Workhorse ALLISON 1000MH User manual

2007 W Series
SECTION
7.2
PAGE
1
2007 W Series Chassis
Automatic Transmission – Allison
© 2006 Workhorse Custom Chassis — All Rights Reserved
WORKHORSE CUSTOM CHASSIS
Service Manual
WSM082106
2007
AUTOMATIC TRANSMISSION
ALLISON 1000MH/2100MH/LCT1000
REMOTE
SHIFTER
PRND321
9999.9mi
T1 gear1
4
TRANSMISSION
GEAR ATTAINED
MAXIMUM/
SELECTED
GEAR
SELECTED RANGE
HIGHLIGHTED
OVERDRIVE (O/D) SWITCH "OFF"
(DEPRESSED AT THE TOP)

WORKHORSE CUSTOM CHASSIS
Service Manual
2007 W Series
SECTION
7.2
PAGE
2Automatic Transmission – Allison
2007 W Series Chassis
© 2006 Workhorse Custom Chassis — All Rights Reserved
WSM082106
TABLE OF CONTENTS
SPECIFICATIONS ............................................................. 6
Fastener Tightening specifications ........................... 6
Fluid Capacity Specifications ................................... 7
Transmission General Specifications ....................... 7
Transmission Fluid Temperature (TFT) Sensor
Temperature vs. Resistance Specifications ............. 8
Temperature Versus Resistance (Speed Sensor) .... 9
Temperature Versus Resistance (Solenoid)........... 10
Pressure Switch Manifold (PSM) Logic.................. 10
Transmission Internal Mode Switch Logic.............. 11
Solenoid and Clutch Chart (Normal Mode) ............ 11
Solenoid and Clutch Chart (Tow/Haul) ................... 13
Shift Speed (1-2 and 2-3 Shifts)............................. 14
Shift Speed (3-4, 4-5, 5-6 and CT Downshifts) ...... 14
Line Pressure ......................................................... 16
SPECIAL TOOLS ............................................................ 16
Component Locator................................................ 22
Automatic Transmission Inline Harness Connector
End View .............................................................. 23
Engine Harness to Transmission ........................... 26
Torque Converter Clutch/Converter Housing
Assembly Disassembled View.............................. 26
Torque Converter Housing, 1-2-3-4-5-6 Clutch
Assembly, and 3rd, 5th, and Reverse Clutch
Components Disassembled View......................... 27
Torque Converter Housing/Oil Pump Cover
Assembly .............................................................. 27
Oil Pump Assembly Disassembled View................ 28
Oil Pump Cover Assembly Disassembled View ..... 28
Oil Pump Cover/Oil Pump Assembly and
Associated Parts Disassembled View .................. 29
1-2-3-4, 4-5-6 Clutch Assembly Disassembled
View...................................................................... 29
Torque Converter Housing/Automatic
Transmission Case and Associated Components
Disassembled View .............................................. 30
Automatic Transmission Case Disassembled
View...................................................................... 31
2-6 Clutch/Low and Reverse Clutch Disassembled
View...................................................................... 32
Input Carrier, Intermediate Carrier, and Main Shaft
Disassembled View .............................................. 33
Input Carier and Ring Gear Assembly
Disassembled View .............................................. 33
Output Carrier Disassembled View ........................ 34
Input Carrier Assembly Disassembled View........... 34
Intermediate Carrier Assembly Disassembled
View...................................................................... 35
Output Carrier Assembly, Output Shaft, Low and
Reverse Clutch Retrurn Spring Assembly and Park
Pawl Disassembled View ....................................... 35
Low and Reverse Clutch Piston Housing
Disassembled View .............................................. 36
Output Carrier Assembly Disassembled View........ 36
Low and Reverse Clutch Housing Assembly
Disassembled View ................................................ 37
Control Valve Body Assembly Disassembled View 38
Shift Valve Body Assembly..................................... 39
Main Valve Body Assembly Disassembled View.... 40
Bearing and Bushing Locations ............................. 41
Seal Locations........................................................ 41
Automatic Transmission Internal Connector End
Views.................................................................... 42
INTRODUCTION ............................................................. 50
Objectives Of This Section..................................... 50
Description and Operation ..................................... 50

