main Regulator Valve

J 48129Front Support Spring Installer/
Remover
1
1. Install the J 48129 lead screw 1 in tapped

hole 2 closest to the edge of the tool.
5-2-15.1
4
3
5-2-15.1
V10494.00.00
1
4
3
2. Using holes 3 and 4 in the tool and the two bolt

holes located between main regulator valve 1
and main relief valve 2, install J 48129 with
two bolts, nuts, and washers.
3. Install the slotted spring compressor adapter 3
into the end of the lead screw of J 48129 and
align the slot in spring compressor adapter
with the main regulator valve retaining pin 4.
5-2-15.2
V10495.00.00
4. Compress main regulator valve spring with

J 48129 until the retainer pin is loose.
5. Using a small punch or awl, push the pin out
the backside of the pump housing through the
relief slot in J 48129.
6. Release spring pressure and remove J 48129.
616
MODULE REBUILD
7. Remove valve stop 2, O-ring 1, main regulator
spring 3, and main regulator valve 4.
8. Remove and discard the O-ring from valve

stop 2.
9. Inspect valve stop 2 for damage. Replace a

damaged valve stop.
5-2-16.1
10. Inspect main regulator valve 4 for burrs, raised

edges, or other minor surface damage that may
cause the valve to stick. Remove burrs or
raised edges with crocus cloth. Replace a valve
with damage that cannot be corrected.
V10548.00.00
11. Inspect valve spring 3 for damage. Measure the

free length and compressed length of spring 3.
Free length is approximately 71.30 mm
(2.807 inch)
Compressed length is 35.89 mm
(1.412 inch) when 132.16164.82 N

(29.7137.05 lb) is applied to spring 3.
12. Inspect the retaining pin for damage. Replace a
damaged retaining pin.
f. Remove and Inspect Main Relief Valve
Remover
1. Install J 48129 lead screw into the center hole
of the tool.
5-2-17
V10497.00.00
617

2. Using slotted holes 2 and 3 in the tool and the
two bolt holes located on either side of the
main relief valve, install J 48129 with two
bolts, nuts, and washers. One slotted hole provides relief for the dowel pin pressed into the
pump housing.
5-2-17.1
main relief valve
V10544.00.00
3. Install spring compressor adapter 1 onto the

end of the lead screw of J 48129 and align the
slot in the adapter with main relief valve retaining pin 2.
4. Compress main relief valve spring with
J 48129 until retainer pin 2 is loose.
5. Push pin 2 out of pump housing towards work
surface through the relief slot in J 48129.

2
7. Remove main relief stop 2, O-ring 1, main relief spring 3, and ball 4.
3
4
8. Remove and discard O-ring 1 on valve stop 2.

damaged valve stop.
5-2-18
V10546.01.00
10. Inspect main relief spring 3 for damage. Spring

free length is approximately 35.56 mm
(1.400 inch) Spring force at a compressed
length of 27.15 mm (1.069 inch) is 231.28
311.28 N (51.6869.88 lb). Replace spring 3 if
it does not meet specification or is damaged.
11. Inspect ball 4 for damage. Replace a damaged
ball.
g. Remove and Inspect Lube Regulator Valve
Remover
1. Install J 48129 lead screw in the hole in the
center of the tool.
5-2-18.1
618
V10497.00.00
MODULE REBUILD
2. Using the two slotted holes in the tool and the
two bolt holes located on either side of lube
regulator valve install J 48129 with two bolts,
nuts, and washers.

slot in the adapter with the lube regulator valve
retaining pin.
5-2-18.2
4. Compress lube regulator valve spring with

J 48129 until the retaining pin is loose. Push
retaining pin 2 out of pump housing towards
work surface through the relief slot in J 48129.
V10496.00.00

6. Remove valve stop 2, O-ring 1, lube regulator
spring 3, and lube regulator valve 4.
7. Remove and discard valve stop 1 O-ring.
2
1

damaged valve stop.
5-2-18.3
4
9. Inspect valve 4 for burrs, raised edges, or other

minor surface damage that may cause the valve
to stick. Remove burrs or raised edges with
crocus cloth. Replace a valve with damage that
cannot be corrected.
3
2
1
V10549.00.00
10. Inspect lube regulator spring 3 for damage.

Lube regulator spring 3 free length is approximately 37.37 mm (1.471 inch). Spring force at
a compressed length of 22.89 mm (0.902 inch)
is 50.3966.79 N (11.3315.01 lb).
h. Inspect Pump Assembly
1. Inspect valve bores 1 for surface damage.
Valves must dry and move freely in their bore
by their own weight. Remove high spots with
crocus cloth.
2. Inspect pump housing bushing 2 for damage

and wear. Replace the bushing if the orange
Teflon material around the ID of the bushing
has worn through exposing bronze material.
3. Measure the ID of bushing 2. Replace the
bushing if the ID exceeds 57.20 mm
(2.252 inch).
2
3
V10248.00.00
1
V10248.00.00
4. Replace the bushing and pump housing if the

bushing has spun in the pump housing bore.
619

5. Inspect input seal bore for visible damage.
6. Lightly sand any high spots in the pump housing input seal bore with medium grit crocus
cloth. Make sure all sanding debris is removed
and the bore is clean.
7. Inspect threaded holes for damage. Use an
M10 x 1.5 tap to correct thread damage.
8. Inspect the thrust bearing face, separator face,
and gear cavity machined surfaces for damage.
Replace the pump housing if a machined surface is damaged.
9. Inspect the pump housing for damage or
cracks. Replace the housing if defects are
found.
NOTE:
Measure, as described below, at several locations.
Replace the pump housing and Gerotor gearset if
any of the specifications are not met.
10. Measure the depth of the pump housing gear
cavity. The maximum depth of the gear cavity
is 21.458 mm (0.845 inch).
5-2-20
V10247.00.00
11. Measure the ID of the pump housing gear cavity. The maximum ID of the gear cavity is
114.456 mm (4.506 inch).
5-2-21
V10246.00.00
620
MODULE REBUILD
12. Measure the width of the drive and driven
pump gears. Minimum width allowed is
21.403 mm (0.843 inch).
5-2-22
V10245.00.00
13. Measure the OD of the driven gear. The minimum OD of the driven gear is 114.21 mm
(4.496 inch).
14. Inspect the drive gear input shaft pilot area for
damage.
5-2-23
V10244.00.00
15. The drive gear flats are machined with approximately 2 degrees angularity in either direction
from the centerline across each flat. Measure at
the centerline the distance between the flats of
the drive gear. The maximum distance between
the flats is 42.05 mm (1.656 inch).
16. Install the drive and driven gears into their positions in the pump housing.
5-2-24
V10243.00.00
621

17. Measure the driven gear tooth tip clearance.
Maximum allowable clearance is 0.15 mm
(0.006 inch).
V10242.00.00
V10242.00.00
18. Measure the clearance between driven gear and

main pump body (Driven Gear Diameter
Clearance). The maximum Driven Gear Diametrical Clearance is 0.36 mm (0.014 inch).
V10241.00.00
V10241.00.00
19. Measure the depth from pump housing to

driven gear (pump gear side clearance). Maximum clearance is 0.10 mm (0.004 inch).
20. Remove the gearset from the pump housing.
21. Inspect both gears for damage. Replace the
gearset if specifications are not met or damage
is found.
V10240.00.00
V10240.00.00
622
MODULE REBUILD
22. Inspect separator plate for damage. The separator plate must not be scored, nicked, or
grooved.
23. Measure the separator plate thickness in the
gear wear area. The thickness of the separator
plate must not vary more than 0.025 mm per
25 mm x 25 mm area (0.001 inch per 1.0 x
1.0 inch).
V10239.00.00
24. The minimum thickness of the separator plate

is 4.65 mm (0.183 inch).
V10239.00.00
25. Inspect dowel pins 1 for damage.

1
26. Remove and replace any damaged dowel pins.

27. Press a new dowel pin into the housing until the
top of pin is 9.8010.20 mm (0.3860.402 inch)
from the face of the housing.
V10238.00.00
i. Replace Pump Housing Bushing

Special Tool Required:
J 48123Pump Housing Bushing Installer
V10238.00.00
1. Support pump housing, O-ring side up, on two

wooden blocks.
2. Using a suitable punch, drive the bushing out
of the pump housing.
3. Clean bushing bore of residue. Parts must be
dry before installing bushing.
5-2-30
4. Install bushing on J 48123.

5. Press or drive bushing until the J 48123 tool
seats. The bushing will be flush to 0.25 mm
(0.010 inch) below flush with the bushing bore.
V10237.00.00
623

j. Inspect Front Support
1. Inspect the front support for damage.
2. Inspect thrust bearing surfaces for damage.
3. If the bushing has spun in the front support assembly bore, then replace the front support assembly and the bushing.
5-2-30.1
4. Replace the front support if the front support or

thrust bearing surfaces are damaged.
V10658.00.00
k. Inspect and Replace Front

Support Assembly Roller Bearing
J 48125Front Support Roller Bearing
Remover
J 48139Front Support Roller Bearing
Installer
1. Inspect front support roller bearing for damage
or wear. Replace a damaged or worn roller
bearing. If replacing the roller bearing, also replace the bearing race pressed onto the Rotor A
speed signal wheel hub.
5-2-31
V10499.00.00
2. If replacing the roller bearing, install small

disk of bearing remover J 48125 in the bushing
bore. Install the hook-end J 48125 legs beneath
the roller bearing. When correctly installed the
lead screw of J 48125 presses against disk and
the legs pull up on the roller bearing.
3. Remove the roller bearing.
4. Clean the bearing bore.
5. Install bearing on J 48139 bearing installer.
6. Using J 48139, drive or press the bearing flush
with top of bearing bore.
624
MODULE REBUILD
l. Inspect and Replace Front
Support Assembly Bushing
J 48122Front Support Bushing
Remover/Installer
1. Inspect front support assembly bushing 1 for

damage and wear.
2. Replace the bushing if the orange Teflon material around the ID of the bushing has worn
through, exposing bronze material.
3. Measure the ID of the bushing. Maximum
bushing ID is 51 mm (2.008 inch) ID. Replace
the bushing if specifications are not met.
1
V10236.00.00
V10236.00.00
4. Position the front support assembly, roller

bearing side down, on wooden blocks high
enough from work surface so that bushing 1
can be removed towards the work surface.
5. Install J 48122 into the bushing bore, longer
end in the bushing.
5-2-33
6. Press or drive bushing 1 from front support

housing towards the work surface.
7. Clean the bushing bore of residue. Parts must
be dry before installing bushing.
V10501.00.00
8. Turn the front support assembly, roller bearing

side up.
9. Install bushing 1 on J 48122.

10. Press or drive bushing 1 until J 48122 seats.
The bushing will be flush with or 0.25 mm
(0.010 inch) below the top of bushing bore.
5-2-34
V10500.00.00
625

m. Assemble Front Support/Pump
J 48129Front Support Valve Spring
Remover/Installer
J 46699Front Support Seal Installer
1. Position pump housing O-ring side down supported on wooden blocks.
5-2-35
V10235.00.00
2. Install lube regulator valve 4, small land first.

1
3. Install lube regulator spring 3.

4. Install O-ring 1 on valve stop 2.
5. Install valve stop 2.
5-2-36
4
3
2
1
V10549.00.00
7. Using two slotted holes 2 and 3 in the tool and

the two bolt holes located on either side of lube
regulator valve 1 install J 48129 with two bolts,
nuts, and washers.
5-2-36.1
626

center of the tool.
V10497.00.00
8. Install spring compressor adapter onto the end

of the lead screw of J 48129 and align the slot
in the adapter with the lube regulator valve retaining pin bore.
MODULE REBUILD
9. Compress lube regulator valve spring with
J 48129 until valve stop is compressed far
enough to be retained by pin 2.
10. From the separator plate side of the pump
housing, install pin 2.
11. Release spring pressure.

12. Remove the spring compressor.
V10496.00.00
13. Install main regulator valve 4, small diameter

first.
14. Install main regulator spring 3.
15. Install O-ring 3 on valve stop 2.

16. Install valve stop 2.
5-2-38
V10548.00.00
17. Install the J 48129 lead screw 1 in tapped hole

closest to the edge of the tool 2.
18. Using holes 3 and 4 in the tool and the two bolt
holes located between main regulator valve 1
and main relief valve 2, install J 48129 with
two bolts, nuts, and washers.
19. Install spring compressor adapter onto the end
of the lead screw of J 48129 and align the slot
with the main relief valve retaining pin bore.
5-2-39
4
3
V10494.00.00
627

1
4
3
20. Install J 48129 on the pump housing with two

bolts, washers, and nuts using the two bolt
through holes between the main regulator
valve and the main relief valve
21. Compress the main regulator valve spring with
J 48129 until the valve stop is compressed far
5-2-40
V10495.00.00

housing, install pin 2. Make sure pin 2 is below
the machined surface.
25. Install main relief ball 4 and main relief

spring 3.
2
3
26. Install the O-ring 1 on valve stop 2 and install

valve stop 2.
V10546.01.00

center of the tool.
28. Using slotted holes 2 and 3 in the tool and the

two bolt holes located on either side of the
main relief valve, install J 48129 with two
bolts, nuts, and washers. One slotted hole provides relief for the dowel pin pressed into the
pump housing.
2
628
V10497.00.00
MODULE REBUILD
slot in the adapter with the main relief valve retaining pin bore.
2
30. Compress main relief valve spring with

J 48129 until the valve stop is compressed far
5-2-40A

housing, install pin 2. Make sure pin 2 is below
the machined surface.
V10544.00.00

34. Install the Gerotor gear set into the pump body.
V10234.00.00
V10234.00.00
35. Align dowel pin holes in separator plate 1 with

pump assembly dowel pins 2.
36. Install separator plate over dowel pins.
5-2-42
V10233.00.00
629

2
37. Align dowel pin holes in the front support assembly with dowel pins in the pump assembly.
38. Install front support assembly 1.

2
V10232.00.00
39. Install nine bolts 2 (M10 x 1.5 x 45 mm) located on the inner bolt circle.
40. Install two bolts 2 located near the cast in part
number.
41. Tighten bolts to 5161 Nm (3845 lb ft).
V10232.00.00
42. Install a new O-ring 1 on front support/pump

assembly.
V10231.00.00
1
1
V10231.00.00
43. Install 2 new O-rings 1 and a new input

housing gasket (triple O-ring) 2 into the input
housing.
2
1
V10230.00.00
2
V10230.00.00
630
MODULE REBUILD
44. Align front support pump assembly bolt holes
with matching bolt holes inside input housing.
2 2
45. Install front support pump assembly 1 inside

input housing 2.
46. Using a soft faced hammer, drive assembly
down until it seats.
V10228.00.00
47. Install ten M10 x 1.5 x 75 mm bolts. Tighten

V10228.01.00
48. Install a new O-ring on plug 1.

4
49. Install cooler bypass valve stop 4, rectangular

end first, into its bore in the input housing. Install spring 3, ball 2, and plug 1.
3
2
50. Thread an M6 x 1 bolt approximately 8 mm

(516 inch) deep into cooler bypass plug 1 to aid
in installing the plug.
2
3
1
V10255.00.00
V10255.00.00
51. Press in on cooler bypass plug 1 to compress

the cooler bypass spring until retaining pin 2
can be installed.
52. Install pin 2 from the machined surface side.
Make sure the retaining pin is below the machined surface.
2
V10256.00.00
CAUTION:
Installing a thrust bearing assembly upsidedown will cause the bearing fail and progressive
damage to the transmission.
1
V10256.01.00
53. Install thrust bearing 1 (74 mm ID) rounded

edge OD up.
V10227.00.00
1
V10227.01.00
631

54. Install a new input seal 1 on seal installer
J 46699. Position the seal on the tool so the
seal lip is outward and the face of the steel case
is against the driving face of the tool.
J 8092
J 46699
55. Seat seal 1 squarely in the bore and press or

drive the seal into the bore.
5-2-49
56. Drive seal 1 until the installer contacts the top

of the pump assembly. The input seal will now
be flush with the top of the input seal bore.
V10551.00.00
57. Lubricate the seal with clean transmission

fluid.
58. Install a new O-ring 3 onto SAE #16 fitting 2.

59. Install SAE #16 to-cooler fitting 2 (or a shipping plug if the fitting is not used) into input
housing 1.
1
V10257.00.00
2
V10258.00.00
60. Install a new O-ring on SAE #4 plug 2 and install into input housing 1.
61. Tighten plug 1 to 1013 Nm (2736 lb inch).
1
2
V10258.00.00
3
2
632
V10257.00.00
MODULE REBUILD
63.
ROTOR A
WARNING!
To help avoid personal injury or equipment damage, make sure the work table or other supporting device can safely support Rotor A in a vertical
position. Rotor A weighs approximately 90.9 kg
(200 lbs), use care when maneuvering Rotor A.
a. Remove Main Shaft/P2 Carrier
1. Remove thrust bearing 1 from Rotor A speed
signal wheel hub before removing Rotor A
from the stator housing.
2. Inspect the thrust bearing for wear or damage.
XXXXX
XXXX
V10280.00.00
3. Discard a worn or damaged thrust bearing.
V10371.00.00(4-7-5)
4. Before further disassembly, mark a reassembly

balance mark 1 across the assembly from Rotor to flange.
V09889.00.00
V09889.00.00
5. Remove twelve bolts 1 retaining the Rotor A

flange and Rotor A hub.
V10277.00.00
V10277.00.00
633

CAUTION:
To help avoid equipment damage, position main
shaft/P2 carrier assembly vertically. If laid horizontally, the main shaft can drop through the P2
carrier assembly. Exercise care when removing
the main shaft/P2 carrier assembly so the main
shaft does not become damaged.
NOTE:
Prepare wooden blocks on the work surface to support the main shaft/P2 carrier assembly in a vertical
position so that the main shaft does not fall out of
the assembly. Make sure to support the main shaft/
P2 carrier assembly to prevent it from falling to one
side.
6. Lift main shaft/P2 carrier assembly out of the
Rotor assembly using an M10 x 1.5 eye hook
installed in the end of the main shaft and a
hoist.
7. Place the assembly, carrier side down, on
blocks.
V10276.00.00
634
V10276.00.00
MODULE REBUILD
b. Remove P1 Planetary
1
1. Remove P1 sun gear 1 from Rotor A assembly.

2
V10288.00.00
V10288.00.01
2. Remove P1 carrier assembly 1 from Rotor A

assembly.
V10289.00.00
V10289.00.00
3. Remove P1 ring gear/input shaft assembly 1

from the Rotor A assembly.
V10274.00.00
V10274.00.00
635

c. Disassemble Input Shaft/P1 Ring Gear
1. Remove thrust bearing 1 from the bearing bore

in the rear of the input shaft.
2. Inspect the thrust bearing for wear or damage.
V10290.00.00
V10290.00.00
4. Position input shaft/P1 ring gear assembly on

the work surface so that the input shaft is up.
1
5. Remove thrust bearing 1 from the input shaft

pilot.
6. Discard thrust bearing 1 if worn or damaged or
if it does not rotate smoothly.
V10170.00.00
7. Remove O-ring 1 from the input shaft.
V10170.00.00
1
2
V10030.00.00
V10030.00.00
9. Remove the retaining ring from the input shaft/

P1 ring gear assembly.
10. Replace the retaining ring if it is distorted or
has step wear.
V10034.00.00
636
MODULE REBUILD
11. Remove input shaft from P1 ring gear.
1
12. Inspect spline 1 for wear or damage.
13. Replace the input shaft if the spline is worn or

damaged. If splines have more than 0.38 mm
(0.015 inch) movement relative to the splines
in the damper hub, replace the damaged components.
V10040.00.00
14. Inspect thrust bearing surface 2 for wear or

damage.
V10040.00.00
15. Replace the input shaft if the thrust bearing

surface is worn or damaged.
16. Inspect thrust bearing surface 1 in the rear of
the input shaft for wear or damage.
17. Replace the input shaft if the thrust bearing

surface is worn or damaged.
18. Measure the thickness of the input shaft at the
flats. Minimum shaft thickness at the flats is
41.80 mm (1.645 inch).
V10039.00.00
V10039.00.00
19. Replace the input shaft if the specification is

not met.
V10038.00.00
V10038.00.00
637

20. Inspect the bushing journal for surface damage.
21. Measure the outside diameter of the bushing
journal. Minimum bushing journal OD is
50.688 mm (1.995 inch).
V10037.00.00
22. Replace the input shaft if the bushing journal

surface is damaged or the specification is not
met.
V10037.00.00
23. Inspect input shaft bushing 1, pressed inside

the rear of the input shaft for damage or wear.
If the bushing has spun in its bore, replace the
input shaft.
24. Measure the ID of the bushing. The bushing ID

cannot exceed 33.57 mm (1.322 inch).
V10036.00.00
V10036.00.00
25. Replace the bushing if the orange Teflon material on the ID of the bushing has worn
through exposing bronze material or specifications are not met.
d. Replace Input Shaft Bushing
J 48130Input/Output Shaft
Bushing Remover
J 48131Input/Output Shaft Bushing Installer
1. Remove the outer cup of J 48130. Install the

tool collet so that the collet is centered in the
bushing.
5-3-46
V10502.00.00
638
MODULE REBUILD
2. Hold the lead screw stationary with a 38 inch
wrench and tighten the nut with a 34 inch
wrench until the nut is snug against the washer.
Do not over tighten the nut. If the nut is overtightened, bushing removal is more difficult
and the tool may be damaged.
5-3-45.2
V10503.00.00
3. Place the cup over the lead screw and tool collet.
4. Place the tool bearing, stamped side up, over
the lead screw.
5-3-45.3
5. Install the washer and nut.

6. Hold the lead screw stationary with a 38 inch
wrench and tighten the top nut with a 34 inch
wrench. Continue tightening the nut until the
bushing is clear of its bore.
V10504.00.00
7. Clean the bushing bore. Parts must be clean

and dry before installing a new bushing.
J 8092
8. Install a new bushing on J 48131.
J 48131
9. Press or drive the bushing until J 48131 seats.

The bushing must be flush to 0.25 mm
(0.010 inch) below the top of the bore.
5-3-45.4
V10505.00.00
639

e. Inspect P1 Ring Gear
1. Inspect the P1 ring gear for spline wear or
damage.
2. Replace the P1 ring gear if the splines are worn
or damaged.
V10033.00.00
V10033.00.00
3. Inspect the P1 retaining ring for distortion.

4. Replace a distorted or damaged retaining ring.
V100034.00.00
V10034.00.00
f. Assemble P1 Ring Gear/Input Shaft

1. Position the P1 ring gear on the work surface
with the retaining ring groove up.
V10033.00.00
V10033.00.00
640
MODULE REBUILD
2. Install input shaft 1 into P1 ring gear 2.
V10032.00.00
2
V10032.00.00(5-3-50)
3. Install retaining ring 1, retaining the input shaft

and the P1 ring gear.
1
CAUTION:
V0031.00.00
An incorrectly installed thrust bearing causes

progressive transmission damage due to bearing
failure. Make sure the thrust bearing is installed
correctly.
V10031.00.00(5-3-51)
4. Install thrust bearing 1 (105 mm; (4.134 inch)

ID) on the input shaft. If thrust bearing 1 is installed correctly, the rounded edge of the OD is
visible.
ROUNDED EDGE
V09897.00.00
V09897.00.00
641

5. Install O-ring 1 onto input shaft 2.
1
2
NOTE:
The P1 carrier is assembled as part of Rotor A assembly procedure.
V10030.00.00
V10030.00.00
g. Inspect P1 Sun Gear

1. Inspect and replace the P1 sun gear if any of
the following is found:
Spline wear
Damage to splines
Damage to thrust bearing surfaces
5-3-53.1
2. Maximum relative movement between:

Pinion gear spline and sun gear spline
V10657.00.00
P2 drive hub spline and P1 sun gear spline
is 0.38 mm (0.015 inch). Replace any component worn beyond specification.

h. Disassemble and Inspect P1 Carrier
1
1. Position P1 carrier hub down on the work surface.

2. Remove thrust bearing 1 from the P1 carrier
bore.
3. Replace thrust bearing 1 if it is worn or damaged.
V09908.00.00
V09908.00.00
642
MODULE REBUILD
4. Position the P1 carrier, hub up, on the work
surface.
5. Using a feeler gauge, measure end play between the thrust washers and the P1 carrier at
each of the four pinions. End play cannot exceed 1.04 mm (0.041 inch).
6. Replace components that are worn or damaged
and allow excessive pinion end play.
V10180.00.00
V10180.01.00
7. Remove and inspect spiral retaining ring 1

from the P1 carrier.
8. Replace spiral retaining ring 1 if it is deformed.
V10179.00.00
V10179.00.00
9. Remove four spindles 1 from the P1 carrier

spindle bores.
V10178.00.00
V10178.00.00
10. Remove and inspect dowel pin 1 from each

spindle.
11. Replace a dowel pin if it is worn or damaged.
12. Inspect each spindle for damage. Replace a
damaged spindle.
V09996.00.00
2
V09996.00.00
643

13. Remove four pinion gears 2 and eight thrust
washers 1 from P1 carrier 3.
V09994.00.00
V09994.00.00
14. Remove two roller bearing assemblies 1 from

inside each pinion gear 2.
NOTE:
Do not measure thrust washers across the lube slots.
2
1
V09995.00.00
V09995.00.00
15. Measure the thickness of eight thrust washers.

