• Repair Manual Allison 6000 Series
• Repair Manual Allison 6000 Transmission

This Repair Manual describes the mechanical operation, maintenance, and overhaul procedures for Allison CL(B)T 5000, 6000, M 5600, 6600, S 5600, 6600. From oil field pumping, fracturing and service rigs to crash trucks. Allison Transmission's 5000 and 6000 Series are built for vehicles requiring up to 764 kW.

Description. Covers. Allison CL(B)T 5861, 5961, 5962, 5963, 6061, 6062, and 6063 Series. Allison M 5600(A)(R), S 5600(H)(M)(R) Series. Allison M 6600(A)(R), S 6600(H)(M)(R) Series. 326 pages. Instant PDF Download.

Searchable, printable. Compatible with Windows/Mac/Tablet This Repair Manual describes the mechanical operation, maintenance, and overhaul procedures for Allison CL(B)T 5000, 6000, M 5600, 6600, S 5600, 6600 transmissions. It includes detailed OEM specifications, illustrations and step-by-step procedures to aid the mechanic with correctly servicing, overhauling and troubleshooting the Allison 5000, 6000 series transmissions listed to the manufacturer’s standards. The manual is available in a convenient downloadable PDF file.

Allison 5000, 6000 Series Transmission Repair Manual Contents: GENERAL INFORMATION 1- 1. Lllustrations c. Maintenance Information 1-2. SUPPLEMENTARY INFORMATION 1-3. ORDERING PARTS 1-4. DESIGN FEATURES a. Transmission-to-Engine Coupling b.

Torque Converter c. Planetary Gearing d. Hydraulic System f. Power Takeoff g. Lockup Clutch 1-5. SHIFT CONTROL SYSTEMS a.

Manual-Electric Shift b. Automatic-Electric Shift c.

Electronic-Control Shift (CEC 1) d. Electronic-Control Shift (CEC 2) e. Manual-Hydraulic Shift 1–6. Hydraulic Retarder. Parking Brake c.

Transfer Gears (Dropbox) d. Output Disconnects e. Speedometer Drive 1-7. OPERATING INSTRUCTIONS a.

Operator’s Manual b. Manual Mode (CEC 1) c. Manual Mode (CEC 2) d. Cold Weather Starts (CEC I) e.

Cold Weather Starts (CEC 2) f. SPECIFICATIONS AND DATA Section 2.

DESCRIPTION AND OPERATION 2-1. Two Configurations b.

Control Systems 2-2. MOUNTING, INPUT DRIVES a.

Remote Mounting b. DirectMounting 2-3.

LOCKUP CLUTCH 2-4. TORQUE CONVERTER – FIXED CAPACITY 2-5. TORQUE CONVERTER -VARIABLE CAPACITY 2-6.

HYDRAULIC RETARDER 2-7. POWER TAKEOFF (PTO)DRIVES 2-8.

SPLITTER CLUTCHES, GEARING 2-9. HIGH-RANGE CLUTCH (FIFTH AND SIXTH RANGE) 2-10.

INTERMEDIATE-RANGE CLUTCH, PLANETARY (THIRD AND FOURTH RANGE) 2-11. LOW-RANGE CLUTCH, PLANETARY (FIRST AND SECOND RANGE) 2-12.

REVERSE CLUTCH, PLANETARY 2-13. SPEEDOMETER DRIVE 2-14. PARKING BRAKE 2-15.P,STR 2-16. INPUT PRESSURE AND SCAVENGE PUMP 2-17. HOUSING, COVERS a. Front Cover (Remote Mount Models) b.

Repair Manual Allison 6000 Series

Torque Converter Housing c. Main Housing 2-18. HYDRAULIC SYSTEM a. System Functions. System Schematics c. Filter, Main-Pressure Regulator Valve d. Lockup Clutch Shift Valve e.