WORKHORSE CUSTOM CHASSIS
Service Manual Automatic Transmission – Allison
2007 W Series
© 2006 Workhorse Custom Chassis — All Rights Reserved
SECTION
7.2
PAGE
3
2007 W Series Chassis
WSM082106
Definitions and Abbreviations ................................. 50
Transmission Abbreviations ................................... 52
Transmission Identification Information.................. 53
Transmission General Description ......................... 54
Transmission Component and System
Description ........................................................... 55
Transmission Indicators and Messages ................. 58
Electronic Component Description......................... 59
Electronic Controlled Shifter (ECS) System........... 92
DIAGNOSTIC INFORMATION AND PROCEDURES ..... 95
Diagnostic Starting Point - Automatic
Transmission ........................................................ 95
Scan Tool Data List ................................................ 95
Scan Tool Data Definitions ..................................... 99
Diagnostic Trouble Code (DTC) Type Definitions.103
Diagnostic Trouble Code (DTC) List/Type............ 104
DTC P0218 .......................................................... 106
DTC P0561 .......................................................... 110
DTC P0562 .......................................................... 114
DTC P0563 .......................................................... 117
DTC P0602 .......................................................... 120
DTC P0613 .......................................................... 123
DTC P0634 .......................................................... 126
DTC P0658 .......................................................... 129
DTC P0659 .......................................................... 133
DTC P0700 .......................................................... 137
DTC P0701 .......................................................... 139
DTC P0703 .......................................................... 142
DTC P0706 .......................................................... 146
DTC P0708 .......................................................... 150
DTC P0711........................................................... 155
DTC P0712 .......................................................... 160
DTC P0713 .......................................................... 164
DTC P0716 .......................................................... 169
DTC P0717 .......................................................... 173
DTC P0721 .......................................................... 177
DTC P0722 .......................................................... 181
DTC P0726 .......................................................... 185
DTC P0727 .......................................................... 189
DTC P0729 .......................................................... 193
DTC P0731 .......................................................... 196
DTC P0732 .......................................................... 200
DTC P0733 .......................................................... 203
DTC P0734 .......................................................... 206
DTC P0735 .......................................................... 209
DTC P0736 .......................................................... 212
DTC P0741 .......................................................... 216
DTC P0742 .......................................................... 219
DTC P0751 .......................................................... 222
DTC P0752 .......................................................... 227
DTC P0756 .......................................................... 232
DTC P0757 .......................................................... 237
DTC P0761 .......................................................... 242
DTC P0762 .......................................................... 247
DTC P0776 .......................................................... 252
DTC P0777 .......................................................... 256
DTC P0826 .......................................................... 260
DTC P0827 .......................................................... 264
DTC P0828 .......................................................... 268
DTC P0842 .......................................................... 272
DTC P0843 .......................................................... 277
DTC P0847 .......................................................... 282
DTC P0848 .......................................................... 287
DTC P0851 or 0852 ............................................. 292
DTC P0872 .......................................................... 294
DTC P0873 .......................................................... 299
DTC P0873 .......................................................... 304
DTC P0877 .......................................................... 309

WORKHORSE CUSTOM CHASSIS
Service Manual
2007 W Series
SECTION
7.2
PAGE
4Automatic Transmission – Allison
2007 W Series Chassis
© 2006 Workhorse Custom Chassis — All Rights Reserved
WSM082106
DTC P0878 .......................................................... 314
DTC P0880 .......................................................... 318
DTC P0881 .......................................................... 322
DTC P0882 .......................................................... 326
DTC P0883 .......................................................... 329
DTC P0960 .......................................................... 331
DTC P0962 .......................................................... 336
DTC P0963 .......................................................... 340
DTC P0964 .......................................................... 343
DTC P0966 .......................................................... 347
DTC P0967 .......................................................... 351
DTC P0972 .......................................................... 355
DTC P0973 .......................................................... 359
DTC P0974 .......................................................... 363
DTC P0975 .......................................................... 367
DTC P0976 .......................................................... 371
DTC P0977 .......................................................... 375
DTC P0978 .......................................................... 379
DTC P0979 .......................................................... 383
DTC P0980 .......................................................... 387
DTC P1688 .......................................................... 391
DTC P1779 .......................................................... 394
DTC P2670 .......................................................... 398
DTC P2671 .......................................................... 401
DTC P2723 .......................................................... 405
DTC P2724 .......................................................... 409
DTC P2727 .......................................................... 413
DTC P2729 .......................................................... 417
DTC P2730 .......................................................... 420
DTC P2761 .......................................................... 424
DTC P2763 .......................................................... 428
DTC P2764 .......................................................... 432
DTC P2771 .......................................................... 436
Symptoms - Automatic Transmission ................... 440
Functional Test ..................................................... 443
Transmission Fluid Checking ............................... 445
Line Pressure Check............................................ 447
Obtaining Diagnostic Trouble Codes.................... 448
Clutch Test............................................................ 449
FastLearn Procedure ........................................... 450
Limp Home Mode................................................. 452
Road Test ............................................................. 454
Torque Converter Diagnosis.................................459
Flexplate/Torque Converter Vibration Test (8.1L). 463
Noise and Vibration Analysis................................ 465
Fluid Leak Diagnosis............................................ 465
Case Porosity Repair ........................................... 467
Automatic Transmission Oil Cooler Flushing
and Flow Test ..................................................... 467
Excessive Slippage and Clutch Chatter ............... 473
Fluid Leaks from Fluid Fill Tube and/or Vent ........ 474
Fluid Leaks from Transmission Input ................... 474
Fluid Leaks from Transmission Output................. 475
Intermittent Buzzing Noise ................................... 475
Low Main Line Pressure in All Ranges................. 476
Low Main Line Pressure in Specific Ranges,
Normal Pressure in Other Ranges ..................... 476
Low Lubrication Pressure..................................... 477
Contaminated Transmission Fluid ........................ 477
Excessive Flare - Engine Overspeed on
Wide-Open Throttle ............................................ 478
High Stall Speeds (Stall in Ranges 1-6)............... 478
Low Stall Speeds (Stall in Ranges 1-6)................ 479
Transmission Will Not Make a Specific Shift ........ 479
Transmission Will Not Stay In Forward or
Reverse .............................................................. 479
Transmission Will Not Shift to Forward or
Reverse .............................................................. 480