16. Replace any thrust washer with step wear, surface damage, or that is worn below 1.39 mm
(0.055 inch).
17. Replace a thrust washer if the tang is battered
or cracked.
V10014.00.00
V10014.00.00
18. Inspect eight roller bearing assemblies for

wear or damage.
19. Replace a worn or damaged roller bearing assembly.
V10015.00.00
V10015.00.00
644
MODULE REBUILD
20. Inspect four P1 pinion gears, bores, and faces
for wear and spline deformation.
NOTE:
If a pinion gear must be replaced, replace all four
pinion gears as a set.
V10012.00.00
21. Maximum relative movement between pinion
splines and ring gear or sun gear splines is
0.38 mm (0.015 inch). Replace pinions that do
not meet specification.
V10012.00.00(5-3-24)
22. Replace pinion gears that are worn or have

tooth deformation.
23. Inspect P1 carrier spline 1.
24. Replace the carrier if splines are visibly deformed.

25. Inspect the spindle areas for galling, battering,
or other damage. Replace the P1 carrier if
damage is found.
26. Inspect the retaining groove for damage. Replace the P1 carrier if the retaining ring groove
is damaged.
V10177.00.00
V10177.00.00
27. Inspect thrust bearing surface 1 on the P1 carrier for visible wear or damage.
28. Replace the P1 carrier and the thrust bearing if

surface damage is found.
V10176.00.00
V10176.00.00
645

30. Replace the P1 carrier and the thrust bearing if
surface damaged is found.
V10273.00.00
V10273.00.00
i. Assemble P1 Carrier
1. Position the P1 carrier 1 hub side up on the
work surface.
V10175.00.00
V10175.00.00
2. Install two roller bearing assemblies 1 into a

pinion gear 2.
2
1
V09995.00.00
V09995.00.00
3. While keeping roller bearings inside the pinion

gear, install one thrust washer 1, tangs pointing
away from the gear, on each end of the pinion
gear so that when installed in the P1 carrier the
tangs locate into notches 2 in the carrier.
4. Install pinion, roller bearing, thrust washer assembly into the P1 carrier.
V10174.00.00
1
V10174.00.00
646
MODULE REBUILD
5. Install dowel pin 1 in spindle 2.
1
V10173.00.00
2
V10173.00.00
6. Align pinion, roller bearings, and thrust washers with the spindle bore. With dowel pin 2 up,
install spindle 1 through the thrust washers,
roller bearings, and pinion so that dowel pin 1
seats into anti-rotation groove 3 in the P1 carrier.
1
3
V10172.00.00
7. Repeat steps 2 through 6 with the remaining

three pinion gear assemblies.
V10172.00.00
8. Install spiral retaining ring 1 in the P1 carrier

assembly.
V10171.00.00
V10171.00.00
647

9. Position the P1 carrier retaining ring side down
on the work surface.
CAUTION:
5-3-36.1

correctly.
V09908.00.00
10. Install thrust bearing 1 onto the thrust bearing

pilot with the blue stripe down and tabs on the
ID of the thrust bearing up.
11. Measure to confirm correct pinion end play.
Maximum pinion end play is 1.04 mm
(0.041 inch).
12. Determine and correct the cause if end play is
more than the specification.
V10180.00.00
V10180.01.00
j. Disassemble Main Shaft/P2 Carrier

1. Position the P2 carrier/main shaft assembly
vertically so that the P2 carrier can be lifted
free of the main shaft.
CAUTION:
Take steps to prevent the main shaft from falling

to one side while removing the P2 carrier assembly.
V10029.00.00
2. Lift P2 carrier 1 free of the main shaft.

V10029.00.00
648
MODULE REBUILD
3. Position the P2 carrier on the work surface P2
drive 1 hub side up.
2
4. Remove internal retaining ring 2 from the P2

carrier ring gear.
5. Inspect ring gear 1 for deformation. Replace a
deformed retaining ring.
V10028.00.00 1
V100028.00.00(5-3-55)
6. Remove P2 drive hub 1 from P2 carrier asembly.
1
1
V10027.00.00
V100027.00.00
7. Remove thrust bearing 1.

8. Inspect thrust bearing 1 for wear, damage, or
uneven rotation.
9. Discard a worn, damaged, or a thrust bearing
that does not rotate smoothly.
V10026.00.00
V10026.00.00
649

10. Remove P2 carrier assembly 1 from P2 ring
gear 2.
1
1
V10025.00.00
V10025.01.00
11. Remove P2 sun gear 1 from inside P2 ring

gear 2.
1
2
V10024.00.00
V100024.00.00
12. Remove thrust bearing 1 from P2 ring gear.
1
1
13. Inspect thrust bearing 1 for wear or damage.

V10023.00.00
V100023.00.00
15. Position the P2 carrier assembly retaining ring

side up.
1
V10022.00.00
V10022.00.00
650
MODULE REBUILD
(0.041 inch).
V10180.00.00
V10180.01.00
19. Remove and inspect spiral retaining ring 1

from P2 carrier 2.
20. Replace the spiral retaining ring if the retaining
ring is deformed or damaged.
V10021.00.00
V10021.00.00
21. Remove four spindles 1 from P2 carrier 2.

1
V09992.00.00
V09992.00.00
22. Remove dowel pin 1 from each spindle 2.
23. Inspect each dowel pin for wear or damage.
24. Replace worn or damaged dowel pins.

2
V09996.00.00
V09996.00.00
651

25. Remove pinion gear 1 and two thrust washers 2
from each P2 carrier pinion gear location.
V10017.00.00
2
1
V10017.00.00(5-3-66)
26. Remove two roller bearing assemblies 1 from

each pinion gear.
V10016.0.00
V10016.00.00

Thrust washers must be at least 1.39 mm
(0.055 inch) thick.
28. Replace any thrust washer that does not meet
specifications or that is worn or damaged.
V10014.00.00
V10014.00.00
29. Inspect four P2 pinions for spline wear and

tooth deformation.
NOTE:
If a pinion gear must be replaced, replace all four
pinion gears as a set.
V10012.00.00
V10012.00.00(5-3-24)
652
30. Maximum relative movement between the pinion gear and the ring gear is 0.38 mm
(0.015 inch) between the P3 sun gear spline
gear and the pinion 0.38 mm (0.015 inch).
MODULE REBUILD
31. Replace pinions if damaged or worn below
specification.
32. Inspect eight roller bearing assemblies for
wear or damage.
33. Replace a worn or damaged roller bearing assembly.
V10015.00.00
V10015.00.00
34. Inspect the P2 sun gear for tooth distortion,

spline wear, or damage.
35. Inspect the P2 sun gear thrust bearing surface
for excessive wear or damage.
36. Maximum relative movement between the pinion gear and the sun gear is 0.38 mm
(0.015 inch). Maximum relative movement between the P3 sun gear shaft spline and the P2
sun gear is 0.38 mm (0.015 inch).
V09915.00.00
V09915.00.00
37. Replace the sun gear if worn, damaged, or relative movement is out of specification.
38. Inspect P2 carrier splines 1 for wear.
39. Replace the P2 carrier if the splines are visibly
deformed.
V10271.00.00
V10271.00.00
653

40. Inspect thrust bearing surface 1 in the P2 carrier for visible wear or damage.
41. Replace the P2 carrier and thrust bearing if surface damage is found.
V010272.00.00
V10272.00.00
43. Replace the P2 carrier and thrust bearing if surface damage is found.
V10270.00.00
V10270.01.00
44. Inspect the spindle bores 1 for wear or damage.

Replace the P2 carrier if spindle bores are
damaged.
V09999.00.00
V09999.00.00
45. Inspect P2 carrier bushing 1 for damage and

wear.
46. Replace the bushing if the orange Teflon material on the ID of the bushing has worn
through exposing bronze material.
47. Measure the ID of bushing 1. Bushing 1 ID
must not exceed 94.25 mm (3.710 inch) ID.
Replace the bushing if the ID does not meet
specifications.
V09997.00.00
V09997.00.00(5-3-77)
654
48. If the bushing has spun in the P2 carrier bore,

replace the P2 carrier.
MODULE REBUILD
k. Replace P2 Carrier Bushing
Special Tool Required
J 48133P2 Carrier Bushing Installer
1. Position the P2 carrier on the work surface

bushing side down.
1
2. Drive bushing 1 towards the work surface with

a punch and hammer.
3. Remove the P2 carrier bushing. Clean the
bushing bore of residue. Parts must be dry before installing the new bushing.
5-3-78
V10477.00.00
4. Install bushing 1 into the groove of J 48133.

5. Press or drive bushing 1 until J 48133 seats.
The top of the bushing will project above the
bushing bore.
SHOW BUSHING INSTALLER

J 8092
IN
POSITION
IN POSITION
1
J 48133
5-3-80
6. Remove tool. If using the drive handle reinstall J 48133 onto the drive handle with the
groove side towards the handle. If using a
press, turn J 48133 groove side up. Install
J 48133 into the bushing.
1
2
V10498.00.00
7. Drive or press the bushing until J 48133 seats

and the bushing is flush to or 0.25 mm
(0.010 inch) below the top of the bushing bore.
l. Assemble P2 Carrier
NOTE:
Instructions are provided for a single pinion gear/
spindle assembly. The remaining three pinion gear/
spindle assemblies are assembled in the same manner.
1. Install dowel pin 1 into spindle 2.
1
1
2
2
V09996.00.00
V09996.00.00
655

2. Install two roller bearing assemblies 1 in pinion 2.
2
1
V09995.00.00
1
V09995.00.00
3. Install one thrust washer 1 on each side of pinion gear 2 with the thrust washer tangs away
from the pinion and the tangs positioned to locate into notches 3 in the P2 carrier.
4. Align bores in the roller bearings and thrust

washers to the carrier spindle bores.
3
V09994.00.00
1
1
V09994.01.00
5. Install spindle 1 in the P2 carrier so that the

dowel pin locates into P2 carrier slot 2.
1
2
V09993.00.00
V09993.00.00
6. Repeat steps 1 through 4 for the remaining

three spindle/pinion assemblies 1.
V09992.00.00
V09992.00.00
656
MODULE REBUILD
7. Install spiral retaining ring 1 onto P2 carrier 2.
5-3-85.1
2
V10021.00.00

(0.041 inch).
V10180.00.00
V10180.01.00
m. Inspect P2 Drive Hub Assembly

1. Inspect P2 drive hub spline 1 for wear. Maximum relative movement between the P2 drive
hub spline and P1 sun gear spline is 0.38 mm
(0.015 inch). Maximum relative movement between the P2 drive hub and P2 ring gear Rotor
A flange is 0.38 mm (0.015 inch).
2. Replace the P2 drive hub if splines are worn

beyond specification.
V09990.00.00
V09990.00.00
3. Replace the P2 drive hub if the thrust bearing

surface wear or damage is found.
V09989.00.00
V09989.00.00
657

1
4. Inspect P2 drive hub bushings 1 and 2 for damage or wear.
5. Replace the P2 drive hub if either bushing has

spun in its bore.
6. Replace a drive hub bushing if the orange
Teflon material on the ID of the bushing has
worn through, exposing bronze material.
V09918.00.00
V09918.00.00
7. Measure the ID of each bushing. Bushing ID

cannot exceed 51.21 mm (2.016 inch).
n. Replace P2 Drive Hub Bushing
J 48132P2 Drive Hub Bushing Installer
1. Position the P2 drive hub, flange up, on wood

blocks high enough above the work surface to
remove bushing 1.
2. Using a punch, drive bushing 1 free of the

drive hub.
3. Position the P2 drive hub, flange down, on
wood blocks high enough above the work surface to remove bushing 2.
5-3-89.1
V09918.00.00
4. Using a punch, drive bushing 1 free of the

drive hub.
5. Clean both bushing bores of residue. Parts
must be dry before installing a bushing.
658
MODULE REBUILD
6. For bushing 1, nearest to the P2 ring gear, install a bushing on the longer land of J 48132.
7. Press or drive the P2 ring gear side bushing into the P2 drive hub 3.353.65 mm
(0.1320.144 inch below the top face of the
bushing bore.
V09917.00.00
V09917.00.00(5-3-89.1)
8. To install bushing 1, closest to the input shaft,

position the P2 drive hub flange side down.
9. Install a bushing on the shorter land of
J 48132.
V09916.00.00
10. Using J 48132, press or drive bushing 1 flush

to the top of the bushing bore.
V09916.01.00
o. Inspect Main Shaft

1. Inspect input shaft and output shaft bushing
journals 1 for wear or damage.
2. Replace the main shaft if the bushing journals

are worn or damaged.
V09914.00.00
3. Measure input shaft and output shaft bushing
journals 1. Minimum pilot OD is 33.385 mm
(1.314 inch).
4. Replace the main shaft if input shaft and output
shaft bushing journals 1 do not meet specifications.
1
V09914.00.00
5. Inspect the main shaft splines for damage or

wear. Maximum relative movement between
mating splined parts is 0.38 mm (0.015 inch).
6. Replace the main shaft if splines are damaged
or worn beyond specification.
7. Inspect P2 drive hub bushing journal 1 for
damage.
659

8. Measure the OD of journal 1. Minimum OD is
50.925 mm (2.005 inch).
9. Replace the main shaft if specifications are not

met.
V09913.00.00
V09913.00.00
10. Inspect P3 carrier flange bushing journal 4 for

damage.
11. Replace the main shaft if journal 4 is damaged.
4
12. Measure journal 4 OD. Minimum OD is

44.930 mm (1.769 inch).
V09911.00.00
13. Replace the main shaft if journal 4 does not

meet specifications.
V09911.00.00
14. Inspect P3 carrier flange bushing journal 6 for

damage.
15. Replace the main shaft if the journal is damaged.
6
V09909.00.00
16. Measure journal 6 OD. Minimum OD is

44.930 mm (1.769 inch).
17. Replace the main shaft if the journal OD does
not meet specifications.
V09909.00.00
660
MODULE REBUILD
p. Inspect Rotor A Hub
NOTE:
If Rotor A Hub cannot be reused, replace the hub
with a complete Rotor A Hub assembly. The
Rotor A Hub assembly includes Rotor A Hub and
P2 ring gear flange only.
1. Replace the Rotor A Hub assembly if any of

the following are found:
Cracked shorting bars at 2

Stripped threads
Thrust bearing surface damage at 1

Speed signal wheel damage
V10279.00.00
Excessive surface damage to shorting bars

V10279.00.00(5-3-10)
NOTE:
Bearing race 1 may be replaced as a service part
without replacing the Rotor A Hub.
2. Correct surface imperfections with a soft fine

stone or crocus cloth. Remove any rust with
crocus cloth.
3. Inspect M8 threaded holes for thread damage.
Correct damaged threads with a M8 x 1.25 tap.
If thread damage cannot be corrected with a
tap replace the Rotor A hub assembly.
NOTE:
The roller bearing assembly in the front support
must be replaced if the inner race, pressed onto the
speed signal wheel side of Rotor A, is replaced.
4. Inspect roller bearing race 1, pressed onto the

hub of the speed signal wheel, for wear or
damage.
661

5. Replace bearing race 1 if it is damaged or
worn.
6. If roller bearing race 1 has spun on the Rotor A

hub, replace the Rotor A hub and the Rotor A
flange.
2
7. Inspect speed signal wheel for damaged teeth.

Replace the Rotor A assembly if speed signal
wheel teeth are damaged.
V10183.00.00
V10183.00.00(5-3-11)
q. Inspect Rotor A Hub Assembly P2 Ring Gear

1. Inspect P2 ring gear splines 1 for damage or
wear. Maximum relative movement between
P2 ring gear splines and P2 pinion gears is
0.38 mm, 0.015 inch. Replace the Rotor A hub
if spline wear or damage is found.
11
3
V09991.00.00(5-3-86)
4
2. Inspect P2 ring gear to P2 drive hub splines 2

for damage and wear. Maximum relative
movement between P2 ring gear splines and
Rotor A hub splines is 0.38 mm (0.015 inch).
Replace the Rotor A hub if spline wear or damage is found.
V09991.00.00
3. Inspect thrust bearing surface 3 for wear or

damage. Replace the Rotor A hub if wear or
damage is found.
4. Inspect Rotor A flange pilot 4 for surface damage. Remove high spots with a soft stone or
crocus cloth. Replace Rotor A hub assembly if
damage cannot be corrected.
NOTE:
The roller bearing assembly in the stator housing
must be replaced if the inner race, pressed on the
Rotor A flange, is replaced.
662
MODULE REBUILD
5. Inspect roller bearing inner race 3 pressed on
Rotor A flange for damage. Replace the inner
race if damage is found. Replace Rotor A assembly if the inner race has spun on the flange.
r. Replace Rotor A Flange Bearing Race
5-3-86.1
Special Tools Required (Refer to Section 4, Table 41):

J 48125Bearing/Race Remover
J 48138Bearing/Race Installer
V10659.00.00
1. Loosen leg nuts of J 48125 to allow hooked

end 1 of the legs to be positioned in the slots
under the bearing race. Install the hooked end
of the legs in the slots under the bearing race.
The legs will have to be tilted toward the bearing race to install the legs.
5-3-86.2
2. Turn the lead screw counter-clockwise until the

lead screw is retracted far enough to allow the
bridge to be installed in the bearing bore.
V10667.00.00
3. Install bridge 2 and tighten the lead screw to

tension the tool.
4. Using an appropriately-sized wrench tighten
the lead screw until the bearing race is pulled
free of the flange. Remove the bearing race and
J 48125.
5. Install a new bearing race on the Rotor A
flange with stepped side 1 of the race toward
the flange.
J 8092
6. Install J 48138 onto the bearing race.
J 48138
7. Press or drive J 48138 until the tool seats.

When correctly installed, the bearing race is
seated against the Rotor A flange.
5-3-86.3
1
V10675.00.00
663

s. Assemble Main Shaft/P2 Carrier
1. Position the P2 carrier bushing-side up.
1
CAUTION:
correctly.
V09908.00.00
2. Install thrust bearing 1, (64 mm [2.520 inch]

ID) with the blue stripe down and inner race
tabs up, onto the thrust bearing pilot inside the
P2 carrier.
V09908.00.00
NOTE:
The P2 sun gear has a smaller ID then the P1 sun
gear.
3. Install P2 sun gear 1 inside the P2 carrier.
1
V09907.00.00
V09907.00.00
4. Position the P2 ring gear spline-side up.

5. Apply petrolatum to thrust bearing face 1 of
the P2 ring gear.
V09906.00.00
V09906.00.00
664
MODULE REBUILD
CAUTION:
correctly.
6. Use petrolatum to retain thrust bearing 1 in its
bore. Install thrust bearing 1 (64 mm;
2.520 inch ID) into the P2 ring gear so that the
blue strip is visible when thrust bearing 1 is installed.
V09905.00.00
V09905.00.00
7. Lower the P2 ring gear over the P2 carrier assembly.
5-3-103
V10418.00.00(5-3-103)
8. Keeping the P2 carrier inside the P2 ring gear,

turn the P2 ring gear/carrier assembly over so
that the rotor flange is down.
V09903.00.00
V09903.00.00
665

9. Position the P2 drive hub flange-side up.
10. Apply petrolatum to the thrust bearing face inside P2 drive hub to retain thrust bearing.
V09902.00.00
CAUTION:
correctly.
V09902.00.00
11. Install thrust bearing 1 (64 mm; 2.520 inch ID)

inside P2 drive hub 2 so that the thrust bearings tabs are down and the blue strip is visible
when thrust bearing 1 is installed.
V09901.00.00
V09901.00.00
12. Install P2 Drive Hub 1 into P2 carrier

assembly 2, making sure that the thrust bearing
remains in the correct position.
V09899.00.00
V09899.00.00
13. Install retaining ring 1 in the ring groove of P2

ring gear 2.
1
2
V09898.00.00
V09898.00.00
666
MODULE REBUILD
t. Replace Speed Signal Wheel
Roller Bearing Race
Special Tools Required (Refer to Section 4, Table 41):
J 48138Bearing/Race Installer
NOTE:
If the roller bearing race is replaced on the speed
signal wheel hub, also replace the matching roller
bearing pressed into the back housing of the front
support assembly
1. Position Rotor A so that the speed signal wheel
end is up.
2. Loosen leg nuts of J 48125 to allow the hooked
end of the legs to be positioned in the slots under the bearing race. Install the hooked end of
the legs in the slots under the bearing race. The
legs will have to be tilted toward the bearing
race to install the legs.
3. Turn the lead screw counter-clockwise until the
lead screw is retracted far enough to allow the
bridge to be installed in the bearing bore.
4. Install the bridge and tighten the lead screw to
tension the tool.
5. Using an appropriately-sized wrench tighten
the lead screw until the bearing race is pulled
free of the flange. Remove the bearing race and
J 48125.
6. Install a new bearing race 1 on the Rotor A hub
with stepped side of the race toward the flange.
7. Install J 48138 onto the bearing race.
8. Press or drive J 48138 until the tool seats.
When correctly installed, the bearing race is
seated against Rotor A.
9. Press the bearing race until bearing race seats
against the face of hub.
5-3-107.1
V10668.00.00
J 8092
1
J 48138
1
5-3-86.3
2
V10182.00.00
667

u. Assemble Rotor A
1. Position the Rotor A hub, speed signal wheel
down, over the clearance hole in work surface.
If a clearance hole is not available, support Rotor A hub high enough above the work surface
to provide clearance for the input shaft.
V09900.00.00
V09900.00.00
2. Make sure the thrust bearing has been installed

on the input shaft.
3. Install input shaft/P1 ring gear assembly 1 into

Rotor A hub 2 so that the input shaft enters the
center hole of the rotor hub.
V09893.00.00
CAUTION:
V09893.00.00

correctly.
in thrust bearing bore on the P1 ring gear side
of the input shaft so that the blue stripe on
thrust bearing 1 is visible.
V09894.00.00
V10290.00.00
668
MODULE REBUILD
5. Install P1 carrier assembly 1, retaining ring
side down, into P1 ring gear 2.
V09895.00.00
CAUTION:
correctly.
V09895.00.00

into P1 carrier 2 so that the thrust bearings
tabs are facing up and the blue stripe is NOT
visible.
1
2
V09896.00.00
NOTE:
The P1 sun gear has a larger ID than the P2 sun
gear.
7. Install P1 sun gear 1 in P1 carrier 2.
V09896.00.00
1
1
V09892.00.00
V10288.00.01
669

8. Lower the P2 carrier assembly over the main
shaft, Rotor A flange side up. P2 drive hub
splines must fully engage both splines on either side of the largest bushing journal on the
main shaft splines.
9. Install an M10 x 1.5 eye hook in the main
shaft.
10. Lift the P2 planetary/main shaft assembly with
a hoist.
V09891.00.00
V09891.00.00
11. Lower the P2 planetary/main shaft assembly 1

in to Rotor A hub 2.
1
V09890.00.00
2
V09890.00.00
12. Align alignment marks 1 and 2 on Rotor hub

and Rotor flange.
V09889.00.00
V09889.00.00
670
MODULE REBUILD
13. Install twelve M8 x 1.25 x 20 bolts 1 retaining
P2 planetary assembly to the Rotor hub.
14. Tighten bolts to 2429 Nm (1721 lb ft).

15. Verify that a new O-ring has been installed on
the end of the input shaft.
V09888.00.00
V09888.00.00
64.
INSPECT C1 CLUTCH PACK
1. Replace the clutch pack if any of the following

are found:.
Pitted friction material
1
Worn internal splines

Step wear on the internal splines
4-10-1
Galled surfaces
Broken splines
NOTE:
Some discoloration of the friction and reaction
plates is acceptable.
V10373.00.00(4-10-1)
2. Measure the total thickness of the clutch pack.

Clutch pack thickness must be 26.5928.11 mm
(1.0471.107 inch). If clutch pack thickness
does not meet specification, replace the entire
clutch pack.
671

3. Measure the cone of each friction plate.
4. Replace the clutch pack if any clutch plate has
more than 0.25 mm (0.010 inch) cone.
CLUTCH PLATE
LEVEL SURFACE
ART 5-4-4
MEASURE HERE FOR CONE

V00493.01
5. Measure thickness A of each friction plate.

1
6. Replace the clutch pack if any friction plate is

thinner than 2.425 mm (0.095 inch).
7. Measure oil groove depth B of each friction
plate.
5-4-6
8. Replace the clutch pack if friction plate oil

groove depths are less than 0.23 mm
(0.009 inch).
A
B
R57
9. Measure the cone of each steel reaction plate.

A
10. Replace the clutch pack if any clutch plate has

more than 0.25 mm (0.010 inch) cone.
5-4-5
R60
672
MODULE REBUILD
11. Measure the thickness of each steel reaction
plate.
12. Replace the clutch pack if any steel reaction

plate is thinner than 2.41 mm (0.094 inch).
5-4-7
65.
C1 CLUTCH HOUSING
V10678.00.00
a. Remove and Inspect C1 Clutch Hub

1. Using a colored dye penetrant, mark retaining
ring 1 retaining the C1 clutch hub so that the
retaining ring can be re-installed with the same
face uppermost.
2. Remove retaining ring 1.
5-5-1
1
5-5-1
V10606.00.00
3. Remove C1 clutch hub 1.

