Allison 1000/2000 series transmission technical tips
The Allison world series transmissions models 1000,2100,2200,2400,2500 models and variants are found in large variety of truck chassis and busses. Also found in 2001 and up Chevrolet/GMC pickup trucks 2500-3500 chassis. models come wide or close ratio gear sets, with or without PTO provisions, to properly id these units you need the serial number off of the Manf. tag on the right side of the unit, some earlier tags show what model the unit actually is, part numbers etc. give serial number to any Allison dealer and unit can be identified. beware of wrong tags on cases as this can be a common problem. you may be able to identify unit thru OEM chassis Manf./VIN #. (Best bet is to ID unit with both Allison serial number and thru VIN etc. Match the information from both!)
Allison 1K/2K Transmission Tech Tips
Allison 2000 Transmission Wiring Diagram
The best quality and selection on the transmission parts and rebuild kits you need to repair your Allison 1000, 2000, 2400 or upgrade it to the next level. GTP carries OE, aftermarket and HD performance Allison 1000/2000/2400 transmission parts. (USED) AT Allison 2000 RETRAN Transmission assembly. Serial # P/N 29540214 Truck: 2002 MACK MV222 Engine: RENAULT DCI 6 AE G990 To find out more about this.
ALLISON 1000 & 2000 SERIES TRANSMISSION Designed for light commercial vehicles in both on-highway and public transport applications, Allison Transmission’s 1000 and 2000 Series are rated up to a maximum of 224 kW (300 hp) and have up to six speeds available, including two overdrives. Both close and wide ratio gearing are offered. ALLISON 2000 SERIES Transmissions For Sale on RockandDirt.com. Thousands of attachments listings on RockandDirt.com Find New or Used ALLISON 2000 SERIES on RockandDirt.com.
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Complaint: banging, or erratic shift feel on one or all shifts, may correct temporarily if adapts reset but comes back, no codes present.
can be a damaged tone wheel on output (spacer on output can break causing this) damaged wheel or PTO gear on drum, damaged converter 'bumps' and or erratic speed sensors/wiring from trans to TCM for one or more of speed sensors faulty. these are all very common issues with these units. can be seen using Allison DOC software, otherwise its trail and error! the slightest nick or dent in rear tone wheel, dented or out of round drum ring (non PTO) or damaged 'bump' on converter where input sensor reads from can drive you crazy. wiring is common issue too, corroded wires, loose sensor connectors and so-on.
Codes P0871 or P0872 shift valve E stuck on or off.
Cause: Debris has stuck shift valve E in valve body. internal damage such as bearing etc can cause this. if happens on replacement unit right away may be debris from your cooler got in new unit. spring in VB is weak, company called Sonnax makes replacement spring that works wonders, part#37000-02And Allison has now come out with heavier updated spring, Part # 29545966. If you take valve body apart you may or may not actually find valve stuck, very sensitive, timing of stroke can create codes, this is extremely common issue. If pan is loaded with debris your wasting time trying to fix with spring/cleaning
Complaint: Allison transmission Erratic shifting in and out of lock up clutch at any speed. May have ABS light on. No transmission codes.
Cause: Trucks equipped with ABS systems tie the lock up clutch operation into the ABS and you can have faulty wheel speed signals which can shut off lock up back and forth as ABS see missingor erratic wheel speed as wheel lock. Check Ford trucks and International for rotted tone wheel which is part of brake rotors. Can be confirmed by watching ABS wire signal in transmission data.
Complaint: Truck will not back up, may or may not move forward, have upshift problems. May or may not have trouble codes.
Cause: can be NSBU switch on shift lever. if has code for this change out switch, no codes: its guess unless you can see data on DOC or equivalent. can also be other code issues and or mechanical problems inside. good test to try is with engine OFF, disconnect transmission harness at right rear, and start engine. should go into reverse and in forward would be in 3rd gear all the time. if you get back reverse you know internals of unit are ok. diagnose electrical/control problems.
Can be simple problem here: transmission is low on fluid. check and add as neccasary, and find source of your leak as well. Alot of 2006 and up trucks are having cooler line fittingleak problems, usually right at bell housing fittings.
Complaint: ATF venting out of trans vent, GM trucks, others.
problem found in 2001 thru 2003 GM pick up trucks with 1000 series transmission, When let sit overnight or extended idling before driving, worse in colder weather. Lube oil is notdraining back into sump quickly enough causing pressure build up and venting. GM has updated dipstick Part #15115171 which has vent slot added in it to vent more pressure out of unit. This can happen in any Allison transmission, you can also drill small hole in top of fill tube by stick handle end, .062 hole will alleviate chronic venting.
Complaint: Broken P-2 planetary and or broken C-2 clutch hub in spline area.