Flow (Lockup Cutoff) Valve (Models With Non-Electric Lockup) f. Check Valve (Models With Non-Electric Lockup) g. Hydraulic Retarder Valve (Models With Retarder) h. Converter Pressure Relief Valve (All Models) 1. Converter Pressure Regulator Valve (Models With Retarder) j. Lubrication Pressure Regulator Valve (Models Without Retarder) k.

Converter-In Check Valve (Models With Retarder) 2-11 2-19. MANUAL-HYDRAULIC CONTROL SYSTEM a. Manual Selector Valve b. Neutral Trimmer Valve c. Intermediate-Range Trimmer Valve 2-20. MANUAL-HYDRAULIC CONTROL SYSTEM CIRCUITS a.

First Range c. Second Range d. Third Range e.

Fourth Range f. Fifth Range g. Sixth Range h.

Reverse 2-21. MANUAL-ELECTRIC CONTROL HYDRAULIC SYSTEM a.

Reverse Shift Valve b. Low-Range Shift Valve c. Intermediate-Range Shift Valve d. High-Range Shift Valve e. Solenoid Pressure Regulator Valve f. Priority Valve g.

Splitter Shift Valve h. Protection in the Event of Electrical Interruption i. Trimmer System j. Reverse Trimmer k. Low-Range Trimmer I. Intermediate-Range Trimmer m.

Splitter-Low Trimmer. Exhaust Regulator Valve o. Shift Selector Assembly q.

Wiring Harness 2-22. MANUAL-ELECTRIC CONTROL HYDRAULIC SYSTEM CIRCUITS a. Protection in the Event of Electrical Interruption While Operating in Neutral c. Protection in the Event of Electrical Interruption While Operating in Forward Ranges d. First-Range Operation e. Second-Range Operation f.

Third-Range Operation g. Fourth-Range Operation h. Fifth-Range Operation i. Sixth-Range Operation j.

Reverse Operation k. Protection in the Event of Electrical Interruption While Operating in Reverse 1.

Protection in the Event of Electrical Interruption While Operating Dual-Electric Equipment. SPG-CONTROL AUTOMATIC-ELECTRIC HYDRAULIC SYSTEM AND CIRCUITS c. Lock-In-Range Downshift Protection d. Lock-In-Range Reset Procedure e. Operation After Lock-In-Range Reset f. Electrical Connections g. Negative-Ground System h.

Positive-Ground System 1. Fusing and Overload Protection 2-24. CEC 1 ELECTRONIC CONTROL HYDRAULIC SYSTEM AND CIRCUITS (Models Without Trim Boost) a. Electronic Control Unit (ECU) b. Shift Selector c. CHECK TRANS Light d. Throttle Sensor e.

Output Speed Sensor f. Wiring Harnesses g. Lockup (Models With Electric Lockup) h. Operation of the Electronic Control System 2-25.

CEC 1 ELECTRONIC CONTROL HYDRAULIC SYSTEM AND CIRCUITS (Models With Trim Boost) a. Trimmer System b. Reverse Trimmer c. Low-Range Trimmer d.

Intermediate-Range Trimmer e. Splitter-High Trimmer f. Splitter-Low Trimmer g. Trim Boost Valve 2-26. CEC 2 ELECTRONIC CONTROL HYDRAULIC SYSTEM AND CIRCUITS (Models With Trim Boost) a. Electronic Control Unit (ECU) b. Shift Selector c.

CHECK TRANS Light d. Throttle Position Sensor e. Speed Sensors f. External Wiring Harnesses 2-27. TORQUE PATHS THROUGH THE TRANSMISSION a.

Torque Converter Operation 2-39 b. Lockup Operation. Neutral Torque Path. First-Range Torque Path 2-41 e.

Second-Range Torque Path. Third-Range Torque Path. Fourth-Range Torque Path. Fifth-Range Torque Path 2-45 1.

Sixth-Range Torque Path 2-46 J. Reverse or Reverse-I Torque Path. Reverse-2 Torque Path. 2-48 Sectioll3. PREVENTIVE MAINTENANCE 3-1.