1
5-5-2
5-5-2
1
V10634.00.00
673

4. Remove thrust bearing 1 from the back of C1
clutch hub 2.
5. Inspect thrust bearing 1 for wear or roughness

when turned by hand.
5-5-3
6. Replace a worn or rough turning thrust bearing.
5-5-3
V10596.00.00
7. Inspect C1 clutch hub 1 for spline wear and

bearing surface damage.
8. Replace a worn or damaged C1 clutch hub.
1
5-5-4
V10618.00.00
b. Inspect C1 Clutch Housing

1. Inspect the C1 housing. Replace the C1 housing if any of the following are found:
Damaged threads
Damaged or cracked splines
5-5-6
Galling on the thrust bearing face

Battering
5-5-6
V10633.00.00
2. Remove lube pressure tap plug 1.
1
2
V10636.00.00
674
MODULE REBUILD
3. Inspect lube pressure tap plug 1 and O-ring 2
for damage. Replace damaged parts.
5-5-7
1
2
1
5-5-7
V10636.00.00
4. Inspect the lube pressure port 1 threads for

damage.
5. Repair thread damage with a correctly-sized
tap.
5-5-8
1
5-5-8
V10632.00.00
c. Inspect C1 Clutch Housing Roller Bearing

1. Inspect roller bearing 1 for damage to rollers or
races.
2. Inspect roller bearing for wear or roughness

when roller bearing 1 is turned by hand.
1
3. Replace a damaged or rough turning roller

bearing.
5-5-9
V10631.00.00
675

d. Remove and Replace C1 Clutch
Housing Roller Bearing
Tools Required:
J 48347Roller Bearing Installer/Remover
SPACER
REMOVER
BRIDGE
5-5-10.1
NOTE:
If replacing the C1 Clutch Housing roller bearing,
also replace the matching roller bearing race
pressed onto Rotor B.
LEAD SCREW
V10638.00.00
1. Support the C1 clutch housing on wood blocks,

Rotor B side of the housing facing up.
2. Install bearing removal tool against the bolt
head of the J 48365 lead screw.
LEAD SCREW
REMOVER
BEARING
3. Install removal tool/lead screw assembly up

through the C1 clutch housing so that the removal tool bears on the back face of the roller
bearing.
5-5-10
V10639.00.00
4. Install the J 48365 spacer over the lead screw

so that it pilots into the C1 clutch housing,
above the roller bearing.
LEAD SCREW
BRIDGE
SPACER
BEARING
REMOVER
6. Install washer and nut onto leadsrew.
V10640.00.00
676
5. Install the bridge over the lead screw so that it

rests on the spacer.
7. Using appropriately sized wrenches, Tighten

nut until the roller bearing is free of the C1
housing.
MODULE REBUILD
8. Place the C1 Clutch Housing on the work surface or press table so that the roller bearing
race is uppermost.
J 48347
9. Install a new roller bearing on J 48347.
5-5-11
10. Align the roller bearing with the bearing bore.
11. Press or drive the roller bearing until it seats on

the shoulder in the bearing bore.
66.
V10630.00.00
DISASSEMBLE ROTOR B
HUB ASSEMBLY
1. Remove selective bearing race 1.
ROUNDED EDGE
1
5-5-1
1
V10542.00.00
551
NOTE:
Do not lift the Rotor B hub assembly using the speed
signal wheel.
2. Using a sling and hoist, turn Rotor B over so
that the tone wheel rests on the prepared wood
blocks and Rotor B flange 1 is up.
5-6-2
5-5-2
1
1
V10454.00.00
677

2
3. Mark a line for reassembly alignment across

the Rotor B hub and flange.
ART 5-6-3
5-6-3
5-6-3
V09889.00.00
4. Remove twelve bolts 1 retaining Rotor B

flange 3 to Rotor B hub 2.
3
2
ART 5-5-15
5-6-4
V10621.00.00
5. Remove P3 sun gear shaft 1 and Rotor B

flange 2.
1
2
5-6-5
5-6-5
V10532.00.00
5-6-6
5-6-6
678
7. Inspect thrust bearing 1 for damage. Rotate the

bearing to determine the presence of uneven
movement. Replace a damaged or unevenly
turning thrust bearing.
1
V10533.00.00
MODULE REBUILD
8. Remove P3 carrier assembly 2 from Rotor B
hub 1.
5-5-18
5-6-7
V10543.00.00
9. Place the P3 carrier on the work surface with

the P3 carrier flange up.
10. Measure the pinion end play of each of the four
pinions. End play cannot exceed 0.95 mm
(0.037 inch).
11. Excessive pinion end play indicates a worn or
out of specification component. Note for further inspection which pinion exhibits excessive
end play.
5-6-8
5-6-8
V10528.00.00
12. Remove retaining ring 1 retaining P3 carrier

flange 2 to the P3 carrier.
1
13. Inspect retaining ring 1 for damage or excessive wear. Replace a worn of damaged retaining ring.
14. Remove P3 carrier flange 2 from P3 carrier.
5-6-9
2
5-6-9
15. Inspect splines 1 on the P3 carrier flange for
wear. Replace the P3 carrier flange if the
splines are worn.
16. Maximum allowable relative movement between the P3 carrier flange and the C2 backplate is 0.38 mm (0.015 inch).
V10534.00.00
5-5-22
V10527.00.00
5-6-11
679

17. Inspect thrust bearing face 1 on the P3 carrier
flange for damage. Replace the flange if damage is found.
1
5-6-12
V10526.00.00
18. Inspect bushing journals 1 and 2 for galling or

other damage. Replace the P3 carrier flange if
bushing journals are galled or damaged.
1
1
22
V10538.00.00
V10538.00.00
5-6-13
19. Measure bushing journal 2. Minimum bushing

journal diameter is 69.635 mm (2.741 inch).
20. Measure bushing journal 1. Minimum bushing
journal diameter is 65.91 mm (2.595 inch).
21. Replace the P3 carrier flange if bushing journal
measurements are out of specification.
22. Inspect two bushings, located in both ends of
the P3 carrier flange, for wear or damage.
23. Replace a bushing if bronze material is visible
beneath the orange Teflon on the bushing ID.
1
1
2
5-6-14
680
24. Measure each bushings ID. Maximum allowed ID is 45.18 mm (1.779 inch). Replace a
bushing that is not within specification.
V10536.00.00
MODULE REBUILD
a. Replace P3 Carrier Flange Bushing
Tools Required:
J 48141Bushing Installer
Long Punch
1. Support the P3 carrier flange, flange end down,

on wood blocks high enough above the work
surface to allow the bushing to drop free.
2. Using a long punch drive the flange end bushing free of its bore.
V10541.00.00
3. Support the P3 carrier flange, flange end up, on

wood blocks high enough above the work surface to allow the bushing to drop free.
5 6 15
4. Using a long punch drive the bushing free of its

bore.
5-6-16
V10540.00.00
5. Clean both bushing bores of any residue. The

bores must be clean before installing the bushings.
J 48141
6. Mount bushing installer J 48141 onto universal

driver J 8092 with shorter end of the installer
tool away from the driver.
7. Align bushing 1 with its bore and press or drive
the bushing until it seats. The top of the bushing must be flush with the top of the bore or no
more than 0.25 mm (0.010 inch) below the
bore top.
1
5-6-17
V10617.00.00
681

8. Invert the P3 carrier flange so that the flange
end is against the work surface.
9. Remove J 48141 from the universal driver
and remount it with the long side away from
the driver. Install a new bushing 1 on
J 48141. Align the bushing with its bore and
press or drive the bushing until the tool seats.
The top of the bushing must be 5.806.20 mm
(0.2280.244 inch) below the top of the bore.
J 48141
1
V10619.00.00
5-6-18
b. Disassemble P3 Carrier
1. Position the P3 carrier on the work surface so
that spindle retaining pins 1 are visible.
2
1
2. Push spindles 2 up and remove. Remove four

spindles 2.
1
5-6-19
V10535.00.00
3. Remove four pinion gears 1 (two roller bearings inside each pinion) and eight thrust washers 2.
4. Inspect four pinion gears for:
Spline wear or damage
Bore wear or damage
2
1
5-6-20
Faces for wear or damage
Replace worn or damaged pinions.

V10559.00.00
NOTE:
Replace pinion gears as a matched set of four.
682
MODULE REBUILD
5. Inspect eight roller bearings for wear or damage.
6. Replace worn or damaged roller bearings.
5-6-22
V10427.00.00
7. Inspect eight thrust washers for:

Scoring or galling
Batters or cracked retainer tang
NOTE:
Do not measure thrust washer thickness at the lube
slots.
Thrust washer wear or damage may cause pinion
end play measurements to be out of specification.
5-6-24
V10014.00.00

Minimum thickness is 1.45 mm (0.057 inch).
9. Replace a thrust washer if any defects are
found or specifications are not met.
683

10. Remove retaining pin 1 from each spindle 2
and inspect pin 1 for wear or damage. Replace
a worn or damaged retaining pin.
11. Inspect each spindle, including end faces, for

damage. Replace a damaged spindle.
V10556.00.00
5-6-25
3
12. Inspect the P3 carrier for wear or damage.

Inspect:
Four spindle areas 1

Retaining ring groove 2
Splines 3
11
5-6-26
Replace the P3 carrier if excessive wear or

damage is found.
V10428.00.00.
13. Turn the P3 carrier so that the flange mounting

side is down.
14. Inspect thrust bearing surface 1 for galling. Replace the P3 carrier if galling is found.
c. Assemble P3 Carrier
1. Position the P3 carrier so that the flange
mounting side is up.
V10597.00.00
5-6-27
NOTE:
Install all four pinion assemblies using the following
procedure.
2. Install retaining pin 1 into spindle 2.
1
2
2
5-6-28
684
V09996.00.00
MODULE REBUILD
3. Install two roller bearings 1 into pinion 2.
2
5-6-29
V10557.00.00
4. Position a thrust washer, tangs away from the

pinion, on each end of the pinion gear.
5. With roller bearings installed and thrust washers positioned so that the tangs mate into thrust
washer groves 1, install pinion assembly 2 into
the pinion gear pocket in P3 carrier 3.
2
3
5-6-30
V10558.00.00
6. Align pinion, thrust washers, and roller bearings to allow spindle installation.
1
2
7. Install spindle 1 so that retaining pin 2 seats

into retaining pin grove 3.
2
3
8. Install P3 carrier flange 1 onto P3 carrier 2.
5-6-31
V10555.00.00
9. Install P3 carrier flange into P3 carrier.

10. Install internal retaining ring 1 to retain P3 carrier flange 2 to the P3 carrier.
V10554.00.00
685

11. Measure the end play of all four pinions. Maximum end play is 0.95 mm (0.037 inch).
12. If end play is not within specification, disassemble the out of specification pinion assembly and determine the cause.
5-6-34
V10553.00.00
d. Disassemble P3 Ring Gear Flange

1. Remove P3 ring gear assembly 1 from Rotor B
hub 2.
1
2
5-6-35
V10432.00.00
2. Position the P3 ring gear assembly on the work

surface, ring gear down.
3. Remove retaining ring 1 from ring gear 2.

4. Inspect the retaining ring groove for wear or
damage. If the retaining ring slides up or down
in its groove, replace the P3 ring gear.
5-6-36
V10433.00.00
686
MODULE REBUILD
5. Place the P3 ring gear flange, flange side up, on
the work surface.
6. Remove and inspect thrust bearing 1 for wear

or damage. Rotate the bearing to determine the
presence of uneven movement. Replace a damaged or unevenly turning thrust bearing.
7. Inspect the thrust bearing face for galling. Replace the P3 ring gear flange if the thrust bearing surface is galled or damaged.
2
5-6-37
V10434.00.00
8. Inspect splines 2 for excessive wear or damage.

Replace the P3 ring gear flange if excessive
spline wear or spline damage is found. Maximum relative movement between the P3 ring
gear and the C1 clutch hub is 0.38 mm
(0.015 inch).
9. Inspect bushings 1 and 2 for wear or damage.
A worn bushing will display underlaying
bronze material through the orange liner.
10. If either bushing 1 or 2 has spun in its bore, replace the bushing.
2
1
1
5-6-38
11. Measure the ID of bushing 1. Maximum ID is
66.21 mm (2.607 inch). Replace the bushing if
specifications are not met.
V10437.00.00
2
2
5-6-39
V10436.00.00
687

12. Measure the ID of bushing 2. Maximum ID is
70.06 mm (2.758 inch). Replace the bushing if
specifications are not met.
e. P3 Ring Gear Flange Bushing Replacement

1
11
Tools Required:
J 48142P3 Ring Gear Flange Bushing
5-6-40
V10435.00.00
2
1
5-6-41
Installer
Punch
1. Support the P3 ring gear flange, flange side
down, on wood blocks high enough above the
work surface to allow the bushing to be removed.
2. Using a punch, collapse lower bushing and remove.
V10486.00.00
3. Using a punch collapse upper bushing and remove.

2
4. Clean debris from both bushing bores. Parts

must be clean and dry to install new bushings.
5-6-42
V10487.00.00
688
MODULE REBUILD
5. Position the P3 ring gear flange on the work
surface flange end up.
6. Install bushing 1, smaller diameter bushing, on
J 48142.
7. Press or drive bushing 1 into its bore until tool

J 48142 seats. Bushing 1 must be 2626.25 mm
(1.0241.033 inch) below the top of the bushing bore face.
5-6-44
V10491.01.00
8. Install bushing 2, larger ID, on J 48142.

9. Press or drive bushing 2 into its bore until tool
J 48142 seats. Bushing 2 must be 1.101.35 mm
(0.0430.053 inch) below the top of the bushing bore face.
2
5-6-46
V10492.02.00
f. Inspect P3 Ring Gear

1. Inspect the P3 ring gear for excessive wear or
spline damage. Maximum relative movement
between P3 ring gear splines and P3 pinion
gear splines is 0.38 mm (0.015 inch). Replace
the P3 ring gear if excessive wear or spline
damage is found.
5-6-47
V10438.00.00
689

g. Assemble P3 Ring Gear Flange and Ring Gear
1. Position the P2 ring gear flange on the work
surface, flange end up.
ROUNDED EDGE
1
2
CAUTION:
5-6-49

cause the thrust bearing to fail, resulting in progressive damage to the EV Drive.
2. Install thrust bearing 1 onto P3 ring gear

flange 2. Make sure thrust bearing 1 is installed
with rounded, outside diameter 2, up and visible.
V10484.00.00
3. Position P3 ring gear 1 on the work surface so

that retaining ring groove 2 is up.
4. Install P3 ring gear flange 2 into P3 ring gear 1.
2
5-6-50
V10440.00.00
5. Install retaining ring 3.

3
3
1
1
5-6-52
V10441.00.00
690
MODULE REBUILD
h. Inspect Rotor B Hub Assembly
2. Inspect thrust bearing 1 for damage. Inspect

thrust bearing 1 for uneven rotation by hand rotating the thrust bearing. Replace a damaged
thrust bearing or one the exhibits uneven
movement.
3. Inspect the thrust bearing race for galling or

damage. Replace the Rotor B hub if damage or
galling is found.
5-6-52
4. Inspect flange pilot 1 and flange face 2 for

burrs creating high spots. Remove high spots
with a soft stone or crocus cloth.
V10474.00.00
1
2
5. Inspect threaded holes in flange face 2 for

damage. Clean damaged threads using an M8 x
1.25 tap. If thread damage cannot be repaired
with a tap, replace the Rotor B hub.
2
V10442.00.00
5-6-53
6. Inspect Rotor B shorting bars 1 for cracks and
surface damage. Use a fine soft stone or crocus
cloth to remove surface imperfections. Use
crocus cloth to remove rust. Replace Rotor B if
shorting bars are cracked or there is damage to
Rotor B diametrical face 2.
1
1
2
2
7. Position Rotor B on the work surface so that

the tone wheel is up.
5-6-54
V10444.00.00
691

8. Inspect tone wheel teeth 1 for broken, chipped,
or otherwise deformed teeth. Replace Rotor
hub B if tone wheel teeth are damaged or deformed.
5-6-55
1
V10443.00.00
2
21
9. Remove thrust bearing 2. Inspect thrust bearing 2 for damage or uneven rotation. Replace a
thrust bearing that is damaged or rotates unevenly.
10. Inspect thrust bearing 1 bearing race on the
Rotor B hub for galling or other damage. Replace Rotor B hub if galling or other damage is
found.
5-6-56
V10445.00.00
NOTE:
If the roller bearing inner race is replaced, replace
the roller bearing outer race in the C1 clutch housing. If the C1 clutch housing outer race is replaced,
replace the Rotor hub B inner race.
11. Inspect roller bearing inner race 2 for galling
or other damage. Replace roller bearing inner
race 2 if galling or damage is found.
692
MODULE REBUILD
i. Remove and Install Rotor B
Roller Bearing Race (Wheel Side)
BRIDGE A
BRIDGE B
BRIDGE C
V10637.00.00
1. Install legs of J 48125 under the bearing race in

slots provided.
2. Install Bridge C of J 48125 over the inner race.
3. Tighten lead screw of J 48125 until bearing
race is free of the Rotor B hub.
j. Install Rotor B Roller Bearing Inner Race
V10643.00.00
J 48341C1 Housing Inner Race Installer

1. Position Rotor B so that the speed signal wheel

side is up.
J 8092
2. Install a new bearing race on J 48341 with the

stepped face of the race facing down.
3. Press the inner bearing race until it seats on the
hub shoulder.
J 48341
BEARING RACE
V10641.00.00
693

k. Disassemble and Inspect Rotor B
Flange Assembly
1. Separate Rotor B flange 1 from P3 sun gear
shaft 2.
1
2
1
2
2
5-6-57
V10446.00.00
2. Inspect P3 sun gear shaft and splines for damage. Replace the P3 sun gear shaft if damage is
found.
3. Inspect P3 sun gear shaft splines for movement

relative to their mating splines. Relative movement cannot exceed 0.38 mm (0.015 inch).
Measure relative spline movement as follows:
1
5-6-58
Spline 1 relative to P2 sun gear
Spline 2 relative to Rotor B flange
V10447.00.00
Spline 3 to P3 planetary gears
4. Inspect Rotor B flange splines 1 for wear. Replace the Rotor B flange if the splines have excessive wear or are distorted.
2
5-6-59
694
5. Inspect Rotor B flange pilot 2 for surface damage. Remove high spots with soft stone and
crocus cloth. Replace the Rotor B hub assembly if damage cannot be repaired.
V10449.00.00
MODULE REBUILD
NOTE:
If the roller bearing inner race is replaced, replace
the roller bearing outer race in the C1 clutch housing. If the C1 clutch housing outer race is replaced,
replace the Rotor hub B inner race.
6. Inspect roller bearing inner race 1 pressed onto
the Rotor B flange for damage. Replace bearing assembly if inner race is damaged.
1
V10450.00.00
5-6-60
l. Remove Roller Bearing Race, Rotor B Flange
BRIDGE A
BRIDGE B
BRIDGE C
V10637.00.00
1. Install Bridge C over the inner bearing race of

Rotor B flange.
J 48125
2. Install the legs of J 48125 under bearing race 1

in the slots provided.
3. Tighten the lead screw until the bearing race is
free of the flange.
BRIDGE C
V10645.00.00
695

m. Install Roller Bearing Race, Rotor B Flange
J 48138Bearing Installer
1. Position Rotor B flange bearing side up.

2. Install a new bearing race, stepped side down,
onto Rotor B flange.
J 8092
J 48138
BEARING RACE
V10644.00.00
3. Using J 48138, press the bearing race until it

seats on the flange shoulder.
n. Assemble Rotor B
1. Position P3 sun gear shaft 2 on the work surface so that the P3 sun gear is down.
2. Install Rotor B flange 1 onto sun gear shaft 2,

make sure Rotor B flange 1 splines mate with
the middle splines of sun gear shaft 2.
2
1
5-6-61
V10448.00.00
3. Position the Rotor B hub speed signal wheel up

on the work surface.
1
2
CAUTION:
ROUNDED EDGE
5-6-62
V10485.00.00
696

4. Install thrust bearing 1, approximately 105 mm
(4.134 inch) ID, on rotor B hub, make sure
rounded outer edge 2 on the OD of the thrust
bearing is facing up.
MODULE REBUILD
5. Using a hoist and strap, position the Rotor B
hub tone wheel down on blocks high enough
above the work surface to allow installing the
P3 carrier hub.
CAUTION:
5-6-63
V10451.00.00

(4.134 inch) ID, inside rotor B hub, make sure
rounded outer edge on the OD of the race is
facing up.
ROUNDED EDGE
5-6-64
7. Install P3 ring gear flange assembly 1 in

Rotor B Hub 2 so that P3 ring flange goes
through the tone wheel side of Rotor B hub 2.
V10483.00.00
1 2
5-6-65
V10530.00.00
697

CAUTION:
ROUNDED EDGE
1
2

(4.134 inch) ID, on the thrust bearing pilot of
P3 ring gear flange 2, make sure the rounded
outer edge on the OD of the thrust bearing is
facing up.
V10482.00.00
5-6-66
9. Install P3 carrier assembly 1 so that P3 pinions

mesh with P3 ring gear 3 and the P3 carrier
flange locates through the P3 ring gear bushings.
2
1
32
CAUTION:
5-6-67
V10452.00.00
ROUNDED EDGE
1
2

(2.835 inch) ID, in thrust bearing bore 2 of P3
carrier with the blue stripe facing up and guide
tangs facing down into the thrust bearing bore.
1
2
V10481.00.00
698
MODULE REBUILD
11. Install Rotor B flange/P3 sunshaft assembly 1
into Rotor B hub 2.
1
V10453.00.00
5-6-69
12. Align marks on Rotor B flange 2 and Rotor B
hub 1 that were drawn at disassembly.
1
2
5-6-70
V09889.00.00
13. Install twelve M8 x 1.25 x 20 mm bolts 1,

tighten bolts fingertight.
1
1
5-6-71
V10454.00.00
15. Position the Rotor B on wood blocks, sun gear

shaft clear of the work surface, with the tone
wheel up.
NOTE:
If the Rotor B assembly rests on the sunshaft, the selective race measurement will not be accurate. Provide clearance between the sunshaft and the work
surface to make an accurate measurement.
V10476.00.00
5-6-72
699

ROUNDED EDGE
1
16. Confirm that thrust bearing 1, approximately

105 mm (4.134 inch) ID, remained installed on
the thrust bearing pilot of Rotor B hub and that
the rounded outer edge on the OD of the race is
facing up.
V10582.00.00
5-6-73
o. Install Selective C1 Housing

Thrust Bearing Race
1. Install three lifting bolts, M12 x 1.75, evenly
spaced, around the C1 clutch housing.
2. Attach a hoist to the three bolts and lift the C1
clutch housing high enough to install the C1
clutch housing selective thrust bearing.
3. Using petrolatum, install the C1 clutch housing

selective race 2 that was removed, back into its
pocket over the roller bearing.
5-6-74
2
V10580.00.00
4. Install C1 clutch housing over roller bearing

inner race pressed on Rotor B tone wheel side.
5-6-74.1
CAUTION:
V10633.00.00
5-6-75
6100
5. Install the thrust bearing, approximately

105 mm (4.134 inch) ID, onto the back of C1
clutch hub, make sure the rounded outer edge
on the OD of the race is facing up.
V10464.00.00
MODULE REBUILD
6. Install C1 clutch hub 1 into the C1 clutch housing.
1
2
NOTE:
If reinstalling the same retaining ring that was removed during disassembly, install the retaining
ring with the same face down as when removed.
If installing a new retaining ring, orientation makes
no difference.
5-6-76
V10634.00.00
7. Install retaining ring 1 onto C1 clutch hub.

1
5-6-77
1V10606.00.00
8. Install two M4 bolts to use as pry points, approximately 180 degrees apart, into two of C1
hub bolts holes.
9. Install a dial indicator so the tip of the indicator
is resting on the top face of the C1 clutch hub.
Zero the dial indicator.
10. Using two heel bars and the installed bolts, lift
the C1 clutch hub until the dial indicator needle stops moving. Record the amount of needle
movement which indicates end play.
11. The total end play measured must be between
0.100.38 mm (0.0040.015 inch).
5-6-78
V10400.00.00
6101

12. If end play is not within specification, select an
appropriate selective race from the following
table that allows an end play within specification.
Table 61.
Selective Race
(last 4 of P/N
etched on
selective race)
8702
8703
8704
8705
8706
8707
Thickness (mm)
Thickness (inches)
min
max
min
max
4.975
5.025
0.196
0.198
5.153
5.203
0.203
0.205
5.331
5.381
0.210
0.212
5.509
5.559
0.217
0.219
5.687
5.737
0.224
0.226
5.865
5.915
0.231
0.233
Determining The Correct Selective Race Example

If the original selective race was identified as
part number 8705 and the end play measured

0.076 mm (0.003 inch), then a thinner race is
needed to get within specification.
The calculated end play using part number
8704 as the new selective race results in the

following:
([Min of 8705 raceMax of 8704 race] to
[Max of 8705Min of 8704]) + Measured
End play: 0.2170.212= 0.005 inch;
0.2190.210 = 0.009 inch.
Adding the original end play measurement
of 0.003 inch to the min-max limits of
0.0050.009 inch results in a calculated
new end play measurement of 0.008
0.012 inch (0.20 mm0.30 mm).
NOTE:
To increase end play select a thinner selective race.
To decrease end play select a thicker selective race.
13. Install the correct thrust bearing race and remeasure the end play to verify that correct end
play has been achieved.
6102
MODULE REBUILD
67.
REAR COVER
a. Remove Output Speed Sensors

1. Position rear cover on work surface, output
shaft up.
P6 OUTPUT
SPEED
SENSOR
P7 OUTPUT
SPEED SENSOR
2. If not already removed, remove two speed sensors by removing the M8 bolt retaining the
speed sensor to the housing.
5-7-1

housing.
b. Remove Output Yoke/Flange
V08672.00.00
J 46703Output Spanner Nut Socket
1. Remove retaining ring 1 and output nut key 2.

2. Using tool J 46703, remove output nut 3.
3. Remove output yoke or flange.

5-7-2
4
3
V10480.00.00
4. Inspect output yoke/flange seal journal 1 for

wear. Minimum seal journal diameter is
89.78 mm (3.535 inch). Replace the yoke/
flange if seal journal 1 is worn below minimum
diameter or if it is scored or grooved in the seal
area.
5-7-3
5. Inspect slinger assembly 2 on the yoke/flange
for distortion. Replace slinger assembly 2 if it
is distorted.
1
V10669.00.00
6103

6. Inspect the output flange washer 4 for distortion. Replace the washer if it is distorted.
7. Inspect the O-ring groove in the output flange

washer for burrs. Remove burrs with a soft
stone or crocus cloth.
4
3
5-7-4
8. Replace the output flange washer O-ring.