This is due to driveline angle and or torsional vibration due to out of balance drive shafts and driveline problems. On rare occasions this can also be due to engine miss fires due to injector problems, may or may not be noticeable or have trouble codes.if this is found in a transmission being repaired youmust find the cause or it will be back again.CLICK HERE for pictures.
Complaint: MLPS switch plugs wont come out, possible broken switch or connector upon removal (up to 2004 model years).
Cause: Heat has melted the sealant between the plug and switch, you can usually safely remove the plugs if stuck by warming them up with Bic lighter or similar low heat source.pry gently with small screwdriver etc. if you crack the switch or plug ends you will need to replace them, the switch number is: 24229422 or 12450016 Allison part # 29540479 (all are same switch) and fits 4L60E, 4l80E and Allison 1k/2k units up thru 2004,the repair ends for the harnesses are available: large connector part number:15305887 and small connector part number:15305925 from any GM dealer.
Complaint: Truck will not upshift out of first gear, may or may not have codes.
Cause: can be output speed sensor is no good, TCM doesn't know truck is moving. if Ckt is good may not have any codes. this can also happen with input sensor and TCM will simply not know engine is running. however should set code if moving eventually.
Cause: One big problem here is the bolt pads on the torque converter crack and cause leaks, this can happen with reman converter and we strongly reccomend you only installReman torque converters with an upgraded billet front cover to avoid this comeback after rebuild or replacement of the torque converter. A small leak in GM pick up 1000 modelscan be you need to install bronze washers on the bottom bolts inside the housing to prevent weepage. and lastly on rare occasions you can have a cracked main pump housing right in the suction or pressure cavity. Obviously you can have spun pump bushing causing a leak etc. rarely is a front area leak just the front seal alone.
Harsh downshifts, Gm 4x4 pick up only with NP 263HD transfer case.
Cause: The rear transfer case output shaft bushing is completely wiped out, this can cause the output speed sensor which is located in tail housing of transfer case insteadof rear of transmission to grind into the speed reluctor wheel and causing harsh downshifts. May also have trouble codes P0776, P0746 in memory. Alot of times were seeing that the bushing is completly gone and the drive shaft yoke is grinding into the tail housing itself.
Codes P0746 sol.A stuck off, P0747 sol.A stuck on, P0776 sol.B stuck off,P0777 sol.B stuck on. alone or together and may be with other codes.
(if other codes diagnose those first.)Cause: You may automatically think this means solenoid A or B are bad? not usually the case at all. these codes mean a shift that was using these solenoids to happen did not occur when commanded, or did not occur on time etc. this usually means internal damage such as clutches, broken hub, gearset, stuck valves in valve body and so-on. usually replacing one or both of the solenoids is a waste of time and money. on rare cases it can be the solenoid! these two solenoids are very busy guys if you look at flow charts in manuals on all shifts.
Second issue can be erratic speed sensor signals which you will likely only find by graphing the sensor signals. This can cause TCM to set solenoid codes as sees what it thinks is a slip condition or similar.
Allison transmissions are best identified with serial number and part number on tag which is located on right rear passengers side of transmission. There's a TON of wrong units in trucks, wrong tags and so on out there. (You may also encounter an Allison tag that's stamped wrong as well! It can be a real joyous occasion here!) The last guys got the laugh! Beware if changing one unit from truck to truck and so on. you can create all kinds of issues that can be very difficult to diagnose. See sample Allison tag below:
Recommended fluid for Allison 1000 and 2000 series transmissions
Allison Transmissions currently only recommends the use of TES 295/468 fluids in all transmissions. this is synthetic based fluid and available under the followingbrand names/suppliers: Castrol: Transysnd, BP Lubricants: Autran Syn 295, Cognis Corp: Em Gard 2805, International Truck: Fleetrite Synth.ATF.John Deere: HD Syn tran, Mobil: Mobil Delvac Synth. ATF, and Volvo N.A.: Bulldog Synth. ATF. They no longer recommend the use of Dexron fluids in any transmissions.However if you have pre 2006 Transmissions the recommended fluid before then was dexron 3 and equivalents
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Allison 2000 Transmission Filter
| Author | Topic | RTP717
New Member
USA