SCOPE 3-1 3-2. GENERAL INSPECTION AND CARE. IMPORTANCE OF PROPER TRANSMISSION FLUID LEVEL a.

Effects of Improper Fluid Level. Foaming and Aeration. TRANSMISSION FLUID LEVEL CHECK PROCEDURE a. Cold Check. KEEPING TRANSMISSION FLUID CLEAN. TRANSMISSION FLUID RECOMMENDATIONS a. Recommended Automatic Transmission Fluid.

Recommended Viscosity Grade. TRANSMISSION FLUID CHANGE AND FILTER CHANGE INTERVALS. Transmission Fluid Change Interval. Filter Element Change Intervals and Service. FLUID CONTAMINATION a.

Examination at Fluid Change. Metal Particles. Coolant Leakage. Cooler Circuit Filter. TRANSMISSION FLUID AND FILTER CHANGE PROCEDURES. CHECKING FLUID TEMPERATURE, PRESSURES Page a.

Fluid Temperature Gauge 3-9 b. Checking, Adjusting Main Pressure 3-10 c. Checking Lubrication Pressure. Adjusting Lubrication Pressure (Models Without Retarder). Checking Converter-out Pressure.

Checking Fluid Velocity Governor (Pitot) Pressure (Models With Non- Electric Lockup) 3-11 g. Checking Stator Control Pressure (Models With Variable-Capacity Torque Converter).

Checking Range and Splitter Clutch Pressures. Manual Selector Valve Linkage (Manual-Hydraulic Models) 3-12 b. Retarder Valve Linkage. Output Disconnect Linkage. EXTERNAL HYDRAULIC LINES AND COOLER a. External Lines.

ADJUSTING LOCKUP SPEED (Models With Non-Electric Lockup) a. Lockup Speed (in the Equipment). Lockup Speed and Shift Points (Using a Test Stand). Lockup Speed Adjustment. ADJUSTING PARKING BRAKE a. Burnishing New Brakes.

TRANSMISSION STALL TEST AND NEUTRAL COOL-DOWN CHECK a. Stall Test Preparation.

Stall Test Procedures – Equipment Without Smoke-Controlled Engines. Stall Test Procedures – Equipment With Smoke-Controlled Engines. Neutral Cool-Down Check Procedure. 3-16 Paragraph Page 3-17. PRESERVATION AND STORAGE a. Storage, New Transmissions (Prior to Installation).

Preservation Methods. Storage, One Year- Without Transmission Fluid. Storage, One Year- With Transmission Fluid (Normally Installed in the Equipment). Restoring Transmission to Service.

LUBRICATION OF SHIFT SELECTORSPG- CONTROL AUTOMATIC-ELECTRIC MODELS a. Lubrication Intervals 3-17 b. Clean Before Lubricating.

Lubrication Points. TROUBLESHOOTING THE CONTROL SYSTEM.

CHECKING, ADJUSTING MANUALELECTRIC CONTROL SYSTEM a. Field Test Kit. Checking Wiring Harness. Checking Main Control Valve Body. Checking Hydraulic Circuits 3-19 3-21. CHECKING, ADJUSTING SPG-CONTROL AUTOMATIC-ELECTRIC SYSTEM a. Field Test Kit.

Checking Wiring Harnesses 3-20 c. Checking Throttle Potentiometer. Checking Magnetic Pickup (Speed Sensor). Checking Shift Pattern Generator (SPG). Checking 24V Overload Protector.

Checking 12V-to-24V Converter. Checking Control Valve Assembly. Checking Hydraulic Circuit. TESTING SHIFT SELECTOR ASSEMBLY a. Manual-Electric Test Equipment. Shop-Constructed Test Lamp Bank 3-23 c. Testing Manual-Electric Shift Selector 3-24 d.

Testing SPG-Control Automatic- Electric Shift Selector. TROUBLESHOOTING THE TRANSMISSION a. Before Removal or Operation. During Operation 3-28 c.