9. Inspect output lock nut 3 for thread damage.
Replace the locknut if threads are damaged.
V10480.00.00
10. Inspect output shaft key 2 for damage. Replace

output shaft key 2 if it is damaged.
11. Inspect external spiral retaining ring 1 for distortion. Replace the retaining ring if it is distorted.
c. Remove Output Seal
J 24171-ASlide Hammer and Jaw Set
1. Using J 24171-A, remove output seal 1 from

rear cover.
J 24171-A
5-7-6
V10628.00.00
6104
MODULE REBUILD
d. Remove and Inspect Rear Cover Plugs
1. Remove tachograph plug 1 and copper
washer 2.
4
2. Inspect tachograph plug 1 for thread damage.

Replace the plug if it is damaged.
3. Inspect copper washer 2 for damage. Replace
the washer if it is damaged.
4. Remove C1 pressure tap plug 3.

5. Inspect C1 pressure tap plug for damage. Replace the plug if it is damaged.
5-7-7
2
1
1
V10610.00.00
6. Remove the C1 pressure tap plug 3 O-ring and

install a new O-ring.
7. Remove C2 pressure tap plug 4.
8. Inspect C2 pressure tap plug for damage. Replace the plug if it is damaged.
9. Remove the C2 pressure tap plug 3 O-ring and
install a new O-ring.
68.
REAR COVER DISASSEMBLY
a. Remove Output Shaft Assembly

1. Using a press, press the output shaft assembly
free of the rear cover. If a press is not available,
strike the yoke end of the output shaft with a
soft hammer until the output shaft assembly is
free of the rear cover.
V10609.00.00
5-8-1
V10609.00.00
6105

b. Remove and Inspect Taper Bearing
NOTE:
If the taper bearing or its outer race are replaced,
replace both the taper bearing and the outer race as
a set.
1. Remove taper bearing 1 from the rear cover.
2. Inspect the taper bearing for damage, wear, or
uneven rotation. Replace a bearing that is damaged, worn, or rotates unevenly.
5-8-2
5-8-2
3. Inspect taper bearing outer race (bearing cup) 2

for wear or damage. Replace a worn or damaged outer race.
V10607.00.00
1. Remove C1 piston/return spring assembly 1

from the rear cover housing.
3
1
1
2. Remove and discard external sealring 2 and internal lipped sealring 3.
3. Inspect C1 piston 4 for damage. Remove any

high spots in piston seal grooves with a soft
stone or crocus cloth.
2
3
5-8-3 5
5
c. Remove and Inspect C1 Piston

and Return Spring Assembly
4. Inspect C1 return spring assembly 1 for

cracked or broken springs or damage to spring
retainer 1.
V10603.00.00
5. Replace the C1 Piston / Return Spring Assembly if the C1 piston or Return Spring Assembly
are damaged.
d. Inspect Rear Cover
1
5-8-4
1
V10611.00.00
6106
1. Inspect the rear cover for any high spots outside the piston seal surfaces. Repair any high
spots with a soft stone or crocus cloth. If the
rear cover is cracked or is broken replace the
rear cover.
2. Inspect C1 piston bore seal surfaces 1 and 2 for
roughness. Replace rear cover if the C1 piston
seal surfaces feel rough or if the seal surface
areas has been discolored or etched from caustic parts washer solution.
MODULE REBUILD
3. Inspect rear cover sealring bore 1 for grooves.
Replace the rear cover if grooves are found.
1
5-8-5
V10612.00.00
4. Inspect taper bearing races 1 and 2, pressed

into the rear cover, for damage. Replace any
bearing assembly that is damaged.
5-8-6
e. Remove Taper Bearing Race From Rear Cover
V10613.00.00

J 48365Bearing Race Installer/Remover
REMOVAL BRIDGE
TOP BRIDGE
NOTE:
Replace both a taper bearing race and a taper bearing as a set.
1. Special Tool J 48365 must be assembled to remove the taper bearings. The Removal Bridge
is installed under the taper bearing race to be
removed and the top bridge provides the anchor point to remove the race.
Top
Bridge
Lead Screw
LEAD SCREW
5-8-7
Removal Bridge
INSTALLER
Installer
V10635.00.00
6107
5-8-9
REMOVAL
BRIDGE
2. To remove the taper bearing race closest to output seal, position the rear cover piston side
down.
J 48344
3. Install the removal bridge on the lead screw so

that the bridge rests against the lead screw hex
head.
V10458.00.00
4. Install J 48365 so that the shelf of removal

bridge is piloted beneath the under the taper
bearing race located closest to the rear cover
output seal and the lead screw is pointing up.
5. Install the top bridge over the lead screw so
that the Top Bridge rests on the rear cover.
6. Install the washer and nut onto the lead screw
using appropriately-sized wrenches, tighten the
nut until the taper bearing race is free of the
rear housing.
7. Remove the bearing race from J 48365.
J 48344
9. Install the J 48365 lead screw and removal

bridge so that the removal bridge pilots under
the taper bearing race closest to the piston side
of the rear cover and the lead screw is pointing
up.
5-8-10
REMOVAL
BRIDGE
8. To remove the taper bearing race closest to piston, position the rear cover piston side up.
V10461.00.00
10. Install top bridge over the lead screw so that

the top bridge rests on the rear cover.
11. Install washer and nut on the lead screw.
12. Using appropriately-sized wrenches, tighten
the nut until the taper bearing race is free of the
rear housing.
13. Remove the bearing race from J 48365.
6108
MODULE REBUILD
f. Install Taper Bearing Race Into Rear Cover
J 48365Bearing Race Installer/Remover
NOTE:
Replace both a taper bearing race and a taper bearing as a set.
1. To install the taper roller bearing race closest
to the piston side of the rear cover, install bearing race installer onto the lead screw with the
large diameter against the lead screw hex head.
install the race on the lead screw so that when
installed the shoulder of the new bearing race
will seat against the shoulder in the rear cover.
5-8-14
J 348365
INSTALLER
2
2. While holding J 48365 in place, turn the rear

cover piston side down, keeping the bearing
race centered in the rear cover bore.
V10460.00.00

that it rests on the rear cover. install the washer
and nut on the lead screw.
4. Tighten the nut finger tight while making sure
that the bearing race is centered in its bore.
5. Using appropriately-sized wrenches and making sure that the bearing race is centered in its
bore, tighten the nut until the taper bearing
race seats against the shoulder in the rear
cover.
6. To install the taper roller bearing race closest
to the output seal side of the rear cover, install
bearing race installer, large diameter against
the lead screw hex head, onto the lead screw.
install the race on the lead screw, facing so that
when installed in the rear cover the shoulder of
the new bearing race will seat against the
shoulder in the rear cover.
7. While holding J 48365 in place, turn the rear
cover piston side up, keeping the bearing race
centered in the rear cover bore.
INSTALLER
3
2
1
J 48365
5-8-16
V10459.00.00

that the top bridge rests on rear cover. install
the washer and the thread nut onto the lead
screw.
6109

9. Tighten the nut finger tight while making sure
that the bearing race is centered in its bore.
10. Using appropriately-sized wrenches and making sure that the bearing race is centered in its
bore, tighten the nut until the taper bearing
race seats against the shoulder in the rear
cover.
69.
SELECTIVE TACHOGRAPH
WHEEL MEASUREMENT AFTER
BEARING REPLACEMENT
The tachograph wheel not only provides a signal to the

tachograph but also serves as a selective shim for the
taper bearings in the rear cover. Replace the tachograph wheel if either taper bearing is replaced. Use
the following procedures to select a tachograph wheel
of the correct thickness.
J 48344Selective Shim Measurement Tool
TOP BRIDGE
LEAD
Lead Screw
SCREW
Threaded
Bridge
INDEX
PLATE
Index PLate
Top
Bridge
THREADED
BRIDGE
5-9-1RC
V10457.00.00
1. Position the rear cover, output seal side up, on

wood blocks high enough above the work surface to allow holding a taper bearing into the
outer race nearest to the piston side of the rear
cover.
5-9-2RC
V10570.00.00
6110
MODULE REBUILD
2. Install threaded bridge 1 on large OD of a taper
bearing 2.
5-9-3RC
V10550.00.00
3. With threaded bridge 1 in position, install and

hold bottom taper bearing in the taper bearing
race nearest the piston side of the rear cover
Hold the taper bearing and threaded bridge in
position until the lead screw is installed.
21
V10620.00.00
5-9-4RC
4. Install index plate 1 onto taper bearing so that
the index plate pilots on the bearing outer race.
2
1
5-9-5RC
5. Install a taper bearing into the race closest to

the output seal.
V10593.00.00
J 48344
6. Install the top bridge onto the taper bearing.

7. Inset the lead screw through the top bridge, the
index plate, and into the threaded hole in the
threaded bridge.
8. Tighten the lead screw to firmly snug the bearings into their outer races.
5-9-6RC
3
V10462.00.00
6111

J 48344
DEPTH
MICROMETER
10. Measure the thickness, at the inner race, of the

taper bearing that will be installed closest to
the output seal. Record this measurement a Dimension B.
5-9-7RC
9. Using a depth micrometer, measure from the

top bridge to the index plate. Record this measurement as Dimension A.
V10463.00.00
11. Subtract Dimension B from Dimension A to

obtain Dimension C (AB =C).
12. Use the following table to determine the correct tachograph wheel to install.
Table 62. Selective Tachograph Wheels
Dimension
C (mm)
6112
Dimension
C (inch)
Tachograph
ID No.
Part
No.
22.01022.087 0.86600.8696
29541040
22.08822.164 0.86970.8726
29541041
22.16522.241 0.87270.8756
29541042
22.24222.318 0.87570.8786
29541043
22.31922.395 0.87870.8817
29541044
22.39622.472 0.88180.8847
29541045
22.47322.549 0.88480.8877
29541046
22.55022.626 0.88780.8908
29540647
22.62722.703 0.89090.8938
29540648
22.70422.780 0.89390.8969
29540649
22.78122.875 0.89700.8900
10
29540810
MODULE REBUILD
610. DISASSEMBLE AND INSPECT
OUTPUT SHAFT
a. Remove and Inspect Tachograph Wheel,
Output Shaft O-ring, and Seals
1. Position the output shaft on the work surface
shaft up.
2. Remove tachograph wheel 1.

NOTE:
The tachograph wheel is one of three selectable

shims that set proper clearances in the EV Drive.
After overhaul, a selectable tachograph wheel a of
different thickness may be required to get proper
clearances.
5-10-1RC
3. Inspect tachograph wheel 1 for damage. Replace the tachograph wheel if it is damaged or
not of the correct thickness.
V10569.00.00
4. Remove and discard both sealrings 1.

5. Remove and discard O-ring 2.
2
1
V10565.00.00
b. Remove and Inspect C2 Clutch Backplate

1. Supported on wood blocks, position the output
shaft down.
2. Remove internal retaining ring 1 retaining C2
backplate 2 to the C2 clutch housing.
5-10-3RC
3. Inspect retaining ring 1 for damage or distortion. Replace a distorted or damaged retaining
ring.
V10568.00.00
6113

4. Remove C2 backplate 1.
1
5. Inspect backplate 1 for:

1
Galling or deformation on the side facing
the clutch
Deformed splines
Galled thrust bearing surface
5-10-4RC
6. Replace the C2 backplate if any galling or deformation is found.
V10588.01.00
c. Remove and Inspect C2 Drive Hub

1
2. Inspect thrust bearing 1 for wear.

3. Inspect thrust bearing 1 races for cracks or
damage.
4. Replace a thrust bearing with cracked or damaged races or if the thrust bearing is worn.
1
5-10-5RC
V10705.00.00
5. Remove C2 drive hub 1.

5-10-6RC
6. Inspect C2 drive hub 1 for worn splines or

galled thrust bearing surfaces.
1
7. Replace the C2 drive hub if thrust bearing surfaces are galled or splines are worn.
V10706.00.00
6114
MODULE REBUILD
d. Remove and Inspect C2 Clutch Pack
1. Remove C2 clutch pack (seven friction and
seven reaction plates) 1 from C2 housing 2.
2. Inspect each friction plate and reaction plate of

the clutch pack. Replace the entire clutch pack
if a friction plate or a reaction plate does not
meet specifications or a defect is found.
3. Inspect friction plates for defects:

Pitted friction material
Internal splines worn to a sharp point
5-10-7RC
Deformed internal splines

V10567.00.00
4. Measure the total thickness of the C2 clutch

pack. Minimum clutch pack thickness is
30.4532.55 mm (1.1991.281 inch). Replace
the entire C2 clutch pack if specifications are
not met.
5. Measure each friction plates thickness. Minimum friction plate thickness is 2.425 mm
(0.095 inch).
6. Measure each friction plates oil groove depth.
Minimum oil groove depth is 0.23 mm
(0.009 inch).
7. Measure the cone of each friction plate. Maximum friction plate cone is 0.25 mm
(0.010 inch).
8. Inspect reactions plates for galling. Replace the
entire clutch pack if a reaction plate is galled.
9. Measure the cone of each reaction plate. Maximum reaction plate cone is 0.25 mm
(0.010 inch).
10. Measure the thickness of each reaction plate.
Minimum reaction plate thickness is 1.925 mm
(0.075 inch).
6115

e. Remove and Inspect C2 Clutch
Return Spring Assembly
J 48530C2 Retaining Ring Removal Tool

1
5-10-8RC
2. Inspect thrust bearing 1 for cracked or deformed races and wear. Replace the thrust
bearing if worn or the races are cracked or deformed.
V10590.00.00
3. Install J 48530 on the C2 clutch housing so that

two roll pins 2 engage holes in return spring retainer 1.
2
5-10-9
1
5-10-9RC
V10571.00.00
4. Engage arm locator pins 1 of J 48530 between

the teeth of the signal wheel.
2
5. Firmly secure bolts to prevent tool arms 2 from

moving.
2
1
5-10-10RC
V10587.00.00
6116
MODULE REBUILD
6. Compress the C2 return spring assembly until
the retaining ring is loose in its groove.
7. Using retaining ring pliers, remove the retaining ring.
8. Inspect the retaining ring for distortion or damage. Replace a distorted or damaged retaining
ring.
5-10-11RC
V10573.00.00
9. Rotate lead screw counter-clockwise to release

spring pressure. Keep anti-rotation tabs on C2
return spring retainer plate located in the relief
pockets machined in the output shaft for the
tabs. Damage to the tabs will result if tabs do
not stay located in relief pockets cut in output
shaft as spring is uncompressed.
HOLD RAM
TO KEEP
SPRING TABS
LOCATED
10. Slowly release spring pressure and remove

J 48530.
5-10-12RC
V10572.00.00
11. Remove C2 return spring assembly.
12. Inspect return spring assembly for a cracked or

deformed spring retainer 1. Replace the C2 return spring assembly if the retainer is deformed
or cracked.
13. Inspect return springs 2 for damage or if
springs have taken a set. Replace the C2 return
spring assembly if the retainer is deformed or
cracked.
1
2
5-10-13RC
14. Measure spring height. Replace the C2 return

spring assembly if any spring measures less
than 43.8 mm (1.725 inches) in length.
V10566.00.00
6117

f. Remove and Inspect C2 Piston
1. Loosen the C2 piston by applying air pressure
through C2 feed hole 1 located between the
sealring grooves of the output shaft.
1
5-10-14RC
V10592.00.00
2. Remove C2 piston 1 from the C2 clutch housing.
2
1
3. Remove and discard inner seal 2 and outer

seal 3.
1
3
2
5-10-15RC
V10561.00.00
4. Inspect machined surfaces. Replace a C2 piston if machine surfaces are galled.

5. Remove burrs or high spots in piston grooves
or on machined surfaces with a soft stone. Replace the C2 piston if damaged.
g. Remove and Install Output Shaft
Taper Roller Bearing
J 48612Taper Bearing Remover
J 48361Taper Bearing Installer
1. Position output shaft assembly on the work

surface output shaft up.
4
3
4
2
1
2
2. Install J 48612 so that clamp 1 is under taper

bearing 2. Tighten clamp nuts to secure the
clamp in position under the bearing cage, but
not tight as to cause the clamp to contact the
output shaft.
3. Align J 48612 legs 4 to provide a straight pull
and tighten the leg nuts.
5-10-16RC
V10564.00.00
4. Tighten lead screw 3 against the output shaft to

remove taper bearing 2. Discard bearing 2. The
removal procedure damages the bearing. Remove J 48612.
6118
MODULE REBUILD
5. Install a new taper bearing 1 onto the output
shaft so that the bearing rollers taper toward
the output shaft.
6. Install J 48361 2 over the output shaft and resting on taper bearing 1.
21
7. Using a press, press taper bearing 1 onto the

output shaft until it seats.
8. Remove J 48361.
5-10-17RC
h. Inspect Output Shaft
V10563.00.00
1. Inspect the output shaft for damage. Rework

high spots with crocus cloth or a soft stone. If
shaft splines have visible step wear, replace the
output shaft and both taper bearing assemblies.
2. Inspect C2 clutch housing splines for visible
wear. Replace the output shaft if C2 clutch
housing splines are worn.
3. Inspect the output shaft bushing for wear. If
bronze material is visible thought the orange
Teflon coating, replace the bushing.
5-10-18RC
V10562.00.00
4. Measure the ID of the bushing. Maximum ID

is 33.57 mm (1.322 inch). Replace the bushing
if it does not meet specifications.
5. If the bushing has spun in its bore replace the
output shaft.
i. Remove and Install Output Shaft Bushings
J 48130Input/Output Bushing Remover
J 48131Input/Output Bushing Installer
1. Remove the collet and lead screw assembly

from J 48130.
6119

2. Install the collet and lead screw assembly into
the bushing. Using appropriately-sized
wrenches, tighten the lead screw until the mandrel contacts the bushing, but not so tight as to
prevent bushing removal or to cause tool damage.
5-10-20RC
V10575.00.00
5-10-21RC
3. Install cup 1 over the lead screw and collet.
2
1
4. Install bearing 2, markings up, over the lead

screw.
5. Install the washer and nut on the lead screw.
1
V10584.00.00
6. Hold lead screw 1 stationary and tighten nut 2

until the bushing is free of the bushing bore.
1
2
7. Clean residue from the bushing bore. Parts

must be dry before installing a new bushing.
8. Install a new bushing on J 48131.

1
5-10-22RC
V10585.00.00
9. Center bushing in bushing bore and press or

drive the bushing until the J 48131 seats
against top face of the bushing bore. The bushing should be flush to 0.25 mm (0.010 inch)
below the top of the bushing bore.
J 8092
J 48131
5-10-23RC
6120
V10576.00.00
MODULE REBUILD
611. OUTPUT SHAFT ASSEMBLY
a. Install C2 Piston
1. Install a 74 mm ID internal lip piston seal 1
with the grooved side of the internal lip seal toward the taper roller bearing.
2. Install a 132 mm ID sealring 2 on the C2 piston.
1
2
2
V10560.00.00
5-11-1RC
3. Lubricate the piston seals with petrolatum or
transmission fluid.
4. Position C2 piston 1, spring pockets up, over

C2 clutch housing 2 with the wide tooth
aligned with the matching slot in the C2 housing.
5. Install C2 piston 1 into the clutch housing and
tap the piston down evenly into the C2 housing
until it seats against the bottom of the clutch
housing.
5-11-2RC
V10586.00.00
b. Install C2 Piston Return Spring

J 48530C2 Retaining Ring Removal Tool
1. Install C2 piston return spring assembly onto

the C2 piston so that the springs locate inside
the piston spring pockets.
2. Align the return spring assembly so anti-rotation tabs 1 on the spring retainer will engage
with mating pockets 2 in the output shaft when
the return springs are compressed.
1
5-11-3RC
1
V10574.00.00
6121
3. Locate J 48530 over C2 return spring so roll

pins 2 engage with two holes in spring
retainer 1 and J 48530 compressor plate is
flush to the spring retainer plate.
5-11-4
2
5-11-4RC
1
V10571.00.00
4. Engage arm locator pins 1 of J 48530 between

the teeth of the signal wheel.
2
5. Firmly secure bolts to prevent tool arms 1 from

moving.
2
1
5-11-5RC
1
V10587.00.00
HOLD RAM
TO KEEP
SPRING TABS
LOCATED
6. Tighten lead screw to compress the C2 return

spring assembly. Keep anti-rotation tabs on the
C2 return spring retainer plate aligned with tab
pockets in output shaft. Damage to the tabs
will result if tabs do not stay aligned with the
pockets in the output shaft as the return spring
assembly is compressed.
5-11-6RC
V10572.00.00
6122
MODULE REBUILD
7. Install retaining ring 1 into the retaining ring
groove in output shaft 2 to retain the C2 return
spring assembly.
1
8. Relieve spring pressure and remove J 48530.
1
c. Install C2 Clutch Pack,
Tachograph Wheel, Sealrings
5-11-7RC
V10573.00.00
1. Install 59 mm ID thrust bearing 1 so the blue

stripe is visible.
5-11-8RC
V10591.01.00
2. Install C2 drive hub 1 over C2 return spring assembly.
5-11-9RC
V10591.00.00
3. Install 72 mm ID thrust bearing 1 so the blue

stripe is against the hub.
1
5-11-10RC
V10589.01.00
6123

4. Install C2 reaction plate 1.
5. Install C2 friction plate 2.
2
1
5-11-11RC
6. Continue installing a reaction plate followed

by a friction until all seven reaction plates and
all seven friction plates are installed. The top
plate will be a friction plate.
V10605.00.00
NOTE:
The C2 clutch pack must have a minimum thickness
specification of 30.4532.55 mm (1.991.281 inch).
Refer to Paragraph 610d, Remove and Inspect C2
Clutch.
7. Install C2 backplate 1.
5-11-12RC
1
V10588.01.00
8. Install retaining ring 1 to retain C2 backplate 2

to the C2 clutch housing.
2
2
5-11-13RC
V10568.00.00
6124
MODULE REBUILD
9. Position output shaft so that the shaft is up.
2
10. Install sealrings 1. Make sure the sealring gaps

are not aligned.
11. Install O-ring 2.

2
1
5-11-14RC
V10565.00.00
12. Install selected tachograph wheel 1.

1
5-11-15RC
612. ASSEMBLE REAR

COVER MODULE
V10569.00.00
a. Install C1 Piston Assembly

1. Install new internal 1 and external 2 piston
seals on C1 piston.
2. Install C1 piston assembly 3 in the rear cover
so anti-rotation tab on C1 piston engages its
mating slot in rear cover.
3
ANTI-ROTATION TAB
3
5-12-1RC
V10604.00.00
6125

b. Install Rear Cover and Taper Bearing
J 48361Taper Bearing Installer
1. Install rear cover on output shaft assembly.

J 48361
2. Install taper bearing over output shaft with

larger diameter facing up, taper facing down.
5-12-3RC
NOTE:
Use either the same bearing removed from this location or the new bearing that was measured to select
the tachograph wheel. The bearing must rotate
freely in the outer bearing race.
V10608.00.00
3. Make sure bearing 1 is centered in the outer

bearing race.
4. Using J 48361, press bearing 1 until it seats.
c. Install Output Seal and O-ring
J 46702Output Seal Installer
1. Install new output seal 1 on J 46702 output seal

installer.
2. Drive output seal 1 into rear cover until
J 46702 is flush with rear cover.
J 46702
5-12-4RC
6126
V10629.00.00
MODULE REBUILD
3. Install a new O-ring 2 on the output shaft.
2
1
d. Install Output Yoke/Flange

5-12-5RC
V10565.00.00
J 46703Output Spanner Nut Socket
1. Inspect yoke or flange output seal surface for

damage. Replace a yoke or flange if output the
seal surface is worn or damaged.
2. Measure output seal journal diameter. Minimum allowable output seal journal diameter is
89.78 mm (3.535 inch).
4
3
3. Install output yoke or flange assembly.
4. Install output nut 3.

5. Using tool J 46703, tighten the output nut to
340 Nm (250 lb ft), aligning the slots in the
output nut to the keyway in the output shaft.
V10480.00.00
6. Install output key 2.

7. Install output retaining ring 1.
e. Install Rear Cover Plugs and Seals
1. Install copper washer 2 on tachograph plug 1. Install the plug if a tachograph sensor is not installed. Torque plug to 6067 Nm (4449 lb ft.).
2. Install C1 pressure tap plug 3. Make sure the

plug has an O-ring fitted.
3. Install C2 pressure tap plug 4. Make sure the
plug has an O-ring fitted.
4. Tighten pressure tap plugs 3 and 4 to 1013 Nm
(710 lb ft).
2
1
5-12-8RC
V10610.00.00
6127

613. CONTROL MAIN VALVE BODY
The control main valve body regulates control main
and exhaust backfill hydraulic pressure. The valve
body contains three valves:
Exhaust Backfill (shortest valve)
CONTROL
MAIN
RELIEF
Control Main Regulator

Control Main Relief (longest valve)
CAUTION:
EXHAUST
BACKFILL
CONTROL
MAIN REGULATOR
CONTROL MAIN VALVE BODY

V08701.00.00
Use extreme care when removing or installing

valve bodies or the solenoid filters. Do not drop
small parts through the openings in the stator
housing. Parts lodged in this area may be impossible to remove and if left in place may cause significant damage to the EV Drive.
a. Remove Internal Harness
MOTOR A TEMP
1. Disconnect the internal harness from all solenoids, the C1 and C2 pressure switches, and
the motor temperature sensor.
OIL TEMP
C2 SOLENOID
C1 SOLENOID
C1 BLOCKING SOLENOID
OLS
BOOST SOLENOID
C2 PRESSURE SWITCH
C1 PRESSURE SWITCH
DEUTSCH
CONNECTOR
MOTOR B TEMP
V08748.00.00
2. Remove two M6 x 1.0 x 60 mm bolts 4 retaining the oil level sensor bracket to the relay
valve body.
1
2
3. Remove oil level sensor 3 and bracket 5.
3
4
4. Disconnect the internal harness from the oil

level sensor and remove the internal harness.
5. Remove two bolts 1 retaining OLS 3 to

bracket 5.
V10654.00.00
6128
6. Remove four ferrules 2 from the OLS bolt

holes. Inspect the ferrules for cracks or other
visible damage. Replace damaged ferrules.
MODULE REBUILD
b. Control Main Valve Body Removal
1. Rotate the EV Drive until the control deck is
up.
1
2
2. Remove eight bolts 1 retaining the control

main valve body to the control deck.
5-9-2
3. Remove control main valve body 2, separator
plate 3, and oil transfer plate 4.
V10614.00.00
c. Control Main Valve Body Disassembly

J 46706Relay and CM Valve Installer
J 33163Valve Tray Set
1. Align the blade of tool J 46706 with the slot in

the retaining clip and compress control relief
valve spring 1.
CAUTION:
EV Drive damage may occur when valve
springs and other parts are mistakenly interchanged. Interchanging parts can be avoided
by:
Tagging each part as the part is
removed.
Using Valve Tray Set J 33163 to
simplify correct valve body reassembly.
Protect the C1/C2 valve assembly parts from
damage by:
Handling all valves carefully.
Protecting the control valve assembly
parts during removal, cleaning,
inspection, and installation.
Keeping the parts in clean containers
until the parts are installed.
When the valves are installed dry, the weight of
the valves must be sufficient to move the valves
through the valve bores. If the valves do not
move freely, the transmission may be damaged.
5-9-3
V10670.00.00
2. Remove retaining clip 2.