WORKHORSE CUSTOM CHASSIS
Service Manual Automatic Transmission – Allison
2007 W Series
© 2006 Workhorse Custom Chassis — All Rights Reserved
SECTION
7.2
PAGE
5
2007 W Series Chassis
WSM082106
Transmission Overheats ...................................... 481
Transmission Does Not Shift Properly ................. 482
Abnormal Activities or Responses........................ 482
REPAIR INSTRUCTIONS.............................................. 483
Transmission Control Module Replacement ........ 483
Transmission Fluid Filter Adapter Replacement... 484
Transmission Fluid Cooler Hose/Pipe Connector
Replacement ........................................................ 486
Automatic Transmission Fluid and Filter
Replacement ...................................................... 487
Filler Tube and Seal Replacement .......................488
Transmission Fluid Cooler Hose/Pipe
Replacement ...................................................... 490
Transmission Heat Shield Replacement .............. 501
Transmission Mount Replacement....................... 502
Transmission Replacement (L18) Engine) ........... 504
Emergency Removal From Park .......................... 522
Electronic Shift Controller (ECS) Actuator Initial
Installation .......................................................... 522

WORKHORSE CUSTOM CHASSIS
Service Manual
2007 W Series
SECTION
7.2
PAGE
6Automatic Transmission – Allison
2007 W Series Chassis
© 2006 Workhorse Custom Chassis — All Rights Reserved
WSM082106
Application Specification
Metric English
Shift Cable Bracket to Transmission
Bolts
25 N·m 18 lb ft
Shift Cable Support to Steering Column
Brace Bolt
10 N·m 89 lb in
Shift Lever to Shift Selector Shaft Nut 24 N·m 18 lb ft
Shipping Bracket to Torque Converter
Housing Bolts
27 N·m 20 lb ft
Shipping Bracket to Torque Converter
Lug Bolts
27 N·m 20 lb ft
Torque Converter Housing Inspection
Cover to Transmission Bolts
10 N·m 89 lb in
Torque Converter to Flywheel Bolts 60 N·m 44 lb ft
Transmission Fluid Pressure Switch to
Main Valve Body Bolts
12 N·m 108 lb in
Transmission Mount to Adapter Bolts
(4WD)
47 N·m 35 lb ft
Transmission Mount to Transmission
Bolts (2WD)
50 N·m 37 lb ft
Transmission Mount to Transmission
Support Nuts
40 N·m 30 lb ft
Transmission Support to Frame Nuts
and Bolts
70 N·m 52 lb ft
Transmission to Engine Studs and Bolts 50 N·m 37 lb ft
Turbine Speed Sensor to Main Housing
Bolt
12 N·m 108 lb in
Wire Harness/Vent Tube Bracket to
Transmission Nut
18 N·m 13 lb ft
Yoke Assembly to Output Shaft Bolt 123 N·m 91 lb ft
SPECIFICATIONS
FASTENER TIGHTENING SPECIFICATIONS
Application Specification
Metric English
Control Module Cover to Radiator
Shroud Bolts
9 N·m 80 lb in
Control Valve Assembly to Main
Housing Bolts
12 N·m 108 lb in
Converter Housing to Front Support
Assembly Bolts
56 N·m 41 lb ft
Detent Lever Retaining Nut 29 N·m 21 lb ft
Detent Spring Assembly to Main Valve
Body Bolts
12 N·m 108 lb in
Filler Tube Bracket to Transmission
Nuts
18 N·m 13 lb ft
Fuel Line Bracket to Transmission Nut 18 N·m 13 lb ft
Fuel Line Retainer to Transmission
Bolts
2.5 N·m 22 lb in
Heat Shield to Transmission Bolts 17 N·m 13 lb ft
Heat Shield to Transmission Nut 25 N·m 18 lb ft
Hydraulic Connector Assembly 25 N·m 18 lb ft
Input Speed Sensor to Torque
Converter Housing Bolt
12 N·m 108 lb in
Main Pressure Tap Plug 12 N·m 108 lb in
Oil Cooler Line Clip to Oil Pan Nut 9 N·m 80 lb in
Oil Cooler to Radiator Brace Bolts 12 N·m 106 lb in
Oil Pan Drain Plug 35 N·m 26 lb ft
Oil Pan to Main Housing Bolts 27 N·m 20 lb ft
Output Speed Sensor to Rear Cover
Bolt
12 N·m 108 lb in
Power Take-Off (PTO) Cover to Main
Housing Bolts
43 N·m 32 lb ft