After Removal From Equipment 3-28 d. Troubleshooting Table. Electronic Controls Troubleshooting 3-28 Section 4. GENERAL OVERHAUL INFORMATION 4-l. SCOPE.- 4-1 4-2. PROCEDURESSUBffiCT TO CHANGE 4-1.

WELDING PROCEDURES FOR ELECTRONIC CONTROL EQUIPMENT 4-1 4-4. REMOVAL, INSTALLATION OF TRANSMISSION 4-1 4-5. REMOVAL OF WIRING HARNESSES (Manual-Electric and SPG-Control Models) a. Manual-Electric Shift Model.

SPG-Control Automatic-Electric Shift Model. REMOVAL OF REMOTE COMPONENTS (Manual-Electric and SPG-Control Models) a.

Shift Selector Assembly. Shift Pattern Generator (SPG), 12V-to-24V Converter, 24V Overload Protector, Throttle Potentiometer. INSTALLATION OF EXTERIOR COMPONENTS (Manual-Electric and SPG-Control Models). TOOLS,EQUIPMENT a. Special Tools. Improvised Tools and Equipment 4-6 c. Mechanic’s Tools, Shop Equipment 4-6 4-9.

REPLACEMENTPARTS a. Ordering Infonnation. Parts Nonnally Replaced. Parts Replacement 4-7 4-10. CAREFUL HANDLING. 4-8 Paragraph Page 4-11. CLEANING, INSPECTION a.

Dirt-Free Assembly. Cleaning Parts 4-9 c. Cleaning Bearings. Inspecting Bearings. Keeping Bearings Clean 4-10 f. Inspecting Cast Parts, Machined Surfaces. Inspecting Bushings, Thrust Washers.

Inspecting Seals, Gaskets 4-11 1. Inspecting Seal Contact Surfaces 4-11 j.

Inspecting Gears. Inspecting Splined Parts. Inspecting Threaded Parts.

Inspecting Retaining Rings. Inspecting Springs.

Inspecting Clutch Plates. Inspecting Swaged, Interference- Fit Parts. Inspecting Balls in Clutch Pistons.

Inspecting Pump Gears. ASSEMBLY PROCEDURES a. Clutches, Pistons 4-12 b. Parts Lubrication. External Plugs, Hydraulic Fittings.

Oil-Soluble Grease. Sealing Compounds. Lip-Type Seals (Metal-Encased) 4-14 g. Interference-Fit Parts. Sleeve-Type Bearings.

Bearings (Ball or Roller) 4-15 4-13. REMOVING (OR INSTALLING) TRANSMISSION a. Drain Transmission Fluid. Check Linkages and Lines.

Remove, Clean Transmission. Install Transmission. WEAR LIMITS. SPRING SPECIFICATIONS.

TIGHT-FIT FLANGES a. Removal of Flanges. Installation of Flanges. TEFLON® LIP-TYPE SEALRINGS a. DETERMINING PrO BACKLASH LIMITS a. Determining Backlash Between Drive and Driven Gear (Quantity A).

Determining Backlash Between Drive and Driven Gear (Quantity B). Determining the Total Backlash in the Gear Train (Quantity C). TORQUE SPECIFICATIONS. 4-19 Sectiorl5. DISASSEMBLY OF TRANSMISSION 5-1. GENERAL INFORMATION FOR DISASSEMBLY OF TRANSMISSION a.

Preparation for Disassembly. Removal of Control Components 5-l c.

Repair Manual Allison 6000 Transmission

Disassembly Information. Lifting, Handling. TRANSMISSION DISASSEMBLY a. Removal of Exterior Components 5-1 b. Removal of Torque Converter and Related Components. Removing Torque Converter Elements.