3. Ease the valve spring pressure.
4. Remove valve 3 and spring 1.
6129

the retaining clip and compress control main
regulator valve spring 1.

5-9-4
V10671.00.00

the retaining clip and compress exhaust backfill valve spring 1.

5-7-5

3
1
d. Control Main Valve Body Assembly

V10417.00.00(5-7-5)
NOTE:
The three valves can be installed in any order.
1. Install exhaust backfill valve 3, the shortest
valve, into its bore, either end first.
2. Install spring 1.
the retaining clip and compress valve spring 1.
Insert retaining clip 2.
5-9-6
3
1
V10417.00.00(5-7-5)
6130
MODULE REBUILD
4. Install control main regulator valve 3 into its
bore, small end first.
5. Install valve spring 1, coded yellow.

5-9-7
(Use 5-9-4)
V10671.00.00
7. Install the control relief valve 3, the longest

valve, into its bore, small end first.
8. Install valve spring 1, coded yellow.

5-9-8
(Use 5-9-3)
3
1
V10670.00.00
e. Installation
1. Install oil transfer plate 4 and separator plate 3
onto the control deck.
2. Install control valve body 2, aligning the bolt
holes in the valve body with the bolt holes in
the separator plate, oil transfer plate and, the
control deck.
1
2
5-9-9
(Use 5-9-2)
3. Install eight bolts 1.

4. Using a criss-cross pattern, tighten bolts to
1013 Nm (710 lb ft).
V10614.00.00
6131

614. C1/C2 VALVE BODY
J 46705C1/C2 Trim/Blocking Valve
Installer
CAUTION:
by:
removed.
Protect the C1/C2 valve assembly parts from
damage by:
The C1/C2 valve body controls C1 clutch and C2
clutch pressure, C1 and C2 clutch trim pressure,
and control main pressure.
a. C1/C2 Valve Body Removal
1. Remove eighteen bolts 1.
1
2. Remove C1/C2 valve body 2, separator plate 3,

and channel plate 4.
2
3
4
5-10-1
V10649.00.00
6132
MODULE REBUILD
b. Solenoid Filter Replacement
1. Using a small-bladed screwdriver or a pick, remove two solenoid filters 1 from the control
deck.
2. Install two new filters 1 by pressing them into
their filter bores.
5-10-1A
c. C1/C2 Valve Body Solenoid Disassembly

CAUTION:
by:
removed.
Protect the control valve assembly parts from
damage by:
V10652.00.00
The C1/C2 valve body contains five solenoids, valves,

and spring assemblies. The solenoids are:
C1 BlockingCENL solenoid, black band
C2 BlockingCENL solenoid, black band
5-10-2
C1OENL trim solenoid
C1 TRIM
C2OENL trim solenoid
C2 TRIM
C2 BLOCKING
Main BoostOENH, green band
C1 BLOCKING
MAIN BOOST
V10650.00.00
6133

1. Remove C1 clutch solenoid/C2 clutch solenoid
bracket 1.
2. Remove C1 and C2 blocking solenoid retaining clips 2.
5-10-3
3. Remove C1 and C2 blocking solenoids.
4. Carefully work C1 trim solenoid 3 and C2 trim

solenoid 4 free of the valve body.
4
V10647.01.00
5. Remove 6 mm bolt 1 and remove main control

solenoid forked retainer 2.
6. Carefully work main solenoid 3 free of the
valve body.
5-7-13
1
7. Measure the resistance of each solenoid. Replace any solenoid that does not meet specifications (refer to Table 63 and Table 64).
Table 63. C1 Trim/C2 Trim/Main Boost Solenoid
Resistance Table
2
3
V10425.00.00(5-7-22)
Temperature
C
Temperature
F
Resistance
(Ohms)
32
4.474.81
20
68
4.855.25
40
104
5.235.66
80
176
7.107.90
120
248
8.108.90
Table 64. C1/C2 Blocking Solenoid Resistance
6134
Temperature
C
Temperature
F
Resistance
(Ohms)
32
19.3521.19
20
68
21.0023.00
40
104
22.6524.81
80
176
24.7629.24
120
248
29.0631.74
MODULE REBUILD
d. C1/C2 Valve Body Disassembly
J 46705C1/C2 Trim/Blocking Valve Installer
CAUTION:
Transmission damage may occur when valve
by:
removed.
Protect the control valve assembly parts from
damage by:
1. Position the C1/C2 valve body on the work
surface with the machined surface up.
the retaining clip and compress C1 blocking
valve spring 3 until retaining clip 1 can be removed. Remove retaining clip 1.
3. Remove C1 blocking valve 2 and spring 3.

5-7-14
3
2
V10420.00.00(5-7-14)
6135

the retaining clip and compress C2 blocking
valve spring 3 until retaining clip 1 can be removed. Remove retaining clip 1.
5-7-15
3
2
V10421.00.00(5-7-15)

the retaining clip and compress C2 trim valve
spring 3 until retaining clip 1 can be removed.
Remove retaining clip 1.
7. Remove C2 trim valve 2 and spring 3.

5-7-16
3
2
V10422.00.00(5-7-16)

the retaining clip and compress C1 trim valve
spring 3 until retaining clip 1 can be removed.
Remove retaining clip 1.
9. Remove C1 trim valve 2 and spring 3.
5-7-17

3
11. Inspect the C1/C2 valve body for debris. Remove any debris found.
V10423.00.00(5-7-17)
6136
MODULE REBUILD
e. C1/C2 Valve Body Assembly
1. Install spring 3 into the C1 blocking valve
bore.
2. Install blocking valve 2, smallest diameter end

first.
5-7-18
(Use 5-7-14)
3
2

Insert retaining clip 1. Make sure the retaining
clip is below the valve body surface.
V10420.00.00(5-7-14)
4. Install spring 3 into the C2 blocking valve

bore.
5. Install blocking valve 2, smallest diameter end

first.
5-7-19
(Use 5-7-15)
3
2
V10421.00.00(5-7-15)
7. Install spring 3 into the C2 trim valve bore.
8. Install C2 trim valve 2, smallest diameter end

first.
5-7-20
3
(Use 5-7-16)
2
V10422.00.00(5-7-16)
10. Install spring 3 into the C1 trim valve bore.
11. Install C1 trim valve 2, smallest diameter end

first.
13. Turn the C1/C2 valve body machined surface
down.
5-7-21
(Use 5-7-17)
3
V10423.00.00(5-7-17)
6137

14. Lubricate the green O-ring on main boost solenoid 1 with transmission fluid and insert the
solenoid into its bore, connector pins facing
away from the valve bodys smooth, machined,
surface.
5-7-22
(Use 5-7-13)
15. Install solenoid fork retainer 2 and bolt 3.

Tighten bolt 3 to 1013 Nm (710 lb ft).
2
3
V10425.00.00(5-7-22)
16. Lubricate the O-ring on C1 blocking

solenoid 1. Insert the solenoid into its valve
body bore, connector pins facing away from
the valve bodys smooth, machined surface.
17. Insert solenoid retention clip 2.
5-7-23
1
V10426.00.00(5-7-23)
18. Lubricate the O-ring on C2 blocking

solenoid 1. Insert the solenoid into its valve
body bore, connector pins facing away from
the valve bodys smooth, machined, surface.
5-7-24
19. Insert solenoid retention clip 2.

1
V10595.00.00
6138
MODULE REBUILD
20. Lubricate the black O-rings on C2 trim solenoid 3 and C1 trim solenoid 4.
21. Insert the solenoids into their valve body bores,
connector pins facing away from the valve
bodys machined surface.
5-10-16
22. Install trim solenoid spring retention plate so

that the retention plate retains C1 and C2 solenoids and fits snugly over dowel pin.
3
4
V10672.00.00
f. C1/C2 Valve Body Installation

1. Align bolt holes of C1/C2 valve body 2, separator plate 3, and oil transfer plate 4 with bolts
in the control deck.
2. Install fourteen bolts 1. Tighten bolts to
1013 Nm (710 lb ft).
2
3
5-10-16A
(Use 5-10-)
V10649.00.00
615. C1/C2 RELAY VALVE BODY

J 46706Relay and CM Valve Installer
a. C1/C2 Relay Valve Body Removal

1. Remove six bolts 1 retaining the C1/C2 relay
valve body to the control deck.
2. Remove C1/C2 relay valve body 2.

2
5-12-1
V10653.00.00
6139

b. C1/C2 Relay Valve Body Disassembly
1. Position the C1/C2 relay valve body machined
face down on the work surface.
2. Remove two bolts 1 from C1 pressure
switch 2.
4
2
3. Remove C1 pressure switch 2.

4. Remove two bolts 3 from C2 pressure
switch 4.
5-12-2
5. Remove C2 pressure switch 4.
3
1
V10674.00.00
6. Turn the C1/C2 relay valve body smooth surface up.
1
3

the retaining clip and compress C2 relay valve
spring 1 and remove retaining clip 3.
5-7-30
8. Remove C2 relay spring 1 and valve 2.
V10429.00.00.(5-7-30)

the retaining clip and compress C1 relay valve
spring 1 and remove retaining clip 3.
1
2
10. Remove C1 relay valve spring 1 and valve 2.

5-7-31
V10431.00.00
6140
MODULE REBUILD
c. C1/C2 Relay Valve Body Assembly
1. Insert C2 relay valve 2 into the relay valve
bore.
1
3
2. Insert C2 relay valve spring 1, no color code,

into the relay valve bore.
the retaining clip and compress the relay valve
spring. Install retaining clip 3. Make sure the
5-7-32
(Use 5-7-30)
V10429.00.00.(5-7-30)
4. Insert C1 relay valve 2 into the relay valve

bore.
5. Insert purple color coded C1 relay valve
spring 1 into the C1 relay valve bore.
1
3
V10431.00.00

the retaining clip and compress the relay valve
spring. Install retaining clip 3. Make sure the
V10431.00.00
7. Lubricate the O-ring on C2 pressure switch 4.

install the pressure switch. onto the valve body.
8. Install two bolts 3 retaining the pressure switch
to the valve body. Tighten bolts 3 to 58 Nm
(4471 lb inch).
4
2
NOTE:
The C3 pressure switch closes at 206.8 +/- 48.3 KPa
(30 +/- 7 psi). Switch resistance in the closed position
is 2 Ohms maximum. Switch resistance in the open
position is 20 kOhms to infinity. On a DVOM, infinity is often indicated by OL (Over Limit).
5-12-7
(Use removal art)
3
1
V10674.00.00
6141

9. Lubricate the O-ring on C1 pressure switch 2.
install the pressure switch onto the valve body.
4
2
10. Install two bolts 1 retaining the pressure switch

to the valve body. Tighten bolts 1 to 58 Nm
(4471 lb inch).
5-12-8
(Use Removal Art)
NOTE:
1
V10674.00.00
The C3 pressure switch closes at 206.8 +/- 48.3 KPa

(30 +/- 7 psi). Switch resistance in the closed position
is 2 Ohms maximum. Switch resistance in the open
position is 20 kOhms to infinity. On a DVOM, infinity is often indicated by OL (OverLimit).
d. C1/C2 Relay Valve Body Installation
1. Align C1/C2 relay valve body 2 bolt holes with
the bolt holes in the control deck.
2. Install six M8 bolts 1.

2

5-12-9
(Use Removal art)
616. INSTALL INTERNAL HARNESS

V10653.00.00
a. Install Oil Level Sensor

NOTE:
Install the OLS after the C1/C2 relay valve body is
installed.
1. Install two ferrules 5 into each bolt hole in the
OLS base.
2. Align the bolt holes in bracket 4 with the bolt

holes in the OLS base and install two shoulder
bolts 3. Tighten bolts 3 to 1013 Nm (710 lb ft).
5-7-27 5
(Use 5-7-26)
3. Connect the internal harness to the OLS.

4. Position OLS bracket 4 over the bolt holes in
the control deck and the relay valve body.
4
V10414.00.00(5-7-26)
6142
5. Install two bolts 1 retaining the OLS to the

control deck. Tighten bolts 1 to 1013 Nm
(710 lb ft).
MODULE REBUILD
b. Install Internal Harness
1. Install two clips and three bolts retaining the
internal wiring harness to the control deck.
Tighten bolts 1013 Nm (710 lb ft).
2. Connect the internal harness to all solenoids,
pressure switches, and RTDs
3. Inspect the O-ring on main connector 1. Replace a damaged O-ring.
MOTOR A TEMP
OIL TEMP
C2 SOLENOID
C1 SOLENOID
OLS
BOOST SOLENOID
C2 PRESSURE SWITCH
C1 PRESSURE SWITCH
DEUTSCH
CONNECTOR
MOTOR B TEMP
V08748.00.00
4. Inspect O-ring 1 on the main connector.

5. Install main connector 1 into the stator housing
main connector port.
1
2
6. Install panel nut 2 retaining the main connector

to the stator housing. Tighten panel nut tightly
enough to prevent fluid leakage.
V10676.00.00
617. DPIM BYPASS

The DPIM bypass prevents excess hydraulic pressure
from building up in the DPIM cooling circuit. When
DPIM cooling circuit pressure exceeds 482.76 kPa
(70 psi) the DPIM bypass opens, exhausting excess
pressure to the sump.
a. DPIM Bypass Removal
1. Remove two bolts 1.
2. Remove stop 2, spring 3, ball 4, and washer 5.
3. Inspect removed parts for wear or damage. Replace any worn or damaged parts.
2
3
5-13-1
4
5
V10673.00.00
6143

b. DPIM Bypass Installation
1. Install threaded orifice plug 5, small diameter

first into the DPIM bypass bore. Tighten plug 5
to 2429 Nm (1821 lb ft).
5-13-2
4
(Use removal art)
2. Install ball 4, and spring 3 into the DPIM bypass bore.
1
3
3. Install stop 2 so that the stud fits inside

spring 3.
V10673.00.00
4. Install two bolts 1. Tighten bolts to 58 Nm

(4872 lb inch).
618. STATOR HOUSING

a. Preparation of Stator Housing for Cleaning
NOTE:
The stator housing motor windings may be damaged by certain solvents, aggressive cleaning techniques, or debris trapped within the windings.
Allison Transmission recommends that stator housing cleaning and electrical testing for re-use qualification be sublet to a qualified motor shop skilled in
motor winding cleaning.
INPUT
HOUSING
MODULE
MAIN
HOUSING
MODULE
CLUTCH
HOUSING
MODULE
1. Remove the following from the stator housing

using procedures described in Section 4 and
Section 5:
REAR
COVER
MODULE
Flywheel Damper Assembly

Input Housing
Rotor A
Rotor B
OIL PAN
CONTROL VALVE
ASSEMBLIES AND
CONTROL DECK
V07543.01.02
C1 Clutch Housing
Rear Cover Module
Oil Pan
Valve Bodies
Internal Wiring Harness
Motor Speed Sensors
Filters
Breather
Stator Housing Plugs
6144
MODULE REBUILD
2. Remove solenoid screen filters 1 located in the
control deck of the stator housing.
1
V10652.00.00
3. Remove all pressure taps and plugs from the

stator housing.
OIL TO COOLER PORT

HIGH VOLTAGE
LUG BOX
FOR MOTOR "A"
P2 MOTOR A
SPEED SENSOR
P4 MOTOR B
SPEED SENSOR
OIL FROM DPIM PORT
OIL TO DPIM PORT
NAMEPLATE
FILL TUBE PROVISION

MAIN PRESSURE TAP
4. Remove two screws 1 retaining the DPIM bypass to the control deck.
5. Remove stop 2, spring 3, ball 4, and washer 5.
V07584.05.00
2
3
4
5
V10673.00.00
6. Remove four M8 x 70 mm bolts retaining each

High Voltage Lug Box cover to the stator housing.
7. Remove both the Rotor A and Rotor B High
Voltage Lug Box covers.
V10324.00.00
6145

8. On each High Voltage Lug Box, remove exterior panel nut 1 retaining the connector to the
lug box.
9. Remove the connector from the lug box.

10. Loosen HVIL switch panel nut 2. Remove the
HVIL switch.
2
V10616.00.00
5-18-7
11. If present, remove four 8 mm bolts 3 retaining
each access plate 2 to the stator housing and remove the access cover and gasket 1.
5-18-8
3
V10627.00.00
12. Inspect the stator housing casting for irreparable damage such as cracks or porosity. Do not
use the stator housing if casting damage exists.
13. Measure each motor for isolation resistance using an AMB-45 Amprobe or equivalent. For
each motor, measure between a high-voltage
motor stud and the stator housing. Resistance
must be greater than 100 mega Ohms. If resistance is less than 100 mega Ohms, replace the
stator housing.
V10626.00.00
6146
14. Sublet stator housing for cleaning and windings testing as per Allison Electric Drive specification in Appendix B of this manual.
MODULE REBUILD
b. Inspect and Replace Stator
Housing Roller Bearings
J 48149Stator Protector
J 48139Bearing Installer
1. Position stator housing so that the roller bearings in the center support are accessible.
A
2
2. If stator housing is qualified to re-use, inspect

roller bearings 2 for damage and replace bearings if wear is excessive or if a roller bearings
is damaged.
A
2
NOTE:
Both center support roller bearing are replaced using the same procedure for each bearing.
5-18-10
SECTION
A-A
V10598.01.00
3. Install the stator protector J 48149 ring.
5-18-11
V10625.00.00
4. Install the stator protector J 48149 sleeve.

5-18-12
V10624.00.00
6147

A
5. Install J 48125 bridge 1 in ID of center support

bearing 2 so that the bridges lip fits under the
roller bearing.
A
1
5-18-13
SECTION
A-A
V10600.01.00
6. Install the legs of J 48125 under bearing

rollers.
5-18-14
1
7. Tighten the lead screw until the roller bearing

is free of the center support casting.
8. Remove the roller bearing.
SECTION
A-A
V10599.01.00
619. INSTALL STATOR HOUSING

EXTERNAL PARTS
After a stator housing has been cleaned by a motor
shop, plugs and pressure taps must be installed,
O-rings and gaskets must be replaced.
a. Install Pressure Taps and Plugs
1. Install new O-rings on four small pressure taps.
2. Install pressure taps into the stator housing.
Tighten pressure taps 1013 Nm (710 lb ft).
3. Install new O-rings on five large plugs. Install
plug assemblies in stator housing. Torque plug
assemblies 3745 N m (2733 lb ft).
V10623.00.00
6148
MODULE REBUILD
4. Install a new oil seal for the dipstick.
5. Install new plug and seal in the unused dipstick
provision.
OIL TO COOLER PORT

HIGH VOLTAGE
LUG BOX
FOR MOTOR "A"
P2 MOTOR A
SPEED SENSOR
P4 MOTOR B
SPEED SENSOR
OIL FROM DPIM PORT
OIL TO DPIM PORT
NAMEPLATE
FILL TUBE PROVISION

MAIN PRESSURE TAP
V07584.05.00
6. Install two new trim solenoid filter screens 1 in

the control deck.
1
7. Seat filter screens 1 by tapping screens lightly

with a small mallet until they seat in their
bores.
5-18-17
V10652.00.00
b. Inspect and Install DPIM

Bypass Valve Assembly
1. Inspect DPIM bypass ball, stop, and bolts for
damage. Replace parts as needed.
2. Replace DPIM bypass spring 3 if it is damaged.
Spring free height is 34.49 mm (1.36 inch).
Length under load is 25.70 mm (1.01 inch) with
a spring force of 49.3959.77 N (11.113.44 lb).
3. Install threaded orifice plug 5 and ball 4 into
bypass bore. Tighten plug 5 to 2429 Nm
(1821 lb ft).
2
3
4
5
V10673.00.00
4. Install spring 3 onto stop2 and insert into bore.

5. Compress spring 3 manually and thread bolts
evenly to clamp valve stop to bottom of control
deck. Tighten bolts 58 N m (4 6 lb ft).
6149

c. Install New Lug Box and Access
Cover O-rings and Gaskets
NOTE:
Replace two lug box and access cover O-rings and
gaskets using the same procedure for both lug boxes
and access covers.
1. Remove two screws 1 retaining the lug box to

the stator housing. Remove lug box.
2. Replace O-ring 2 between the lug box and the

stator housing.
3. Reinstall the lug box using two screws 1.
Tighten screws 1 so as to prevent water and dirt
from penetrating the O-ring.
V10601.00.00
5-18-20
4. Measure dimension A, between the barrel and
the spacer nut. Adjust the barrel until dimension A is 17.7518.75 mm (0.6990.738 inch).
1
A
2
V10679.00.00
5. Install HVIL switch 1 with the switch roller

away from connector hole 2 and with the roller
bracket facing the wall of the lug box. The
panel nut and lock washer must be on the roller
side of the cast-in switch support.
4
2
2
5-18-21
6150
6. Tighten panel nut 3 to retain HVIL switch 1 in

position.
V10615.00.00
MODULE REBUILD
7. Install HVIL switch connector O-ring 1 and insert connector 2 into hole 3.
8. Tighten panel nut 4 to retain the connector in

the lug box and to prevent intrusion of water or
dirt.
2
1
3
2
5-18-22
V10642.00.00
9. Install a new lug box gasket 1.

10. Align lug box cover 2 with bolt holes and install four bolts 3. Tighten bolts to 2429 Nm
(1821 lb ft).
V10622.00.00
11. Install a new access cover gasket 1.

12. Install four 8 mm x 25 bolts 2. Tighten bolts to
2429 Nm (1821 lb ft).
V10627.00.00
6151

NOTES
6152
SECTION 7E V DRIVE ASSEMBLY

71.
INSTALL SUCTION FILTER
1. Inspect O-ring 1 for wear or damage. Replace

O-ring 1 if worn, cut, or otherwise damaged.
Install the suction filter.
2. Install two clips retaining the suction filter to

the control deck.
4-13-1
3. Retain the each clip with one bolt. Tighten

72.
V10656.00.00
INSTALL OIL PAN
1. Install gasket 4.
1
2. Install oil pan 3.

3. Install thirty-two M8 bolts 1 in the perimeter
of the oil pan. Install four bolts 2. Tighten
4-12-1
3
4
V10662.00.00
73.
INSTALL LUBE FILTER
1. Install cartridge-type lube filter 1.

3
2. Install filter cover 2.

3. Install four M8 bolts 3 into the lube filter cover 2.
Tighten bolts to 2429 Nm (1821 lb ft).
4-11-1
4-11-1
V10392.00.00
71

74.
INSTALL ROTOR B / C1 CLUTCH

HOUSING
1. Position stator housing 2 so that the rear is facing up.

1
2. Install the gasket between stator housing 2 and

C1 clutch housing 1.
4-10-3
3. Attach a sling to the C1 clutch housing assembly.
4-10-3
4. Attach a hoist to the sling and lift the C1 clutch

housing/Rotor B assembly from the work
table.
V10579.00.00
5. Position the Rotor B/C1 clutch housing assembly above the stator housing and carefully
lower the Rotor B/C1 clutch housing assembly
into the Motor B stator until the C1 clutch
housing seats against the stator housing. Remove the sling.
6. Align the bolt holes in the C1 clutch housing
with the bolt holes in the stator housing.
7. Install fifteen M12 x 45 mm bolts 1 into the C1

clutch housing. Tighten bolts to 90110 Nm
(6681 lb ft).
XXXXX
XXXX

4-10-2
4-10-2
V10375.00.00.(4-10-2)
8. Install a steel reaction plate of C1 clutch pack 1

into C1 clutch housing 2.
1
4-10-1
9. Alternating a friction plates with a steel reaction, install five friction plates and six steel reaction plates in C1 clutch housing 2.
V10373.00.00(4-10-1)
72
E V DRIVE ASSEMBLY
75.
INSTALL REAR COVER
1. Install gasket 1, between the rear cover assembly and the C1 clutch housing.
1
4-9-7
4-9-7
4-9-8
4-9-8
V10581.00.00
2. Using a hoist, position the rear cover, bolt

holes aligned, onto the C1 housing assembly.
3. Install eight M10 x 75 mm bolts 1 into the rear
cover. Tighten bolts finger tight.
4-9-3
1
1
4-9-4
4-9-3
1
V10379.00.00
4. Install M10 x 50 mm bolt 1 into rear cover.