9 Posts | | Posted - 03/02/2005 : 6:51:31 PM | | Greetings to all. I work at a fleet of around 450 buses and we have about 150 buses with the Allison 2000 series transmission. We are starting to have numerous problems with these transmissions not going in reverse and defaulting and also some will not upshift. After checking many of them for codes we have changed a few solenoids that were showing failures or problems. These transmissions came with the transynd fluid which is suppose to be good for 100,000 miles. We have changed the spin on filters as recommended from Allison. We are still having the same problems with some of the same buses. After talking with Allison the have told us to remove the valve bodys and clean thoroughly amd then change internal and external filters. A lot if these are out of warranty so they are ours. Has anyone else had any of these same problems with this series transmission? Please give me any feedback you might have regarding this problem. |
| rswboe
Top Member
USA
675 Posts | | Posted - 03/03/2005 : 11:38:22 AM | | We had some interface problems a while back, corrosion in the main interface plug on the side of the trans. Apparently the body manufacturer left the transmissions w/ plg uncovered exposed to the elements before installing them in the bus. There was also a recall on the nss switch, check the color of the switch, I believe it should be light brown. Also check the nss harness plug, see if it shows signs of overheating, or melting. | | Live each like it's going to be your last, one day you'll be right! |
| wagonmaster
Top Member
USA
2298 Posts | | Posted - 03/05/2005 : 8:39:28 PM | With the mileage claims from Allison is also a time limit or hour limit. I'm implying that you've done anything wrong, but check your hours/time vs. the mileage and see if you've changed the fluid in a timely manner. We have been using C4 in our Allison transmissions (545's and MD3060's mostley with a couple of 2000's)and we have had the usual solenoid issues, but nothing in huge groups in our fleet of over 1000 units (including some medium duty trucks). We have just begun to recieve our first Allisons with the factory fill of Transyn and am now unhappy because Allison won't certify any other fluid to meet their spec even though several, including Chevron do meet it.You are held hostage by them, unfairly, in my opinion. I'm not looking forward to the time when we HAVE to buy their fluid at change time, but we MUST to keep the extended warranty. The others are fine for the standard warranty, but Transyn must be used for the extended version.
If anyone ever comes up with a decent replacement for their transmissions, sign me up! We'll gladly do some testing or R & D for them!
Joe | Joe
Land of the Free, because of the Brave! |
| raytobe
Advanced Member
USA
293 Posts | | Posted - 03/05/2005 : 10:51:31 PM | | Listen to this-- we mix the synth with dextron-- as per shop foreman. Can't wait until they start failing, Now THAT'S going to be fun. |
| transrand
Active Member
USA
27 Posts | | Posted - 03/08/2005 : 4:37:54 PM | | I would first check to see if it has the neww nsbu switch. It slides on to the selector shaft on the left hand side. It shold be brown in color with a black deflector shield over the selector shaft. Also ther is a field action on these transmissions. You might want to call your local Allison dealer to get the serial number breaks to see if any of your transmissions fall into this. |
| Joe Hartnett
Advanced Member
USA
359 Posts | | Posted - 03/10/2005 : 8:16:37 PM | | My Allison people have told me that it is safe to mix the different fluids. Allison has a field action letter for the convertors on these transmissions. The last I checked a couple of weeks back,the convertors were in short supply and my local dealer couldnt do the job. I have been having the transmissions overhauled at the same time, since Allison is paying the cost to swing the units. |
| synman
Active Member
USA
37 Posts | | Posted - 03/11/2005 : 10:29:09 AM | | suggest you check federal warrenty law(MAGNUSON-MOSS ACT)which states a manufacture cannot require the use of a specific brand of lubricant or any other part, unless it is provided by the manufacture free of charge under the terms of the warranty.To void a warrenty a lubricant must be directly responsible for the failure. If the oil did not cause the problem the warranty cannot be voided,regardless of brand or length of time in use. Oil analysis is acceptable as proof of oil's serviceability.( in lieu of regular oil changes,for instance. P.S. amsoil makes a 100% synthetic fluid engineered specifically for allison TES-295 transmissions. It is called TORQUE-DRIVE SYN. AUTO. TRANS. FLUID. It might be a good idea for school bus magazine to publish the MAGNUSON-MOSS ACT of the Federal Warranty law for its readers.It might help allison 2000 owners | | Edited by - synman on 03/14/2005 07:10:59 AM |
| DTC951
Senior Member
USA
161 Posts | | Posted - 03/11/2005 : 2:47:16 PM | Wow, we only have 7 buses with this tranny, they all seem to operate properly. However as time goes by the fleet will become A2000's. How much extra is the MD3060 and what extra features does it come with? It seems that the tranny makes a big difference in the performance of the bus. We have 2 1993 DT360 IHC's with the MT643 bought used, what a difference between our normal 1993's, DT360 AT545.