Removal of Torque Converter Housing, Retarder Housing, and Related Components. Removal of Pump, PTO, and Idler Gears. Separating Converter Housing and Retarder Housing, and Removing Related Parts. Disassembly of Retarder Housing, Turbine Shaft, and Related Parts (Models With Retarder). Disassembly of Converter Housing, Turbine Shaft, and Related Parts (Models Without Retarder). Removal of Transmission Output Components. Removal of Range Planetaries, Clutches, and Related Parts From Output End of Transmission Main Housing.

Removal of Splitter Clutch and Related Parts. 5-26 Paragraph Page Section 6. 2015 cavalier service manual download. REBUILD OF SUBASSEMBLIES 6–l.

GENERALORMATIONFOR REBUUD OF SUBASSEMBLIES. MANUAL-ELECTRIC CONTROL SHIFT SELECTOR a. SHIFT PATTERN GENERATOR (SPG), 24V OVERLOAD PROTECTOR, l2V-to-24V CONVERTER. SPG-CONTROL SIDFT SELECTOR a.

SPG-CONTROL THROTTLE POTENTIOMETER a. Assembly 6-11 6–7. CEC I SHIFT SELECTOR – LEVER a. Assembly 6-13 6–8. CEC 1 SHIFT SELECTOR – PUSHBUTTON a. Assembly 6-17 6–9.

ELECTRONIC CONTROL UNIT (ECU) CEC I PROM REPLACEMENT a. Removal of PROM.

Installation of PROM. CEC 2 SHIFT SELECTOR- LEVER a. Assembly 6-19 6–11. CEC 2 SHIFT SELECTOR -PUSHBUTTON a. PARKING BRAKE ASSEMBLY a. FILTER ASSEMBLIES a. Disassembly – Earlier Filters.

Assembly- Earlier Filters. Disassembly – High-Efficiency Filters.

Assembly – High-Efficiency Filters. Disassembly – Allison Remote Filter.

Assembly – Allison Remote Filter 6-23 6-14. STATOR CONTROL VALVE BODY (Models With Variable-Capacity Torque Converter) a. Assembly 6-24 6-15. MAIN-PRESSURE REGULATOR VALVE BODY ASSEMBLY a. Assembly 6-24 6-16. NON-ELECTRIC LOCKUP VALVE BODY ASSEMBLY a. Disassembly 6-24 a.

ELECTRIC-CONTROL LOCKUP VALVE BODY ASSEMBLY a. Assembly 6-26 6-18. MAIN-PRESSURE TRANSFER TUBE ASSEMBLY a. Assembly 6-26 6-19. MANUAL-HYDRAULIC CONTROL VALVE BODY ASSEMBLY a. Assembly 6-27 6-20. ELECTRIC/ELECTRONIC-CONTROL VALVE BODY ASSEMBLY (Models Without Trim Boost) a.

ELECTRONIC-CONTROL VALVE BODY ASSEMBLY (Models With Trim Boost) a. STRAINER ASSEMBLY a. Assembly 6-38 6-23. HYDRAULIC RETARDER CONTROL VALVE BODY ASSEMBLY a. 6-38 Paragraph Page 6-24. LOCKUP-CLUTCH PISTON REWORK a. Inspection 6-39 b.

Repair 6-39 6-25. CONVERTERDRIVEHOUSINGASSEMBLY (Remote-Mount Models) a. Disassembly 6-39 b. Inspection and Repair. Assembly 6-40 6-26. FLYWHEEL ASSEMBLY (Direct-Mount Models) a. Inspection and Repair.

Assembly 6-41 6-27. STATOR ASSEMBLY – FIXED-CAPACITY TORQUE CONVERTER a.

Assembly 6-41 6-28. STATOR ASSEMBLY- VARIABLECAPACITY TORQUE CONVERTER a. Assembly 6-42 6-29. TORQUE CONVERTER PUMP ASSEMBLY a. Assembly 6-44 6-30. INPUT PRESSURE, SCAVENGE PUMP ASSEMBLY a. TORQUE CONVERTER HOUSING ASSEMBLY a.