5. Tighten bolt finger tight.
4-9-2
4-9-2
V10378.00.00.(4-9-2)
73

6. Install two M12 x 100 mm bolts 1 into the rear
cover.
7. Tighten bolts finger tight.
XXXXX
XXXX
4-9-4
V10377.00.00.(4-9-5)
11
8. Install eighteen M12 x 55 mm bolts 1 into the

rear cover bolt circle.
1
1
9. Tighten all bolts to 90110 Nm (6681 lb ft).

1
1
1
4-9-5
1
1
1
1
4-9-6
4-9-6
495
V10380.00.00(4-9-5)
10. Using a criss-cross pattern, tighten eight

M10 x 75 mm bolts 1 to 5161 Nm (3845 lb ft).
4-9-3
1
1
4-9-4
4-9-3
1
V10379.00.00
11. Tighten two M12 x 100 mm bolts 1 to 90 110 Nm

(6681 lb ft).
XXXXX
XXXX
4-9-4
V10377.00.00.(4-9-5)
74
E V DRIVE ASSEMBLY
12. Tighten M10 x 50 mm bolt 1 to 5161 Nm
( 3845 lb ft).
4-9-2
4-9-2
V10378.00.00.(4-9-2)
76.
INSTALL ROTOR A
1. Position the EV Drive so that the front is up.

2. With Rotor A on the work surface and the input
shaft through the clearance hole in work surface, screw an M16 x 2 eye bolt into the input
shaft.
4-8-2
4-8-2
4-8-2
V10386.00.00(4-9-1)
3. Attach a hoist to the eye bolt.

4. Position Rotor A over the stator housing.
XXXXX
6. Remove the hoist and eye bolt.
XXXX
4-8-1
5. Guiding the main shaft into position, install

Rotor A into the stator housing.
4-8-1
4-8-1
V10372.00.00
75

77.
INSTALL INPUT HOUSING
1. Install thrust bearing 1 (72 mm ID).

1
XXXXX
XXXX

4-7-5
4-7-5
4-6-10
V10371.00.00(4-7-5)
2. Install a new stator housing/input housing

gasket.
1
4-7-4
4-6-9
4-6-9
4-7-4
V10376.00.00.(4-7-4)
3. Attach a sling to the input housing.

4. Attach a hoist to the sling.
4-7-3
5. Lift the input housing and position the input

housing on the stator housing.
6. Remove the sling.
4-7-3
4-7-3
V10578.00.00
7. Install twenty-nine M10 x 1.25 x 35 mm

bolts 1 into input housing.
1
8. Evenly tighten the twenty-nine bolts retaining the

input housing to the stator housing to 5161 Nm
(3845 lb ft).
4-7-1
4-7-1
4-6-6
V10660.01.00
76
E V DRIVE ASSEMBLY
78.
INSTALL INPUT DAMPER

J 38548End Play Gauge
1. Attach a sling to damper assembly 1.

2. Attach a hoist to the sling and position damper
assembly 1 over input housing 2.
3. Lower the damper assembly onto the input
housing, aligning the bolt holes, and remove
the sling.
4-6-5
4-6-5
4-6-5
V10577.00.00
4. Insert a heel bar into an input housing bolt

hole. Insert two bolts into adjacent flexplate
adapter bolt holes. Place a screwdriver between
the bolts and the heel bar so as prevent the input damper from rotating.
4-6-3
4-6-3
4-6-3
4-6-3
V10583.00.00
77

DEPTH MICROMETER
TOOL HEIGHT
(CONSTANT)
J 38548
DIM.
DIM.
B
C
DIM. A
100 MM
(3.937 in.)
V10594.00.00
5. Install the J 38548 sleeve into the input damper

front cover.
6. Install the J 38548 bolt through the sleeve and
into the end of the input shaft. Tighten the bolt
to 2734 Nm (2025 lb ft).
7. Measure from the top of the J 38548 sleeve to
the face of the input shaft. Record this measurement as dimension B. Subtract dimension
B from dimension A, which is the 100 mm
(3.937 inches) height of J 38458, to determine
dimension C.
8. Use dimension C and Table 71 to determine
the correct selective input shim to install.
Table 71.
Dimension C
Use P/N
Shim Step Dimension
0.40930.6597 mm
(0.01610.0260 in.)
29505688
0.000 mm;
NO STEP
0.65980.8377 mm
(0.02610.0330 in.)
29505681
0.1780.228 mm
(0.0070.009 in.)
0.83781.0157 mm
(0.03300.0400 1n.)
29505682
0.3560.406 mm
(0.0140.016 in.)
1.01581.1937 mm
(0.04010.0470 in.)
29505683
0.5340.584 mm
(0.0210.023 in.)
1.19381.3707 mm
(0.04710.0540 in.)
29505684
0.7110.761 mm
(0.0280.030 in.)
1.37081.5487 mm
(0.05410.0610 in.)
29505685
0.8890.939 mm
(0.0350.037 in.)
1.54881.6823 mm
(0.06110.0662 in.)
29505686
1.0671.117 mm
(0.0420.044 in.)
9. Remove J 38458.
10. Install the correct selective shim 2 with the
shim step toward the input shaft.
11. Preventing the input damper assembly from rotating, install bolt 1. Tighten bolt 1 to 135155 Nm
(100114 lb ft).
78
E V DRIVE ASSEMBLY
12. Make sure the O-ring is installed on the
threaded plug.
13. Install threaded plug and O-ring 1 using a

34 inch Allen wrench.
11
14. Tighten threaded plug to 5060 Nm (3744 lb ft).

4-6-2
4-6-2
4-6-2
4-6-2
V10488.00.00
15. Install shipping brackets 1 to prevent damper

movement.
11
4-6-1
79.
INSTALL CONTROL
MAIN FILTER
4-6-1
4-6-1
4-6-1
V10539.00.00
J 45023 Control Main Filter Wrench
1. Make sure magnet 2 is on the filter attachment

tube.
2. Lubricate the gasket on control main filter 1

with transmission fluid.
3. By hand, install the control main filter until the

gasket contacts the stator housing.
4-5-1
CAUTION:
Turning the control main filter more than ONE
FULL TURN after gasket contact will damage
the filter.
V10479.00.00
4. Using J 45023 or by hand, turn the filter ONE

FULL TURN after gasket contact.
79

710. INSTALL OUTPUT
SPEED SENSORS
P7 OUTPUT
SPEED SENSOR
Output speed sensors are labelled on the rear cover P6

and P7.
P6 OUTPUT
SPEED
SENSOR
a. Install Output Speed Sensors

1. Lubricate the O-ring on the speed sensor with
transmission fluid.
2. Carefully work each speed sensor into its bore
in the rear cover, aligning the bracket bolt hole
with the bolt hole in the rear cover.
V08672.00.00
3. Install the M8 bolt retaining the speed sensor to

the rear cover. Tighten the bolt to 2429 Nm
(1821 lb ft).
4. Connect each speed sensor to the wiring harness. Make sure each speed sensor is connected to the correct lead of the wiring harness.
711. INSTALL MOTOR

SPEED SENSORS
Motor speed sensors are labelled on the stator housing
P1P4. P1 and P2 are for Motor A. P3 and P4 are for
Motor B.
V07608.04.00
P3
SPEED SENSOR
P1
SPEED SENSOR
V07608.04.00
710
E V DRIVE ASSEMBLY
a. Install Motor Speed Sensors
1. If removed, install each speed sensor in its
bracket.
2. Carefully insert each speed sensor into the
housing. Make sure the bolt hole in the bracket
is aligned with the threaded hole in the housing.
3. Install the M6 bolt retaining each speed sensor
to the housing. Tighten the bolt to 1013 Nm
(710 lb ft).
4. Connect each speed sensor to the wiring harness. Make sure each speed sensor is connected to the correct lead of the wiring harness.
V07584.04.00
P2
SPEED SENSOR
P4
SPEED SENSOR
V07584.04.00
712. INSTALL OUTPUT

YOKE / FLANGE
J 46703 Output Spanner Nut Socket
1. If removed install slinger 5 into yoke or flange.

2. Install output yoke or flange.
3. Install output nut 3.

4. Using tool J 46703, tighten output nut 3 to
340 Nm (251 lb ft).
NOTE:
Tighten but do not loosen output nut 3 to align an
output nut slot with the keyway.
4-4-1
4
3
V10480.00.00
5. Align an output nut slot with the keyway and

install key 2.
6. Install retaining ring 1.
711

a. Remove EV Drive From Repair Stand
1. Attach a hoist to the EV Drive and take up
the slack in the hoist.
2. Remove four bolts attaching lifting fixture to
adapter plate. Lift the drive and position the
drive on the work table so that it is resting on
the oil pan.
3. Remove eight M14 x 2.0-6G bolts and remove
lifting fixture (J 46701).
J 46701
J-46701
713. INSTALL THE EV DRIVE

CAUTION:
Whenever an EV Drive is exchanged, or has
undergone repairs, the TCM must have the C1
and C2 clutch and main boost pressure adaptives
reset. This will cause the TCM to erase previous
adaptive information and begin to adapt from
the base calibration. Use Allison DOC For PC
(AED)Service Tool to reset the TCM. Refer to
the user guide for instructions (GN3727EN).
1. Inspect the flexplate adapter, if used, for cracks
or other damage. Replace the flexplate adapter
if cracks or other damage is found.
2. Remove the damper retaining brackets just before the EV Drive is ready to be installed in
the vehicle.
V09873.00.00(5-1-1)
DIVISION
OF
GENERAL
INDIANAP
OLIS, MOTORS
INDIANA
XX
XX
XX
CORP.
3. Attach the flexplate adapter to the front

damper. Refer to Foldouts 15, 16, and 17 for
the correct bolt torque specification for the engine configuration used.
XX
XX
RING GEAR
FLEXPLATE ADAPTER
4. Align one of the flexplate bolt holes with the

access opening in the engine flywheel housing.
FLEXPLATE
WEAR PLATE
HUB ADAPTER
5. Lubricate the center pilot boss with

molybdenum disulfide grease (Molycote G or
equivalent).
V07586.01.00
712
E V DRIVE ASSEMBLY
6. Install an M10 x 1.5 headless guide bolt into
one of the flexplate bolt holes in the flexplate
adapter. Align the guide bolt with the flexplate
hole at the access opening.
RING GEAR
7. Push the EV Drive toward the engine while

guiding the pilot boss on the damper into the
flexplate hub adapter or flywheel and the guide
bolt into the hole in the flexplate (a headless
guide bolt in the engine flywheel housing may
also aid in installing the EV Drive).
FLEXPLATE ADAPTER
FLEXPLATE
WEAR PLATE
HUB ADAPTER
V07586.01.00
8. Seat the EV Drive squarely against the engine flywheel housingno force is required. If
interference is encountered, move the
EV Drive away from the engine and investigate the cause.
9. Align the bolt holes in the damper housing
with those in the engine flywheel housing.
10. Install all EV Drive-to-engine bolts and
washers finger tight (a minimum of ten bolts
are required and must include the two top
bolts).
11. Tighten four bolts, at equally spaced intervals,
around the damper housing bolt circle. Use the
torque value specified by the engine or vehicle
manufacturer.
12. Remove the flexplate guide bolt through the
flywheel housing access opening
13. Replace the guide bolt with a self-locking bolt.
Tighten the bolt finger tight.
14. Rotate the engine crankshaft to install the remaining bolts into the flexplate adapter.
15. After all bolts have been installed finger tight,
tighten the bolts to the torque values specified
in Foldouts 15, 16, or 17 for the engine configuration used.
713

16. If used, install the flywheel housing access
cover.
17. Install all bolts, nuts, washers, spacers, isolators, or supports required to support the EV
Drive in the vehicle frame. Tighten bolts to
the torque values recommended by the vehicle
manufacturer.
18. Couple the driveline companion flange or universal joint yoke to the flange or yoke on the
EV Drive. Use bolts and torque values recommended by the vehicle manufacturer.
19. Attach high voltage cabling and install lug
housing covers.
20. Attach cooler lines for the EV Drive and the
DPIM.
21. Connect the external wiring harness, including
speed sensors, HVIL switches, and main
EV Drive connector.
a. Fill the EV Drive
1. Make sure the oil pan drain plug is installed
and tightened to the correct torque value.
OPTIONAL
REAR SUPPORT
BRACKET
BREATHER
MOUNTING
PAD
HIGH VOLTAGE
LUG BOX FOR
MOTOR B
2. Make sure a plug is installed and tight in the

unused fill tube provision.
P1 MOTOR A
SPEED SENSOR
NOTE
The amount of fluid required will vary depending
upon hydraulic hose length and cooler capacity.
V07608.04.01
OUTPUT
SPEED
SENSOR
FLYWHEEL
P3 MOTOR B
SPEED SENSOR
OIL PAN
OIL DRAIN PLUG
FILL TUBE PROVISION
3. Fill the EV Drive with 15 liters (16 quarts) of

approved fluid.
V07608.04.01
4. Perform fluid level check procedures (refer to

Section 3 Preventive Maintenance).
714
SECTION 8WEAR LIMITS AND SPRING DATA

81.
WEAR LIMITS DATA
a. Maximum Variations. Wear limits information

in this Section shows the maximum wear at which
components are expected to function satisfactorily. Table 81 lists the Wear Limits Data and is referenced to
the exploded views (Foldouts 2 through 11) in the
back of this manual.
b. Maximum Relative Movement. Maximum relative movement between mating splines or between
spline and gear is 0.38 mm (0.015 inch).
c. Cleaning and Inspection. Parts must be clean to
permit effective inspection for wear or damage. Refer
to Section 4.
82.
SPRING DATA
adjacent parts, or permanent set. Discard springs

which do not meet the load height specifications according to Table 82, Spring Data.
b. Inspection. Inspection criteria (load vs. height)
and identification characteristics of the springs are presented in Table 82. The Spring Data are keyed to the
exploded views (Foldouts 2 through 11) in the back of
this manual.
NOTE:
When more than one spring part number is listed
for the same location, refer to the latest edition of
Parts Catalog PC3717EN to determine which
spring is used in your specific assembly number.
a. Spring Replacement. Springs should be replaced

if there are signs of overheating, wear due to rubbing
Table 81. Wear Limits Data
Wear Limit
Illustration
Foldout 2
Description
Front Cover, DamperPilot OD
12
Hub, DamperMinimum OD for the bushing surface of the

damper hub
17
Bushing, Rear Cover, DamperMaximum ID
8, 15
15
8, 15
(inches)
INPUT DAMPER
Foldout 4
mm
50.82350.893
2.0012.004
56.930
2.241
73.20
2.882
Housing, Pump and Gear Set, GerotorMaximum driven

gear diametrical clearance between driven gear (15) and
main pump body (8)
0.36
0.014
Gear Set, GerotorMaximum allowable gear tooth tip

clearance
0.15
0.006
Housing, Pump and Gear Set, GerotorMaximum gear

side clearance from pump housing (8) to driven gear (15)
0.10
0.004
FRONT SUPPORT/PUMP
Housing, PumpMaximum depth of gear cavity
21.458
0.845
15
Gear Set, GerotorMinimum width of drive and driven

pump gears
21.403
0.843
Housing, PumpMaximum ID
114.456
4.506
15
Gear Set, GerotorMinimum OD
114.21
4.496
15
Gear Set, GerotorMaximum distance flat-to-flat across

center of drive gear
42.05
1.656
81

Table 81. Wear Limits Data (contd)
Wear Limit
Illustration
Foldout 4
mm
(inches)
FRONT SUPPORT/PUMP (contd)
Bushing, Pump HousingMaximum ID
57.20
2.252
26
Plate, SeparatorMinimum thickness of separator plate.

Thickness of separator plate must not vary more than
0.025 mm per 25 mm x 25 mm area (0.001 inch per 1.0 inch
x 1.0 inch)
4.65
0.183
29
Bushing, Front SupportMaximum ID
51.00
2.008
41.80
1.646
50.688
1.995
33.57
1.322
Carrier Assembly, P1 and Washer, ThrustMaximum endplay between P1 carrier (15) and thrust washer (20) at each
pinion
1.04
0.041
Washer, ThrustMinimum thickness
1.39
0.055
Carrier Assembly, P2 and Washer, ThrustMaximum endplay between P2 carrier (32) and thrust washer (39) at each
pinion
1.04
0.041
39
1.39
0.055
34
Bushing, P2 SupportMaximum ID
94.250
3.710
51.21
2.016
Foldout 5
ROTOR A
11
Shaft, InputMinimum dimension between flats
11
Shaft, InputMinimum bushing journal OD
12
Bushing, Main ShaftMaximum ID
15, 20
20
32, 39
28, 30
Bushing, P2 Drive HubMaximum ID
25
Shaft, MainMinimum pilot OD
33.385
1.314
25
Shaft, MainMinimum main shaft bushing journal OD
50.925
2.005
25
Shaft, MainMinimum main shaft P3 carrier flange bushing journal OD
44.930
1.769
89.78
3.535
Foldout 11
82
Description
REAR COVER/OUTPUT
42
Yoke AssemblyMinimum seal journal diameter
Plate Assembly, C2 ClutchMaximum friction or reaction

plate cone or distortion
0.25
0.010
Plate, C2 FrictionMinimum oil groove depth
0.23
0.009
Plate, C2 FrictionMinimum thickness
2.425
0.095
Plate, C2 ReactionMinimum thickness
1.925
0.075
C2 Clutch Plate Assembly
30.4532.55
1.1991.281
17
Bushing, Output ShaftMaximum ID
33.57
1.322
WEAR LIMITS AND SPRING DATA

Table 81. Wear Limits Data (contd)
Wear Limit
Illustration
Foldout 6
9, 12
Description
mm
(inches)
ROTOR B
Carrier, P3 and Washer, ThrustMaximum endplay
between P3 carrier (9) and thrust washer (12)
0.94
0.037
16
Flange, P3 CarrierMinimum bushing journal diameter

closest to thrust bearing surface
69.635
2.741
16
Flange, P3 CarrierMinimum bushing journal diameter
65.91
2.595
17
Bushing, P3 Carrier FlangeMaximum ID
45.18
1.779
12
1.45
0.057
13
Gear Set, P3 PinionMaximum endplay
0.95
0.037
25
Bushing, P3 Ring FlangeMaximum ID of bushing farthest from thrust bearing
66.21
2.607
23
Bushing, P3 Ring FlangeMaximum ID of bushing closest

to thrust bearing
70.06
2.758
Foldout 10
C1 HOUSING
14
Plate, C1 FrictionMinimum thickness
2.425
0.0955
15
Plate, C1 ReactionMinimum thickness
2.410
0.0948
13
Plate Assembly, C1 ClutchMaximum friction or reaction

plate cone or distortion
0.23
0.009
13
C1 Clutch Plate Assembly
26.5928.11
1.0471.107
83
84
80, 86,
92, 96
105,
114
113
12
25
11
11
12, 15
22
19
10
Ref.
14
Foldout
3
Spring Assembly, C1 Return
Spring Assembly, C2 Return
Exhaust Backfill
Control Main Regulator/Relief
Trim Valve
Relay (550 Kpa)
Cooler Bypass
Main Relief
Lube Regulator
Main Regulator
Spring
Cooler Bypass
29538716
29538726
29538831
29538829
29541050
29540664
29541066
29538781
29538787
29540623
Part No.
29541066
Yellow
Purple
Light
Blue
Red
Color
Code
12.08
14.50
7.05
12.32
7.78
9.11
9.24
6.53
11.94
11.88
No.
Coils
9.24
Wire Dia.
mm (in.)
1.700.03
(0.070.001)
2.292.39
(0.0900.094)
1.420.05
(0.060.002)
3.050.05
(0.120.002)
1.700.03
(0.070.001)
1.420.03
(0.060.001)
0.890.03
(0.040.001)
1.270.03
(0.050.001)
0.790.03
(0.030.001)
1.3211.371
(0.0520.054)
1.090.03
(0.0430.001)
Table 82. Spring Data

Spring
OD
mm (in.)
13.97
(0.55)
21.59
(0.85)
11.43
(0.45)
21.08
(0.83)
13.97
(0.55)
11.94
(0.47)
11.43
(0.45)
13.72
(0.54)
13.97
(0.55)
10.50
(0.41)
8.76
(0.35)
Approx.
Free
Length
mm (in.)
34.49
(1.36)
71.33
(2.81)
37.27
(1.47)
35.56
(1.40)
34.49
(1.36)
29.65
(1.17)
26.30
(1.04)
48.84
(1.92)
22.13
(0.87)
47.00
(1.85)
30.73
(1.21)
mm (in.)
25.70
(1.01)
35.89
(1.41)
22.89
(0.90)
27.15
(1.07)
25.70
(1.01)
18.24
(0.72)
15.85
(0.62)
21.74
(0.86)
13.69
(0.54)
33.27
(1.31)
23.32
(0.92)
N (lb) min.
54.585.19
(12.271.17)
148.4916.33
(33.383.67)
58.5916.33
(13.173.67)
270.7840.50
(60.879.10)
54.585.19
(12.271.17)
56.057.08
(12.601.59)
9.561.05
(2.150.24)
36.641.55
(8.240.35)
2.780.19
(0.620.43)
1248.2062.41
(280.6114.03)
1067.6053.38
(240.0012.00)
Length Under Load
SECTION 9CUSTOMER SERVICE

91.
OWNER ASSISTANCE
The satisfaction and goodwill of the owners of Allison

transmissions are of primary concern to Allison
Transmission (AT), its distributors, and their dealers.
As an owner of an Allison transmission, you have
service locations throughout the world that are eager to
meet your parts and service needs with:
Expert service by trained personnel
Emergency service 24 hours a day in many
areas
Step TwoIf your problem cannot be resolved readily

at the distributor level without additional assistance,
contact the Allison Transmission Regional Office
responsible for your local distributor. You will be
assisted by a member of the Regional Service
Managers staff, depending on the nature of your
problem.
For prompt assistance, please have the following
information available:
Name and location of authorized distributor
or dealer
Complete parts support
Type and make of equipment
Sales teams to help determine your power
requirements
Transmission model number, serial number,
and assembly number
Product information and literature
Refer to the Worldwide Sales and Service Directory

(SA2229EN) or the Allison transmission web site
www.allisontransmission.com for a current listing of
Allison Transmission authorized distributor and service
dealers. This directory is available from SGI, Inc.
Normally, any situation that arises in connection with
the sale, operation, or service of your transmission will
be handled by the distributor or dealer in your area
(check the telephone directory for the Allison
Transmission service outlet nearest you).
We recognize, however, that despite the best intentions
of everyone concerned, misunderstandings may occur.
To further assure your complete satisfaction, we have
developed the following three-step procedure to be
followed in the event you have a problem that has not
been handled satisfactorily.
Step OneDiscuss the problem with a member of
management from the distributorship or
dealership. Complaints are frequently the result of a
breakdown in communication and can be quickly
resolved by a member of management. If you have
already discussed the problem with the Sales or Service
Manager, contact the General Manager. All AT dealers
are associated with an AT distributor. If the problem
originates with a dealer, explain the matter to a
management member of the distributorship with whom
the dealer has his service agreement. The dealer will
provide his AT distributors name, address, and
telephone number on request.
Transmission delivery date and
accumulated miles and/or hours of

operation
Nature of problem
Chronological summary of unit's history
Step ThreeIf you contacted a regional office and

you are still not satisfied, present the entire matter in
writing or by phone to the Home Office:
Manager, Warranty Administration
Allison Transmission
P. O. Box 894, Mail Code 462-470-PF9
Indianapolis, IN 46206-0894
Phone: 1-800-252-5283
The inclusion of all pertinent information will assist the
Home Office in expediting the matter. If an additional
review by the Home Office of all the facts involved
indicates that some further action can be taken, the
Regional Office will be advised.
When contacting the Regional or Home Office, please
keep in mind that ultimately your problem will likely
be resolved at the distributorship or dealership utilizing
their facilities, equipment, and personnel. Therefore, it
is suggested that you follow the above steps in
sequence when experiencing a problem.
Your purchase of an Allison Transmission product is
greatly appreciated, and it is our sincere desire to
assure complete satisfaction.
91

92.
SERVICE LITERATURE
Table 91. EP 40/50 Series Literature
Additional service literature is available (see Table 91).

This service literature provides fully illustrated
instructions for the operation, maintenance, service,
overhaul, and parts support for your transmission. To
be sure that you get maximum performance and service
life from your unit, you may order publications from:
Automatic Transmission Fluid

Technicians Guide
GN2055EN
*Operators Manual
OM3491EN
Principles of Operation
PO3603EN
*Parts Catalog
PC3717EN
SGI, Inc.
Attn: Allison Literature Fulfillment Desk
8350 Allison Avenue
Indianapolis, IN 46268
TOLL FREE: 888-666-5799
INTERNATIONAL: 317-471-4995
Parts Catalog CD-ROM
CD3717EN
Service Manual
SM3602EN
Service Manual (ESS)
SM4162EN
Troubleshooting Manual
TS3715EN
92
*Also available on the Internet at www.allisontransmission.com
APPENDIX AMATERIAL SAFETY DATA SHEET
A1
A2
MATERIAL SAFETY DATA SHEET
A3

NOTES
A4
APPENDIX
STATOR
BSTATOR
HOUSING
HOUSING
RE-USE REUSE
REQUIREMENTS
REQUIREMENTS
Prior to reassembly of the Ev Drive the following
procedures must be completed to make sure the
stator assemblies are reusable. This document outlines the required inspections and electrical qualification tests that must be performed.
Visual Inspection
Inspect the stator windings for the following:
1. Burninspect end windings and stator core for
evidence of burns or discoloration due to heat. If
evidence of burn is detected, do not reuse the stator assembly.
2. Debrisinspect the end windings for debris. If
visible debris or evidence of debris (nicked wires)
is detected on the stator windings, do not reuse the
stator assembly. If visible debris or evidence of debris (nicked wires) is not detected on the stator
windings, follow the steps outlined in the electrical qualification test.
Electrical Qualification Tests
Stator hi-pot and surge test voltages (voltage tolerance +/-25V)
Stator Test Voltage

Operational voltage peak to
peak (for reference only)
AC Test
Voltage
1200V
DC Test
Voltage
1650V
675V
930V
4. Measure resistance between phase 1 to 2, 2 to 3,

and 3 to 1. Resistance must be between 53.2 x 10-3
and 58.8 x 10-3 Ohms corrected to 25C. Imbalance
between resistance measurements must not exceed
1.5 percent calculated using (RMAX/RAVERAGE).
5. Motor RTD:
Resistance measured across the RTD leads should
range from 107113 Ohms.
NOTE: All electrical tests must be performed between 1930C (6686F).
Cleaning Requirements
1. Surge Test all three phases at voltage and condition as follows:
NOTE: All chemicals used in the cleaning process

must not contain silicone. Silicone contamination of
the stator assembly will result in deteriorated transmission fluid life.
Surge testing shall be performed in both the forward and reverse direction. For both phase 1 to 2
and phase 2 to 3 in both directions, the imbalance
ratio between surge period measurements shall be
between 94 percent and 106 percent. Calculated
using:
Test Instrument Requirements
Resistance (R)0.001 Ohms using a balanced

bridge method.
Forward Ratios: Forward Return 2/Forward Return 1 &

Forward Return 3/Forward Return 1
Impedence (Z)at least 3 Ohms impedence.
Reverse Ratios: Reverse Return 2/Reverse Return 1 &

Reverse Return 3/Reverse Return 1
Inductance (L)at least 1 mH inductance
2. Test stator for corona inception between 825875

VAC. No corona inception can be detected.
Phase Angle (Fi)from 0 to 90 degrees.
Insulation Resistance (MegOhms)from 0 to

at least 100 mega Ohms.
Current/Frequency Response (I/F)frequency

doubling test with a range of 15 to 50
precent reduction in current.
3. Hi-Pot test all three phase leads combined with

ground to stator housing assembly. Test duration
should be between 1.0 and 1.5 seconds. Test voltage and condition as follows, maximum allowable
real leakage current of 15.0 x 10-6 amps.
B1

Stator Qualification Electrical Test
4. Phase to Phase Resistance
NOTE: All electrical tests must be performed between 1930C (6686F).