-Barry | | Edited by - DTC951 on 03/11/2005 2:53:00 PM |
| Joe Hartnett
Advanced Member
USA
359 Posts | | Posted - 03/15/2005 : 4:34:01 PM | | The law that synman is talking about has been discussed before in the froums. I belive most filter cataloges have it printed in them. |
| DTC951
Senior Member
USA
161 Posts | | Posted - 03/18/2005 : 07:18:31 AM | Hi Everyone,
Does anyone know if puting the bus in gear when the RPM control is on, its at a higher RPM is bad for the bus? Shouldn't the computer kick the RPM's down automaticly? I did this the other day on a 2002 Thom, Freight, 3126E, A2000 and the bus didn't have power in OD, it was like it was still in N. The regular driver then after reported shifting problems, and the bus is at the dealer getting fixed. Maybe a new tranny... The driver said the 'range' light came on.
-Barry
|
| kd4jfd
Top Member
USA
1168 Posts | | Posted - 03/18/2005 : 4:09:59 PM | Barry,
If the RPM control was still on, and not turned off, it will give you the 'range inhibited' light. | | 539 -Repair work in progress! |
| DTC951
Senior Member
USA
161 Posts | | Posted - 03/19/2005 : 1:29:42 PM | Hi,
Will that 'range inhibited' light cause the bus not to have power in Over Drive? Our older 2000 Thom. Freights with AT545's and 3126e's don't have this light. I guess this is a feature of the A2000.
-Barry |
| B. Busguy33
Top Member
USA
3444 Posts | | Posted - 03/19/2005 : 8:43:15 PM | | Do all A2000s come with the 'range inhibited' light and the 'economy mode' button? Just wondering if this is optional or standard equipment with these transmissions. |
| Peter
Top Member
USA
1057 Posts | | Posted - 03/19/2005 : 9:13:30 PM | | Our BB/IHs have them both but I don't think that our Freightliners have the economy mode button. Need to check to be sure, though. | | Spicer is nicer. |
| Thomasbus24
Administrator
USA
4501 Posts | | Posted - 03/25/2005 : 11:41:18 AM | quote:Originally posted by B. Busguy33
Do all A2000s come with the 'range inhibited' light and the 'economy mode' button? Just wondering if this is optional or standard equipment with these transmissions.
Every 2000 equipped bus SHOULD have the inhibited light or something similar...but we all know how things that SHOULD be sometimes arent!
As for the Economy button...no...that is not standard with this series. The two buses I had with 2000's in them lacked this feature. |
| crw49
New Member
USA
4 Posts | | Posted - 03/30/2005 : 12:55:48 PM | quote:Originally posted by RTP717
Greetings to all. I work at a fleet of around 450 buses and we have about 150 buses with the Allison 2000 series transmission. We are starting to have numerous problems with these transmissions not going in reverse and defaulting and also some will not upshift. After checking many of them for codes we have changed a few solenoids that were showing failures or problems. These transmissions came with the transynd fluid which is suppose to be good for 100,000 miles. We have changed the spin on filters as recommended from Allison. We are still having the same problems with some of the same buses. After talking with Allison the have told us to remove the valve bodys and clean thoroughly amd then change internal and external filters. A lot if these are out of warranty so they are ours. Has anyone else had any of these same problems with this series transmission? Please give me any feedback you might have regarding this problem.
|
| crw49
New Member
USA
4 Posts | | Posted - 03/30/2005 : 12:57:00 PM | quote:Originally posted by RTP717
Greetings to all. I work at a fleet of around 450 buses and we have about 150 buses with the Allison 2000 series transmission. We are starting to have numerous problems with these transmissions not going in reverse and defaulting and also some will not upshift. After checking many of them for codes we have changed a few solenoids that were showing failures or problems. These transmissions came with the transynd fluid which is suppose to be good for 100,000 miles. We have changed the spin on filters as recommended from Allison. We are still having the same problems with some of the same buses. After talking with Allison the have told us to remove the valve bodys and clean thoroughly amd then change internal and external filters. A lot if these are out of warranty so they are ours. Has anyone else had any of these same problems with this series transmission? Please give me any feedback you might have regarding this problem.
|
| crw49
New Member
USA
4 Posts | | Posted - 03/30/2005 : 1:04:38 PM | quote:Originally posted by RTP717
Greetings to all. I work at a fleet of around 450 buses and we have about 150 buses with the Allison 2000 series transmission. We are starting to have numerous problems with these transmissions not going in reverse and defaulting and also some will not upshift. After checking many of them for codes we have changed a few solenoids that were showing failures or problems. These transmissions came with the transynd fluid which is suppose to be good for 100,000 miles. We have changed the spin on filters as recommended from Allison. We are still having the same problems with some of the same buses. After talking with Allison the have told us to remove the valve bodys and clean thoroughly amd then change internal and external filters. A lot if these are out of warranty so they are ours. Has anyone else had any of these same problems with this series transmission? Please give me any feedback you might have regarding this problem.
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