Disassembly 6-45 b. Assembly 6-46 6-32. SPLITTER SUN GEAR ASSEMBLY a. Assembly 6-47 6-33. SPLITTER PLANETARY CARRIER ASSEMBLY a.

SPLITTER-LOW CLUTCH AND DRUM ASSEMBLY (CL(B)T, M 5600, and S 5600 Models) a. Assembly 6-5 6-35. SPLITIER-LOW CLUTCH AND DRUM ASSEMBLY (M 6600, S 6600 Series Models) a. Disassembly 6-51 b.

Assembly 6-52 6-36. HYDRAULIC RETARDER HOUSING ASSEMBLY a. Disassembly 6-52 b. Assembly 6-52 6-37. OUTPUT DRIVE HOUSING ASSEMBLY a. Disassembly 6-52 b. OUTPUT DRIVE HOUSING a.

Disassembly 6-53 b. BEARING RETAINER ASSEMBLY a.

OUTPUT DISCONNECT ASSEMBLY a. Disassembly 6-54 b. Assembly 6-55 6-41.

OUTPUTDRIVEGEARASSEMBLY a. Assembly 6-57 6-42. OUTPUT IDLER GEAR ASSEMBLY a. TRANSFER GEAR HOUSING (DROPBOX) ASSEMBLY a. 6-58 6-44.REVERSEPLANETARY CARRIER ASSEMBLY a.

LOW-RANGE PLANETARY CARRIER ASSEMBLY a. SPLITTER OUTPUT SHAFf AND COLLECTOR RING ASSEMBLY a. Disassembly 6-62 b.

Inspection and Repair. 6-63 Paragraph 6-47. INTERMEDIATE-RANGE PLANETARY CARRIER ASSEMBLY Page a. Assembly 6-63 6-48. HIGH-RANGE CLUTCH AND DRUM ASSEMBLY a. Assembly 6-65 6-49. TRANSMISSION MAIN HOUSING ASSEMBLY a.

Assembly 6-66 Section 7. ASSEMBLY OF TRANSMISSION 7- 1. GENERAL INFORMATION FOR FINAL ASSEMBLY. TRANSMISSION ASSEMBLY (All Models) a. Installing Splitter Ring Gear, Intermediate-Range Carrier Assembly, High-Range Clutch, and Intermediate- Range Clutch.

Installing Low-Range Ring Gear, Low-Range Clutch, and Reverse Clutch Anchor 7-5 c. Installing Low-Range and Reverse Planetaries and Reverse Clutch. Installing Output Drive Housing Components (Straight-Through Models) e. Installing Transfer Gear Housing Assembly and Rear Cover (Dropbox Models) f. Installing Splitter Output Shaft Retaining Ring, Splitter-High Clutch g.

Installing Splitter Planetary, SplitterLow Clutch, and Hydraulic Retarder (Models With Retarder) h. Installing Converter Housing Components i. Installing Torque Converter Housing (Models With Retarder). Installing Splitter Planetary, SplitterLow Clutch, and Converter Housing (Models Without Retarder).

Installing Torque Converter Pump, Stators. Installing Torque Converter Turbine, Lockup Clutch, and Input Components. Installing Exterior Components (All Models). Power Takeoff Gear Backlash. INSTALLATION OF CONTROL COMPONENTS. 7-37 Section 8.

WEAR LIMITS AND SPRING DATA 8-1. WEAR LIMITS DATA a. Maximum Variations.

Cleaning, Inspection. SPRING DATA.

. Introduction. 00 General Information. 01 Engine.

09 Air Intake. 13 Air Compressor. 15 Alternators and Starters. 20 Engine Cooling/Radiator. 26 Transmission. 30 Throttle Control.

32 Suspension. 33 Front Axle. 35 Rear Axle. 40 Wheels and Tires.

41 Driveline. 42 Brakes. 46 Steering. 47 Fuel. 49 Exhaust. 54 Electrical, Instruments, and Controls. 83 Heater and Air Conditioner.