Phase
1. Surge Test
AB
Passed
Motor A
Motor B
BC
CA
Phase to Phase Resistance Imbalance
2. Corona Test
IMBALANCE = RMAX/RAVG) < 1.5%

Passed
Motor A
Motor B
3. Hi-Pot Test
5. Motor RTD
Motor RTD
Passed
Motor A
Motor B
Motor A R1
Motor A R2
Motor B R1
Motor B R2
B2
Measured Resistance
()
(0.05320.0588)
Measured
Resistance ()
(107113)
APPENDIX CE V DRIVE POST-OVERHAUL TESTING

Perform the following tests after completing an overhaul of the EV Drive as outlined in the EV Drive
Service Manual. The Motor Isolation test must be performed before installing the EV Drive into the vehicle chassis. After installing the EV Drive into the vehicle chassis, perform the In-Vehicle Tests.
1. Motor Spin Test

With the vehicle ignition ON, engine not running,
Use Allison DOC for PC (AED) to perform motor spin tests on motors A & B. Confirm that both
motors successfully pass the spin test and that a
speed measurement is observed in the data monitor screen. If no DTCs are logged, perform the Engine Start-Up test.
Motor Isolation Test
Using the AMB 45 Amprobe (high impedance

measuring device), measure the isolation
resistance of Motors A & B to the stator
housing.
2. Engine Start-Up
With the vehicle ignition ON, depress the

engine start button. The EP System performs a
motor diagnostic test and begins engine
cranking if the motor diagnostic test is
successful.
Make sure the following vehicle conditions exist

before performing the In-Vehicle Tests.
Allow the engine to idle at its low idle setting

for 5 minutes.
EV Drive properly installed in the vehicle
Vehicle parked on a level surface with wheels

on the ground
Determine that the transmission fluid level is

correct, add or drain fluid until the fluid level
is correct.
Vehicle driveline installed
Vehicle parking brake applied
Using Allison DOC for PC (AED), check

for any DTCs. If no DTCs are logged, perform
the Main Pressure Schedule Test.
Transmission fluid level correct
EV Drive C1, C2, and Main Boost adaptives

reset using Allison DOC for PC (AED).
No EP System fault codes are active.

Troubleshoot and diagnose any active
diagnostic trouble codes.
All EV Drive adaptation equipment properly

installed including; flex-plates, ring gear,
chassis signal harness, high voltage
harnessing.
All DPIM and ESS signal and high voltage

cabling is properly installed.
Motor Isolation resistance must exceed

100 mega Ohms between the motors and the
stator housing.
In-Vehicle Test Procedures
3. Main Pressure Schedule Check
Install pressure gauges capable of accurately

reading fluid pressures defined in Table C1.
Confirm that the following pressure schedules
are met with EV Drive in neutral while
operating the engine at the speeds defined
below.
Full Main Boost Test must be commanded

used Allison DOC for PC (AED) Action
Requests.
Table C1. Pressure Schedule (Minimum Acceptable)

Engine Input
Speed
(rpm)
19502000
Range
Full Boost
Main Pressure
(kPa)
Low Main
Pressure
(kPa)
Lube Pressure
(kPa)
Control Main
Pressure
(kPa)
C1 / C2
Backfill
(kPa)
2030 (294 psi)
770 (112 psi)
30 (4 psi)
495 (72 psi)
8 (1 psi)
C1
P3 SPEED SENSOR
P1 SPEED SENSOR
V10552.00.00
OIL TO COOLER PORT

HIGH VOLTAGE
LUG BOX
FOR MOTOR "A"
P2 MOTOR A
SPEED SENSOR
C2 PRESSURE TAP
C1 PRESSURE TAP
P4 MOTOR B
SPEED SENSOR
OIL TO DPIM PORT/LUBE PRESSURE TAP

OIL FROM DPIM PORT
NAMEPLATE
FILL TUBE PROVISION

MAIN PRESSURE TAP
Figure 1. Pressure Tap Locations
C2
V07584.05.01
APPENDIX CE V DRIVE POST-OVERHAUL TESTING

4. C1 and C2 Clutch Apply Test
6. Post Test Drive Inspection
Install pressure gauges capable of accurately reading

the fluid pressures defined in Table C2. With the
EV Drive in neutral and using Allison DOC for PC
(AED) Action Requests menu, perform a clutch test and
confirm the pressure schedules in Table C2 are met.
Confirm that the transmission fluid level is correct using the PBSS or Allison DOC for PC (AED). Inspect the EV Drive for fluid leaks at the following locations:
Table C2. C1 and C2 Pressure Schedule

Engine
Input Speed
C1 Pressure
(rpm)
Range
kPa (psi)
755795
C2 Pressure
kPa (psi)
Main 70 (10) Main 70 (10)
Output seal
Bell housing (input seal)
Cooler out port (transmission input
housing)
Cooler return port
Lube filter housing
5. Final Test Drive
Control Main Filter
Perform final test drive using Allison DOC for PC

(AED) to monitor the following:
Variable
Sump Oil Temperature
Motor A/B Temperature
EV Drive Fluid Level
C1 slip speed
C2 slip speed
Diagnostic Trouble Codes
Value Range
<149F (65C)
<212F (100C)
+/ 1 quart
0 in Mode 1
0 in Mode 2
None
Lube outlet port to DPIM (stator housing)

Lube return port from DPIM (oil pan)
Drain plug
C3

NOTES
C4
APPENDIX DBIPD AND DIPD TEST PROCEDURES

D1.
BIPD INTRODUCTION
When installing an Energy Storage System (ESS)

potentially damaging voltages must be prevented from
being applied to various low voltage system
interconnection points.
When connected and then energized, the BIPD performs a one second illumination test of all indicator
lamps.
D3.
OPERATING INSTRUCTIONS
The Battery Pack Installation Protection Device

(BIPD) tests for the presence of any potentially damaging voltages. The BIPD interfaces to the system by
way of the ESS low voltage connectors and wiring
harnessing.
The BIPD connects to the system wiring harness in the

same manner as the ESS. To ensure a meaningful test
all wiring installation and any other vehicle construction that could potentially damage system wiring must
be completed before testing with the BIPD.
The BIPD is used after the system is completed but before the ESS is connected to the system wiring. The
BIPD is connected to the low voltage control system
wiring in place of the ESS. The systems low voltage
supply is energized, and the vehicle ignition switch is
turned on. BIPD testing confirms that the low voltage
wiring harness contains no mis-wiring, shorts, or
grounds that could damage the ESS.
Use the BIPD to test the vehicle low voltage harness

installation after any maintenance or modification that
affects Energy Storage System low voltage interface
wiring.
The BIPD provides a visual indication verifying that

no potentially damaging voltages could be applied to
the ESS low voltage system interconnection points.
The BIPD does not prove that a wiring installation
is correctly installed for proper ESS operation.
D2.
FUNCTIONAL DESCRIPTION
The BIPD detects the presence of voltage levels above

or below those allowed on any single pin, or
combination of pins associated with the Battery Pack
low voltage system interconnections. Table D1
provides a listing of the maximum, minimum, and
failure voltages for each interconnection point.
The BIPD provides a visual indication of the following:
1. Proper low voltage supply and ground connections to the system
2. Supply power within proper voltage range
3. Proper system initial conditions met
4. No improper voltage applied to any applicable
pin(s)
NOTE:
A failed test turns off the associated indicator lamp.
a. BIPD Test Procedure

A BIPD test cannot be conducted with the ESS
connected to the low voltage wiring harness. Disconnect the low voltage wiring harness from the
ESS before conducting a BIPD test.
b. Establish Proper Initial Test Conditions
Various BIPD display combinations may exist as
proper initial system conditions for testing. These
displays are evaluated in subsequent operations
and may be ignored until initial test conditions are
established.
1. Ensure all 12VDC and/or 24VDC power-interrupting devices, power cut-off switches, circuit
breakers, etc. are configured for normal system
operation of the test system.
2. Connect the BIPD to the ESS low voltage harness connector.
3. Turn the vehicle Ignition ON. Transit buses
use Day Run or Night Run.
c. BIPD Test Result Summary
If all four BIPD display lamps illuminate, the low
voltage harness does not contain voltages that
could damage a Battery Pack.
NOTE:
BIPD testing does not verify that the vehicle wiring
is correct. It is only verifies that potentially damaging voltages will not be applied to the ESS through
the low voltage interface.
D1

If any of the four BIPD display lamps is not illuminated, the vehicle low voltage wiring interface
contains errors that could damage the ESS. Low
voltage wiring harness errors must be located and
corrected before installing the ESS.
The Supply Voltage OK lamp will not

illuminate if any of the following improper
conditions exist:
12V supply voltage is less than 10VDC
12V supply voltage is greater than 18VDC
d. BIPD Test Result Evaluation

1. Power Circuits OK Lamp
An illuminated Power Circuits OK lamp indicates that each of the 12V supply and return
pins and each of the 24V supply and return
pins are properly connected.
The Power Circuit OK lamp will not illuminate
if any of the following improper conditions
exist:
No 12V supply pin is connected.
3. Setup OK Lamp
An illuminated Setup OK lamp indicates the
vehicle ignition signal is properly applied.
The Setup OK lamp will not illuminate if any
of the following improper conditions exist:
Either of the two 12V supply pins are not

Vehicle Ignition is not on or turned to Day
connected or are improperly connected to

another electrical point within the system
Run or Night Run
Any one of the three 12V ground pins are
No 12V or 24V Return pin is connected
not connected or are improperly connected

to another electrical point within the system
Any one of the three 24V supply pins are
not connected or are improperly connected

to another electrical point within the system
Any one of the three 24V return pins are not
connected or are improperly connected to

another electrical point within the system
12V supply voltage is greater than 18VDC
NOTE:
The BIPD will function with any one 12V supply
and any one 12V return pin connected correctly.
NOTE:
The vehicle ignition power is applied to Pin E. The
BIPD must detect 12V (nominal) before the Setup
OK lamp will illuminate.
4. Test Result OK Lamp
An illuminated Test Result OK lamp indicates
that no potentially damaging voltage has been
detected on any DPIM low voltage pin.
The Test Result OK lamp will not illuminate if
any of the following improper conditions exist:
A potentially damaging voltage is detected
at any low voltage interface pin
2. Supply Voltage OK Lamp

An illuminated Supply Voltage OK lamp indicates that the 12V and 24V supply voltages are
within acceptable limits.
D2

12V supply voltage is greater than 18VD

Table D1. Maximum/Minimum Allowable Voltages
Connector Pin
Signal Name
Maximum
Allowable
Voltage
Minimum
Allowable
Voltage
Test Fail Voltage
CAN HI
18VDC
N/A
17VDC
CAN LO
18VDC
N/A
17VDC
CAN Shield
0VDC
N/A
2VDC
ES Relay Closed
N/A
N/A
N/A
Ignition
N/A
N/A
N/A
+12V Battery Supply
18VDC
9VDC
17VDC/10VDC
+12V Battery Return
N/A
N/A
N/A
+12V Battery Return
N/A
N/A
N/A
No Connection
N/A
N/A
N/A
No Connection
N/A
N/A
N/A
ES Wake-Up
N/A
N/A
N/A
No Connection
N/A
N/A
N/A
No Connection
N/A
N/A
N/A
+12V Battery Supply
18VDC
9VDC
17VDC/10VDC
No Connection
N/A
N/A
N/A
+12V Battery Return
N/A
N/S
N/A
No Connection
N/A
N/A
N/A
No Connection
N/A
N/A
N/A
No Connection
N/A
N/A
N/A
No Connection
N/A
N/A
N/A
No Connection
N/A
N/A
N/A
No Connection
N/A
N/A
N/A
No Connection
N/A
N/A
N/A
+24V Battery Return
N/A
N/A
N/A
+24V Battery Supply
N/A
18VDC
18VDC
+24V Battery Supply
N/A
18VDC
18VDC
+24V Battery Supply
N/A
18VDC
18VDC
No Connection
N/A
N/A
N/A
+24V Battery Return
N/A
N/A
N/A
+24V Battery Return
N/A
N/A
N/A
No Connection
N/A
N/A
N/A
D3

D4.
DIPD INTRODUCTION
Before connecting a Dual Power Inverter Module

(DPIM), system control wiring must be tested to prevent damaging voltages from being applied to various
low voltage system interconnection points.
The DPIM Installation Protection Device (DIPD) tests
for the presence of any damaging voltages. The DIPD
interfaces to the system by way of the DPIM low voltage connectors and wiring harnessing.
The DIPD is used after the system is completed but
before the DIPM is connected to the system control
wiring. The DIPD is connected to the low voltage control system wiring in place of the DPIM. The systems
low voltage supply is energized, and the vehicle ignition switch is turned on. DIPD testing confirms that
the low voltage wiring harness contains no mis-wiring,
shorts, or grounds that could damage the DPIM.
The DIPD detects the presence of voltage levels,
above the maximum allowed on any single pin, or
combination of pins associated with the DPIM low
voltage system interconnections. In some instances, a
voltage significantly lower than the maximum allowable will be considered a failure if that voltage level is
indicative of improper wiring. Table D2 provides a
listing of the (nominal/maximum) voltage failure set
point for each interconnection point.
The DIPD provides a visual indication verifying that
no potentially damaging voltages could be applied to
the DPIM low voltage system interconnection points.
The DIPD does not prove that a wiring installation
is correctly installed for proper ESS operation.
D5.
FUNCTIONAL DESCRIPTION
The DIPD simulates the 12V sensor supply voltages

normally supplied by the DPIM internal circuitry and
makes appropriate measurements to ensure this power
has not been inadvertently routed to another interconnection point on the DPIM which could be damaged
by the application of 12VDC.
The DIPD provides a visual indication of the following:
Proper low voltage supply and ground
connections to the system

Supply power within proper voltage range
D4
Proper system initial conditions met

No improper voltage applied to any applicable
pin(s)
NOTE:
A failed test turns off or blinks the associated indicator lamp.
When connected and then energized, the DIPD performs a one second illumination test of all indicator
lamps.
D6.
OPERATING INSTRUCTIONS
The DIPD connects to the control system by way of

three low voltage connectors that are mated to the system harnessing in the same manner as a DPIM. These
connectors are designated as J1 (Red, 32-pin),
J2 (Gray, 32-pin) and J3 (Black, 24-pin)
All wiring installation and any other construction efforts which could damage system wiring, must be
completed throughout the entire vehicle before conducting DIPD testing.
Use the DIPD to test the vehicle low voltage harness
installation after any maintenance or modification that
affects Energy Storage System low voltage interface
wiring.
a. DIPD Test Procedure
DIPD testing requires that a DPIM is not connected to the low voltage wiring harness. If a
DPIM is connected, the DPIM must be fully deenergized and the low voltage wiring harness connectors (J1, J2, and J3) disconnected from the
DPIM before testing.
b. Establish Proper Initial Test Conditions
Various DIPD display combinations may exist as
proper initial system conditions for testing are being established in the steps below. These displays
are evaluated in subsequent operations and may
be ignored until initial test conditions are established.
1. Ensure all 12VDC and/or 24VDC power-interrupting devices, power cut-off switches, circuit
breakers, etc. are configured for normal system
operation of the test system.

Table D2. Maximum Allowable Voltage To Prevent Damage To DPIM
Maximum
Connector Allowable
J1 pin
Voltage
Test Fail
Maximum
Voltage Connector Allowable
(Max)
J2 pin
Voltage
Test Fail
Maximum
(Max)
J3 pin
Voltage
Test
Fail
Voltage
(Max)
7V
5V
7V
5V
32V
18V
7V
5V
7V
5V
32V
18V
7V
5V
7V
5V
25V
18V
7V
5V
7V
5V
25V
18V
No
connection
N/A
No
connection
N/A
32V
18V
25V
5V
25V
5V
32V
18V
14V
14V
14V
14V
32V
5V
32V
3V
32V
3V
25V
5V
25V
5V
25V
5V
25V
5V
10
14V
14V
10
14V
14V
10
No
connection
N/A
11
25V
5V
11
25V
5V
11
No
connection
N/A
12
14V
14V
12
14V
14V
12
32V
5V
13
32V
5V
13
32V
5V
13
32V
3V
14
No
connection
N/A
14
No
connection
N/A
14
18V
18V
15
10V
5V
15
10V
5V
15
18V
18V
16
No
connection
5V
16
No
connection
5V
16
32V
N/A
17
32V
3V
17
32V
3V
17
32V
N/A
18
32V
3V
18
32V
3V
18
32V
N/A
19
7V
5V
19
7V
5V
19
32V
N/A
20
7V
5V
20
7V
5V
20
32V
N/A
21
32V
3V
21
32V
3V
21
32V
N/A
22
32V
8V
22
32V
8V
22
32V
3V
23
14V
5V
23
14V
5V
23
18V
18V
24
32V
3V
24
32V
3V
24
18V
18V
25
32V
8V
25
32V
8V
26
14V
5V
26
14V
5V
D5

Table D2. Maximum Allowable Voltage To Prevent Damage To DPIM (contd)
Maximum
Connector Allowable
J1 pin
Voltage
D6
Test Fail
Maximum
(Max)
J2 pin
Voltage
Test Fail
Maximum
(Max)
J3 pin
Voltage
27
32V
8V
27
32V
8V
28
14V
5V
28
14V
5V
29
32V
3V
29
32V
3V
30
32V
3V
30
32V
3V
31
10V
5V
31
10V
5V
32
32V
5V
32
32V
5V
Test
Fail
Voltage
(Max)
F OLDOUT 1
10
11
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
12
13
14
Flywheel Damper Assembly

Input Housing
Front Support Assembly
Motor A
P1 Planetary
P2 Planetary
Main Shaft
Motor B
P3 Planetary
C1 Clutch Housing
C1 Clutch
C2 Clutch
Rear Cover
Output Shaft
Stator Housing
Oil Pan
Control Valve Bodies
Main Pump Assembly
Input Shaft
Control Deck
15
16
17
19
18
V07180.03.00
Foldout 1. Allison Electric Drives
F OLDOUT 2
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
Plug, Pilot, Threaded, D

O-ring, 34.6 ID
Bolt Heavy Hx Flange Hd, M16 x 2 x 30, A
Selective Shim, Turbine
Selective Shim, Turbine, 5.448 mm (0.214 inch)
Damper Assembly, Input, Complete
Front Cover assembly
Flywheel
Dowel pin, 10 x 24
Thrust bearing, 74 mm ID
Damper assembly
Bolt, M8 x 1.25 x 20, C
Damper hub
O-ring, 330 mm ID
Input damper back housing assembly
Housing
Back housing bushing, 73 mm ID
Bolt, M8 x 1.25 x 20, B
Torque
Nm
lb ft
A
B
C
D
135155
2429
3541
5060
100114
1821
2630
3744
5
3 4
7
8
10
11
12
9
13
14
16
15
17
18
V09788.00.00
Foldout 2. Input Damper
F OLDOUT 3
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
Bolt, M10 x 1.25 x 25, A

Damper shipping bracket
Shipping plug, SAE No. 16
Bolt, M10 x 1.25 x 35, A
Input housing module
Input housing assembly
Pressure tap plug
Straight thread plug
O-ring 9 mm ID
Input housing
Cooler bypass plug
O-ring, 22 mm ID
Steel ball
Cooler bypass spring
Cooler bypass stop
Plug
Pin, 316 x 1.74 inch
Input housing gasket
Input housing O-ring
Gasket
2
1
6
4
8
7
9
16
19
12
13
Nm
lb ft
5161
3835
20
19
15
14
17
11
16
Torque
10
16
18
V09789.00.00
Foldout 3. Input Housing
F OLDOUT 4
13
12
11
10
4
9
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
28
29
30
31
32
Front support/pump assembly

Pump assembly
O-ring, 126 mm OD
Input oil seal
Pump and bushing assembly
Pump housing bushing, 57 mm ID
Pump housing
Main regulator valve
Main regulator valve spring
Main regulator valve stop
O-ring, 22 mm ID
Pin, 316 x 1.74 mm
Dowel pin, 10 x 24 mm
Gerotor gear set
Pin, 716 x 1.74
O-ring, 17mm ID
Lube regulator valve stop
Lube regulator valve spring
Lube regulator valve
Ball
Main relief valve spring
Main relief valve stop
O-ring, 22 mm ID
Pin, 316 x 1.74
Separator plate
Front support assembly
Front support
Front support bushing, 51 mm ID
Bolt, front support, M10 x 1.5 x 45
Assembly, roller bearing
Bolt, front support to input housing, M10 x 1.5 x 75
25
24
23
14
22
21
15
14
20
19
18
17
16
26
28
27
29
30
31
32
V09787.00.00
Foldout 4. Front Support/Pump
F OLDOUT 5
2
3
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
Rotor A assembly
Rotor A hub and P2 ring
P2 ring gear
Bolt, M8 x 1.25 x 20 (12), A
Input shaft assembly
Retaining ring, 175 mm ID
O-ring, 25 mm ID
Input shaft assembly
Input shaft
Main shaft bushing, 33.5 mm ID
P1 ring gear
Thrust bearing, 64.0 mm ID
P1 carrier assembly
P1 carrier
P1 carrier spindle (4)
Retaining ring, 152 mm OD
Dowel pin, 3.10 x 11.13 mm (4)
Thrust washer (8)
Roller bearing assembly (8)
P1 pinion gear set
P1 sun gear
25
26
27
28
29
30
31
32
33
34
35
36
37
38
39
40
41
42
43
44
Main shaft
Retaining ring, 175 mm ID
P2 Drive hub assembly
P2 Drive hub bushing 51 mm ID
P2 drive hub
P2 Drive hub bushing, 51 mm ID
P2 carrier assembly
P2 carrier and bushing assembly
P2 support bushing, 94 mm ID
P2 carrier
Retaining ring, 152 mm OD
Dowel pin, 3.892 x 6.35 (4)
P2 thrust washer (8)
P2 roller bearing assembly (8)
P2 pinion gear set
P2 sun gear
Torque
A
Nm
2429
5
20
21
17
22
20
19
18
7
6
14
16
15
9
10
11
23
24
13
12
39
40
36
25
41
38
lb ft
1821
39
35
37
33
34
26
32
28
27
29
30
42
31
43
44
V09790.00.00
Foldout 5. Rotor A
F OLDOUT 6
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
28
Rotor B assembly
Rotor B hub and flange
Bolt, M8 x 1.25 x 20 (12), A
Rotor B flange
P3 sun gear shaft
P3 output flange
P3 Carrier assembly
P3 carrier
Dowel pin, 3.10 x 11.13 mm (4)
Thrust washer (8)
P3 pinion gear set
Roller bearing (8)
P3 output flange
P3 carrier flange
Flange bushing (2)
Retaining ring
P3 ring gear assembly
P3 ring gear
P3 ring gear flange assembly
P3 ring gear flange bushing, 70 ID
P3 ring gear flange
P3 ring gear flange bushing, 66 mm ID
Retaining ring, 188 mm groove dia
Torque
A
Nm
2429
3
1
2
4
6
28
8
19
9
7
15
17
27
16
10
12
11
17
18
13
20
14
12
lb ft
1821
21
23
22
24
25
26
V09791.00.00
Foldout 6. Rotor B
F OLDOUT 7
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
28
29
30
31
32
33
34
35
36
37
38
39
40
41
42
43
44
45
46
47
48
49
50
51
52
53
54
55
56
57
58
59
60
61
62
63
Stator housing assembly

