Allison 1000 and 2000 Series Gen 4 (2005-11) Service manual

VOCATIONAL MODELS

1000 EVS 2100 EVS 2200 EVS 2500 EVS

1000 HS 2100 HS 2200 HS 2500 HS

1000 MH 2100 MH 2200 MH 2500 MH

1000 PTS 2100 PTS 2200 PTS 2500 PTS

1000 RDS 2100 RDS 2200 RDS 2500 RDS

1000 SP 2100 SP 2200 SP 2500 SP

B 210 B 220

1000 SeriesTM 2000 SeriesTM 2000 MH Series 2400 SeriesTM

Service manual :

SECTION I PREVENTIVE MAINTENANCE
SECTION II REMOVING TRANSMISSION
SECTION III PREPARING THE TRANSMISSION FOR INSTALLATION
SECTION IV PREPARING VEHICLE FOR TRANSMISSION
SECTION V INSTALLING TRANSMISSION INTO VEHICLE
SECTION VI CUSTOMER SERVICE

1000 2000 Series Gen 4 Troubleshooting Manual

This manual provides troubleshooting information for Allison Transmission 1000 and 2000 Product

Families transmissions. Service Manual SM3191 EN, Mechanics Tips MT3190EN, and Parts Catalog

PC3062EN may be used in conjunction with this manual.

This manual includes:

. Description of the electronic control system.

– Description of the electronic control system components.

. Description of diagnostic codes, system responses to faults, and troubleshooting.

. Wire, terminal. and connector repair information.

Specific instructions for using many of the available or required service tools and equipment are not

included in this manual. The service tool manufacturer will furnish instructions for using the tools or

equipment.

Additional information may be published from time to time in Service Information Letters (SIL) and will be

included in future revisions of this and other manuals. Please use these SlLs to obtain up-to-date

information concerning Allison Transmission products.

This publication is revised periodically to include improvements, new models, special tools, and

procedures. A revision is indicated by a new date on the title page and rear cover. Check with your

Allison Transmission service outlet for the currently applicable publication. Additional copies of this

publication may be purchased from authorized Allison Transmission service outlets. Look in your

telephone directory under the heading of Transmissions —Truck, Tractor, etc.

Take time to review the Table of Contents and the manual. Reviewing the Table of Contents will aid you in

quickly locating information.

Allison Gen 4 DTC Info

The Transmission Control Module (TCM) of your Allison Automatic

monitors the transmission’s electronic controls; and when a problem

condition is detected. it:

– Restricts shifting

– Illuminates the CHECK TRANS’ light on the instrument panel

— Registers a diagnostic code

Continued illumination of the CHECK TRANS light during vehicle

operation (other than start-up) indicates that the TCM has signaled

a diagnostic code.

Pressure Specs and Tests

Checking main pressures helps to determine if a transmission malfunction is due to a mechanical or an electrical

problem. Properly making these pressure checks requires transmission and vehicle (or test stand) preparation,

recording of data, and comparing recorded data against specifications provided.

Wiring:

• Hydraulic Schematics
• Wire & Connector Tables
• Wiring Schematics