Plug assembly
Plug, straight thread O-ring boss, B
O-ring, 16.4 ID
Plug assembly
O-ring, 16.4 ID
Cable housing cover gasket
High voltage connector cover
Cover assembly bolt
Plug assembly
O-ring, 16.4 ID
O-ring, Uniform No. 017
Insulator, High Voltage Stud
Ring, Retaining External
Nut, HV stud
O-ring, 101.26 ID
Seal, lugbox splitline
Cable housing
O-ring
Socket Hd cap screw, 10-24, A
Switch assembly, HVIL
Spacer, HVIL switch
Gasket, cable housing
Cover, cable housing
Bolt, metric flanged large Hx Hd 5
O-ring
Stator housing roller bearing
Harness assembly RTD
Secondary lock
Terminal, M M/P 150 clip slot
Connector, 2M M/P 150 clip slot
Secondary lock
Cover, cable housing
Cover, high voltage connector
Bolt, cover assembly
Pan guide spring pin, 316 x 12
Pan guide spring pin, 316 x 12
Screw, self seal Hx flange, M8 x 1.25 x 25
O-ring, uniform No. 107
Insulator, high voltage stud
Ring, retaining external
Nut, HV stud
O-ring, 101.26 ID
Seal, lug box splitline
Cable housing
O-ring
Cable housing cover gasket
Cable housing cover
Bolt, flanged large Hx Hd, M8 x 1.25 x 70, C
HVIL switch assembly
HVIL switch spacer
Stator housing roller bearing
Harness assembly, RTD
Lock, secondary
64
65
66
67
68
69
70
71
72
73
74
75
76
77
78
79
80
81
82
83
84
85
86
87
88
89
90
91
92
93
94
95
96
97
98
99
100
101
102
103
104
105
106
107
108
109
110
111
112
113
114
115
116
117
118

Lock, secondary
Plug assembly
O-ring, 16.4 ID
Plug assembly
O-ring, 16.4 ID
Plug assembly
O-ring, 8.92 ID
Plug, straight thread, B
Motor speed sensor assembly
O-ring, 15.6 ID
Motor speed sensor clip
Bolt, heavy Hx flange Hd, M6 x 1 x 12, A
Motor speed sensor cover
Motor speed sensor shipping cover
Oil vent assembly
O-ring, 15.6 ID
Clip, sensor, motor speed
Plug assembly
O-ring, 16.4 ID
Nameplate
Rivet
O-ring, 15.6 ID
Plug assembly
O-ring, 8.92 ID
Plug assembly
O-ring, 8.92 ID
Fill tube seal
Oil fill hole plug
Plug assembly
Packing, O-ring, 8.92 ID
Plug assembly
O-ring, 16.4 ID
O-ring, 15.6 ID
Shipping cover
74
71
68
1
72
73
69 70
80
76
78
7
9
63
27
23
10
24
26
8
25
2
66
79
77
64
67
81
61
62
75
65
22
21
20
58
19
60
12
13
59
28
18
11
29
17
16
57
15
55
56
48
51 50 49
52
14
46
47
82
83
45
44
54 53
118
8788
30
112
111
110
85
43
107
116 117
31
42
106
115
114
113
86
84
109
108
105
103
104
102
41
100
101
99
98
33
34
95
97
32
96
40
94
37
DIVISIO
N
OF
GENER
INDIAN
AL
APOLIS
MOTOR
, INDIAN
XX
XX
XX
S CORP.
A
XX
XX
XX
X
XX
XX
TID
93
36
35
92
90
91
38
39
89
V08422.05.01
Torque
A
B
C
Nm
1013
6068
2429
lb ft
710
4450
1821
Foldout 7. Stator Housing
F OLDOUT 8
4
2
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
Bolt, heavy Hx flange Hd, M8 x 1.25 x 30, A

Suction filter retaining clip (2)
Suction filter assembly
Seal
Bolt, heavy Hx flange Hd, M8 x 1.25 x 75.0, A
Oil pan gasket
Oil pan
Oil drain plug assembly, B
O-ring
Plug Hx, hollow
Shipping plug assembly, SAE No. 16
Tube
Control main filter magnet
Control main filter
Oil filter assembly
O-ring
Filter cover
Bolt, flanged large Hx Hd, M8 x 1.25 x 70, A
Shipping plug assembly, SAE No. 16
8
9
15
Torque
A
B
Nm
2429
2433
10
12
lb ft
1821
1824
13
16
11
14
17
5
18
19
5
V08424.00.00
Foldout 8, Oil Pan and Filters
F OLDOUT 9
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
28
29
30
31
32
33
34
35
36
37
38
39
40
41
42
43
44
45
46
47
48
49
50
51
52
53
54
55
56
57
58
59
60
Bolt, M5 x 0.8 x 14, B

DPIM bypass stop
Cooler bypass spring
Ball, corrosion resistant steel
DPIM orifice plug, C
Oil transfer plate
Control main valve body separator plate
Wiring harness clip
Bolt, heavy Hx flange Hd M6 x 1.0 x 25, A
Solenoid Screen
Shift relay body assembly
Relay valve spring (550 Kpa)
Relay valve
Spring retaining clip
Relay valve spring (550 Kpa)
Relay valve
Retaining spring clip
O-ring
Pressure switch, N/O
Connector, two-way
Terminal, socket
Spiral wrap
Bolt, M5 x 0.8 x 14, B
Relay valve body
Bolt/Screw
Oil level sensor bracket
Oil level sensor assembly
OLS Viton ferrule
Shoulder bolt, M6 x 1.0 x 45, A
Internal harness
Retainer nut
O-ring
Connector assembly, 31-way receptacle
Bulkhead adapter
Cavity plug
Seal, auxiliary, 31-way
Terminal, pin
Conduit retainer
backshell
connector
terminal
Connector 2F M/P 150.2 P2
Terminal, 150.2 SER (FEM)
Connector 2F M/P 150.2 P2
Terminal, 150.2 SER (FEM)
Connector
Terminal
Connector, 3F M/P 150
Terminal, female 150 SER
Connector
Terminal
Secondary lock
Terminal, F M/P 150 SER
Secondary lock
Connector, C3PS
Terminal, male
Connector, C3PS
61
62
63
64
65
66
67
68
69
70
71
72
73
74
75
76
77
78
79
80
81
82
83
84
85
86
87
88
89
90
91
92
93
94
95
96
97
98
99
100
101
102
103
104
105
106
107
108
109
110
111
112
113
114
Terminal, Male
Secondary lock
Temperature sensor
Wiring harness clip
Wiring harness clip
C1, C2 valve assembly
C1, C2 valve body
Dowel pin, metric unhardened ground
Solenoid retaining clip
Solenoid assembly, N/O Variable Bleed
O-ring, 13.0 mm ID
Trim valve spring
Clutch control valve
Solenoid retainer
Solenoid assembly, N/C On/Off
O-ring, 10.82 mm ID
O-ring, 13.9 mm ID
Trim valve spring
Retainer, Solenoid
Solenoid assembly, N/C On/Off
O-ring, 10.82 mm ID
O-ring, 13.9 mm ID
Trim valve spring
Solenoid assembly, N/C Variable Bleed
O-ring. 13.5 mm ID
Trim valve spring
Solenoid assembly, N/C Variable Bleed
O-ring, 13.5 mm ID
Solenoid retaining bracket
Separator plate
Oil transfer plate
Control main/backfill valve assembly
Control main regulator/relief spring
Control main relief valve
Control main valve body
Exhaust backfill valve
Control main regulator valve
Exhaust backfill spring
Control main regulator/relief spring
Torque
Nm
lb ft
A
B
C
1013
58
2429
710
46
1821
5
4
3
6
15
17
16
12
7
13
14
11
10
110
21
18
24
109
21
108
107
20
18
19
104
19
20
22
106
22
23
105
114
112 111
113
103
26
25
30
27
31
32
34
28
28
35
36
102
40
29
41
37
38
39
101
46
75
74
33
47
50
42
51
44
76
45
48
79
77
73
86
81
87
92
72
93
96
99
49
78
80
88
63
82
84
90
95
43
83
66
67 58
94
100
98
70
69
65
91
97
71
64
62
85
89
68
53
52
54
56
59
60
61
57
55
V08423.04.00
Foldout 9. Control Module
F OLDOUT 10
1
2
3
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
Gasket, C1 Clutch Housing

Race, Thrust Bearing, Selective
Housing Assembly, C1 clutch
Bearing Assembly, Roller
Housing, C1 Clutch
Plug Assembly, Pressure Tap
Plug, Straight Thread, A
O-ring, 8.92 mm ID
Bolt, Heavy Hx Flange Hd, M12 x 1075 x 45 mm, B
Bearing Assembly, Thrust
Hub, C1 Clutch
Ring, Retaining, External, 74 mm ID
Plate Assembly, C1 Clutch
Plate, C1 Friction
Plate, C1 Reaction
Torque
A
B
Nm
6068
90110
7
8
6
10
11
lb ft
4450
6681
9
12
13
14
15
V10143.00.00
Foldout 10 C1 Housing
F OLDOUT 11
1
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
28
29
30
31
32
33
34
35
36
37
38
39
39
Rear cover output module

Output shaft assembly
Retaining ring, internal, 188 mm OD
C2 backing plate
C2 clutch plate assembly
C2 friction plate, 7
C2 reaction plate, 7
C2 drive hub
C2 piston seal, external
C2 return spring assembly
C2 clutch piston
C2 piston seal, internal, lip, 75 mm ID
C2 piston seal, external, 132 mm ID
Output shaft and bushing assembly
Output shaft bushing
Output shaft
Taper bearing
O-ring
Output shaft seal
Rear cover assembly
C1 piston spring assembly
Pin, C1 return spring assembly
C1 return spring assembly
C1 clutch piston
C1 piston seal, internal, lip, 222 mm ID
C1 piston seal, external, 260 mm ID
Rear cover and plug assembly
Pressure tap plug assembly
Plug, straight thread, A
O-ring, 8.92 mm ID
Tachograph plug, M18 x 1.5
Washer, tachograph plug
Speed sensor assembly
Speed sensor bracket
Bolt, metric type B hx lock, M8 x 1.25 x 20, E
Selective tachograph wheel, No. 0
39
39
39
39
39
39
39
39
39
40
41
42
43
44
45
46
47
48
49
50
51
52
53
54
55
56
57
58
59

Taper bearing assembly
Output seal
Yoke assembly
Output slinger
Output yoke, Spicer 1710
Flange assembly
Output slinger
Companion Flange 1810
Output flange washer
Output nut, lock, D
Key, output shaft
Retaining ring, external, 37.50 groove dia.
Gasket, rear cover assembly
Rear support bracket
speed sensor cover
Bolt, heavy Hx flange Hd, M12 x 1.75 x 55, C
Bolt, heavy Hx flange Hd, M10 x 1.5 x 50, B
Bolt, heavy Hx flange Hd, M10 x 1.5 x 75, B
Bolt, heavy Hx flange Hd, M12 x 1.75 x 100, C
Torque
A
B
C
D
E
Nm
1013
5161
90110
340
2429
lb ft
710
3845
6681
251
1821
2
3
4
5
6
12
13
14
15
17
19
20
10
18
22
11
21
16
24
25
23
55
54
53
26
35
36
27
28
37 38
35
55
36
37 38
39
33 34
42
40
41
43
29
44
56
32
31
30
30
59
58 57
32
45
48
31
49
50
46
47
51
52
V10144.00.00
Foldout 11. Output/Rear Cover
F OLDOUT 12
LUBE
Trans
Cooler
Cooler Return Filter
Exhaust Backfill
MAIN SUPPLY
Cooler Bypass
CONTROL MAIN
Trim Solenoid Filter

(2 Places)
C2
Trim
Solenoid
C1
Trim
Solenoid
OENL (N/O)
OENL (N/O)
Control Main Relief
C1
Blocking
Solenoid
C2
Blocking
Solenoid
CENL (N/C)
CENL (N/C)
Boost
Solenoid
DPIM
Bypass
OENH (N/C)
Sump
Control Main
Filter
BOOST SIGNAL
MAIN SUPPLY
Gear/Bearing/Clutch Lube
Motor Stator Winding Cooling
Main
Regulator
Valve
Main
Relief
DPIM
Lube
Regulator Valve
C2
Clutch
C2
Pressure
Switch
C1
Pressure
Switch
Gerotor
Pump
C1
Clutch
Sump
Suction
Filter
Mode One and Reverse

MAIN PRESSURE
CONTROL MAIN PRESSURE
EXHAUST
EXHAUST BACKFILL
BOOST
LUBRICATION/COOLER
CLUTCH APPLIED PRESSURE
Sump
Foldout 12. First and Reverse Range Hydraulic Schematic
V08400.00.02
F OLDOUT 13
LUBE
Trans
Cooler
Exhaust Backfill
MAIN SUPPLY
Cooler Bypass
CONTROL MAIN

(2 Places)
C2
Trim
Solenoid
C1
Trim
Solenoid
OENL (N/O)
OENL (N/O)
Control Main Relief
C1
Blocking
Solenoid
C2
Blocking
Solenoid
CENL (N/C)
CENL (N/C)
Boost
Solenoid
DPIM
Bypass
OENH (N/C)
Sump
Control Main
Filter
BOOST SIGNAL
MAIN SUPPLY
Main
Regulator
Valve
C2
Relay
Valve
C1
Relay
Valve
Main
Relief
DPIM
C2
Clutch
Lube
Regulator Valve
C2
Pressure
Switch
C1
Pressure
Switch
Gerotor
Pump
C1
Clutch
Sump
Suction
Filter
Mode Two
MAIN PRESSURE
EXHAUST
EXHAUST BACKFILL
BOOST
LUBRICATION/COOLER
CLUTCH APPLIED PRESSURE
Sump
Foldout 13. Second Range Hydraulic Schematic
V08401.00.02
F OLDOUT 14
LUBE
Trans
Cooler
Exhaust Backfill
MAIN SUPPLY
Cooler Bypass
CONTROL MAIN

(2 Places)
C2
Trim
Solenoid
C1
Trim
Solenoid
OENL (N/O)
OENL (N/O)
Control Main Relief
C1
Blocking
Solenoid
C2
Blocking
Solenoid
CENL (N/C)
CENL (N/C)
Boost
Solenoid
DPIM
Bypass
OENH (N/C)
Sump
Control Main
Filter
BOOST SIGNAL
MAIN SUPPLY
Main
Regulator
Valve
C2
Relay
Valve
C1
Relay
Valve
Main
Relief
DPIM
C2
Clutch
Lube
Regulator Valve
C2
Pressure
Switch
C1
Pressure
Switch
Gerotor
Pump
C1
Clutch
Sump
Suction
Filter
Neutral
MAIN PRESSURE
EXHAUST
EXHAUST BACKFILL
BOOST
LUBRICATION/COOLER
Sump
Foldout 14. Neutral Range Hydraulic Schematic
V08402.00.02
F OLDOUT 15
2-BOLT-29513724
STARTER PAD
TORQUE TO 10-13 Nm (7-10 lb-ft)
50.8
134.1
12.0
43.545
REAR FACE OF BLOCK
30.20
138 TEETH
110.00 BOLT CIRCLE
8 HOLES
EQUALLY SPACED
**BOLT AND WASHER KIT-29513139

12-WASHER-9422847
12-BOLT-11505239
DRIVE UNIT ADAPTATION KIT-29513199

GEAR ADAPTER ASSY-29512130
RING GEAR-29502093
*FLEXPLATE ADAPTER-29512131
10-BOLT-11505232
TORQUE TO 51-61 N m (38-45 lb-ft)
A1 TORQUE TO 32-39 N m (24-29 lb-ft)
A2
395.00
373.00
6-BOLT-11515393
VIEW A-A
CRANKSHAFT BOLT PATTERN
FLEXPLATE/BOLTPLATE ASSY-29512126
3-FLEXPLATE-29512127
WEARPLATE-29512128
A
**8-BOLT-CUMMINS-3931446
FOR USE WITHOUT REAR ENGINE PTO
FOR USE WITH REAR ENGINE PTO
HUB ADAPTER-29512125
144.40
ENGINE ADAPTATION KIT-29512124

WEAR PLATE-29512128
2-BOLT-29513724
69.98
CRANKSHAFT
CENTERLINE
DWG
FOR DRIVE UNIT DRIVE DATA NOT SHOWN

SEE DRAWING AS70-008
FOR DRIVE UNIT INSTALLATION DATA NOT SHOWN
SEE BASIC INSTALLATION DRAWINGS
BOLT TORQUES ARE
8% UNLESS OTHERWISE SPECIFIED
*DENOTES PARTS NOT SEPARATELY AVAILABLE

**DENOTES PARTS NOT SUPPLIED WITH DRIVE UNIT ASSEMBLY
UG
15.50
FR2
SPECIFIED DIMENSIONS HAVE PRECEDENCE
OVER COMPUTER GENERATED DATA
CHANGE RESTRICTED
METRIC
25.50
DIMENSIONS FOR REFERENCE ONLY

99.613
THIRD ANGLE
(1)WAS TORQUE TO 36 N
(2)ALTERED LEADER DESTINATION
REV
FR1
DWG. NO.
LTR
AS04-435
SH
m (27 lb-ft)
31MR04
CL RL
DATE
DWN CHK
DESCRIPTION
REVISIONS
G. HAWKINS
31MY02
B. LEAR
12JN02
APPROVED
C. REYES
DATE
12JN02
M. SMITH
PROJ. ENGR.
DATE
05JN02
APPL. ENGR.
D. NEUFER
DATE
07JN02
DRAWN
DATE
General Motors Corporation

Indianapolis, Indiana
CHECKED
DATE
ADAPTATION DRAWINGCUMMINS ISL
MODEL
THE INFORMATION CONTAINED HEREIN IS PROPRIETARY AND THE
PROPERTY OF ALLISON TRANSMISSION, GENERAL MOTORS CORPORATION
AND MAY NOT BE REPRODUCED, DISCLOSED OR USED FOR ANY
PURPOSE OTHER THAN A QUOTATION TO OR ON ORDER FROM ALLISON
TRANSMISSION WITHOUT THE SPECIFIC WRITTEN AUTHORIZATION OF
ALLISON TRANSMISSION.
NO
AS04-435
THIS DRAWING ILLUSTRATES DESIGN STATUS ONLY

AVAILABILITY OF PARTS MUST BE OBTAINED FROM
ALLISON TRANSMISSION SALES AND THE ENGINE
MANUFACTURER
EP40/50
SIZE
CAGE CODE
73342
SCALE
NONE
DWG NO
AS04-435
SHEET
---
UNIGRAPHICS
V10998.00.00
Foldout 15. Adaptation DrawingCummins ISL
F OLDOUT 16
ADAPTER-23049392
131.50
REAR FACE OF BLOCK

8 BOLTS EQUALLY SPACED EXCEPT
ONE BOLT INDICATED B OFFSET
106.50

12-WASHER-9422848
12-BOLT-9425080
40.91
32.20
DRIVE UNIT ADAPTATION KIT-29510720

RING GEAR-23049239
ADAPTER-23049392
12-BOLT-9409030
12-WASHER-9422847
10-BOLT-11505232
12-WASHER-9422847
12-BOLT-9409030
TORQUE TO 36 N m (27 lb-ft)
424.47
407.00
12-BOLT-11505232
318.34
WEARPLATE-29507746
130.00 BOLT CIRCLE
**8-BOLT-CAT P/N 9X2021

FOR USE WITHOUT REAR ENGINE PTO
**8-BOLT-CAT P/N 1465132

FOR USE WITH REAR ENGINE PTO
2-BOLT-29513725
TORQUE TO 7.5-10.0 N m (5-7 lb-ft)
166.00
VIEW A-A
92.00
ENGINE ADAPTATION KIT-29535906

WEAR PLATE-29507746
2-BOLT-29513725
DWG

MANUFACTURER
BOLT TORQUES ARE
UG
FR2
CHANGE RESTRICTED
METRIC

20.39
REV
DESCRIPTION
DATE
NO
AS04-439
CRANKSHAFT
CENTERLINE
DWN CHK
REVISIONS
S. DREW
22AU03
CHECKED
B. LEAR
DATE
22AU03
APPROVED
C. REYES
DATE
22AU03
DRAWN
DATE
PROJ. ENGR.

ADAPTATION DRAWINGCAT C9
DATE
APPL. ENGR.
THIRD ANGLE
31.00
DATE
R. GALE
22AU03
MODEL
FR1
DWG. NO.
LTR
AS04-439
SH

EP40/50
SIZE
CAGE CODE
73342
SCALE
NONE
DWG NO
AS04-439
SHEET
---
UNIGRAPHICS
V10996.00.00
Foldout 16. Adaptation DrawingCAT C9
F OLDOUT 17
2-BOLT-29513724
134.1
110.00 BOLT CIRCLE
50.6
REAR FACE OF BLOCK
31.78
30.20
8 HOLES
EQUALLY SPACED
173 TEETH

12-WASHER-9422847
12-BOLT-11505239
**DRIVE UNIT ADAPTATION KIT-29513198

*RING GEAR-29503806
10-BOLT-11505232
395.00
373.00
VIEW A-A
6-BOLT-11515393
WEARPLATE-29512128
144.40
69.98
25.50
CRANKSHAFT
CENTERLINE
AS04-434

MANUFACTURER
DWG

BOLT TORQUES ARE
15.50
UG

FR2
CHANGE RESTRICTED
99.613
METRIC
THIRD ANGLE
REV
REVISIONS
G. HAWKINS
30MY02
CHECKED
B. LEAR
DATE
12JN02
APPROVED
C. REYES
DATE
12JN02
M. SMITH
PROJ. ENGR.
DATE
07JN02
APPL. ENGR.
D. NEUFER
DATE
07JN02
DRAWN
DATE

ADAPTATION DRAWINGCUMMINS B SERIES,

ISB (6 BOLT)
MODEL
FR1
DWG. NO.
LTR
AS04-434
SH

DWN CHK
DATE
DESCRIPTION
NO
**ENGINE ADAPTATION KIT-29512124

WEAR PLATE-29512128
2-BOLT-29513724
EP40/50
SIZE
CAGE CODE
73342
SCALE
NONE
DWG NO
AS04-434
SHEET
---
UNIGRAPHICS
V10997.00.00
Foldout 17. Adaptation DrawingCummins B Series, ISB (6 Bolt)
SM3602EN_Back_ATI_200#EEB59.pdf
8/27/07
10:08:46 AM
CM
MY
Allison Transmission, Inc.

P.O. Box 894
Indianapolis, IN 46206-0894
1-800-252-5283
CY
CMY
www.allisontransmission.com
SM3602EN 200708
Printed In USA 200708

AED Drive Unit Service Manual SM 3602 200708

Enviado por

Dados do documento

Direitos autorais

Formatos disponíveis

Compartilhar este documento

Compartilhar ou incorporar documento

Opções de compartilhamento

Você considera este documento útil?

Este conteúdo é inapropriado?

Direitos autorais:

Formatos disponíveis

AED Drive Unit Service Manual SM 3602 200708

Enviado por

Direitos autorais:

Formatos disponíveis

SM3602EN_Front_ATI_20#EEB57.

leaders in advanced hybrid technology

ALLISON ELECTRIC DRIVES

SM3602EN Spine Outline.pdf

Allison Transmission, Inc.

Copyright 2007 Allison Transmission, Inc.

E P 40/50 SYSTEM SERVICE MANUAL

Copyright 2007 Allison Transmission, Inc.

IMPORTANT SAFETY NOTICE

WARNINGS, CAUTIONS, AND NOTES

Copyright 2007 Allison Transmission, Inc.

Copyright 2007 Allison Transmission, Inc.

Acronym List for Allison Electric Drive

Allison Electric Drive

Battery Pack Installation Protection Device

Control Area NetworkTwisted shielded pair of wires used to communicate J1939

DPIM Installation Protection Device

Allison Diagnostic Optimized ConnectionPC based diagnostic tool for troubleshooting

Diagnostic Trouble Code

Allison Parallel hybrid system

EV Drive for Parallel hybrid system

High Voltage Interlock LoopSafety circuit that attempts to prevent exposure to

Insulated Gate Bipolar Transistor

Original Equipment Manufacturer

Oil Level Sensor

Pushbutton Shift Selector

Transmission Control ModuleInterfaces with EV Drive

Vehicle Control ModuleInterfaces with vehicle systems

Copyright 2007 Allison Transmission, Inc.

E P 40/50 SYSTEM SERVICE MANUAL

Copyright 2007 Allison Transmission, Inc.

SECTION 2. ELECTRICAL SAFETY

SECTION 3. PREVENTIVE MAINTENANCE

Copyright 2007 Allison Transmission, Inc.

E P 40/50 SYSTEM SERVICE MANUAL

SECTION 4. GENERAL OVERHAUL INFORMATION

Copyright 2007 Allison Transmission, Inc.

Copyright 2007 Allison Transmission, Inc.

E P 40/50 SYSTEM SERVICE MANUAL

E P 40/50 SYSTEM SERVICE MANUAL

CONTROL MAIN VALVE BODY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

SECTION 7. EV DRIVE ASSEMBLY

Copyright 2007 Allison Transmission, Inc.

SECTION 8. WEAR LIMITS AND SPRING DATA

SECTION 9. CUSTOMER SERVICE

Allison Electric Drives

Copyright 2007 Allison Transmission, Inc.

E P 40/50 SYSTEM SERVICE MANUAL

Copyright 2007 Allison Transmission, Inc.

SECTION 1GENERAL INFORMATION

1. The organization or individual has the required

a. Content and Organization

or a Distributor training facility.

This Service Manual describes the maintenance

described and their functions explained.

disassembly, rebuild, and re-assembly of the

2. The work environment is suitable to prevent

Supplementary information will be issued, as required,

Copyright 2007 Allison Transmission, Inc.

E P 40/50 SYSTEM SERVICE MANUAL

Figure 11. EV DriveRight Side

OIL TO COOLER PORT

OIL FROM DPIM PORT

OIL TO DPIM PORT