WORKHORSE CUSTOM CHASSIS
Service Manual Automatic Transmission – Allison
2007 W Series
© 2006 Workhorse Custom Chassis — All Rights Reserved
SECTION
7.2
PAGE
7
2007 W Series Chassis
WSM082106
FLUID CAPACITY SPECIFICATIONS
Fluid Quantities
Transmission Initial Fill Refill
Liters Quarts Liters Quarts
Allison 1000 12 12.7 7 7.4
TRANSMISSION GENERAL SPECIFICATIONS
Torque Converter Clutch Pressure Control Solenoid
(TCC PCS) Specifications
Sump Temperature Resistance
Degrees C Degrees F Ohms
0 32 9.5
20 68 10.5
40 104 11.5
Shift Solenoid 1 (SS1), SS2, SS3, and Modulated Main
Pressure (MAIN MOD) Solenoid Specifications
Sump Temperature Resistance
Degrees C Degrees F Ohms
03220.0
20 68 22.0
40 104 24.5

WORKHORSE CUSTOM CHASSIS
Service Manual
2007 W Series
SECTION
7.2
PAGE
8Automatic Transmission – Allison
2007 W Series Chassis
© 2006 Workhorse Custom Chassis — All Rights Reserved
WSM082106
TRANSMISSION FLUID TEMPERATURE (TFT)
SENSOR TEMPERATURE VS. RESISTANCE
SPECIFICATIONS
Temperature Temperature Minimum Resistance Nominal Resistance Maximum Resistance
°C °F ohms ohms ohms
-45 -49 128565 141951 155338
-40 -40 95826 100735 105644
-35 -31 68952 72315 75679
-30 -22 50153 52480 54807
-25 -13 36854 38478 40103
-20 -4 27345 28488 29631
-15 5 20476 21286 22097
-10 14 15467 16045 16624
-5 23 11781 12197 12612
0 32 9045 9345 9646
5 41 6998 7219 7441
10 50 5458 5623 5787
15 59 4291 4413 4536
20 68 3398 3490 3582
25 77 2710 2779 2849
30 86 2173 2228 2282
35 95 1754 1797 1840
40 104 1424 1459 1493
45 113 1163 1191 1218
50 122 955.0 977.1 999.2
55 131 788.6 806.5 824.5
60 140 654.7 669.3 683.9
65 149 546.3 558.3 570.2
70 158 458.1 467.9 477.8
75 167 385.9 394.1 402.2
80 176 326.6 333.3 340.1

WORKHORSE CUSTOM CHASSIS
Service Manual Automatic Transmission – Allison
2007 W Series
© 2006 Workhorse Custom Chassis — All Rights Reserved
SECTION
7.2
PAGE
9
2007 W Series Chassis
WSM082106
Temperature Temperature Minimum Resistance Nominal Resistance Maximum Resistance
°C °F ohms ohms ohms
85 185 277.5 283.2 288.9
90 194 236.5 241.6 246.7
95 203 202.4 206.9 211.5
100 212 173.8 177.9 182.0
105 221 149.8 153.6 157.3
110 230 129.7 133.0 136.4
115 239 112.6 115.6 118.7
120 248 98.17 100.9 103.6
125 257 85.87 88.29 90.71
130 266 75.35 77.52 79.69
135 275 66.34 68.27 70.21
140 284 58.58 60.31 62.04
145 293 51.88 53.42 54.97
150 302 46.08 47.46 48.84
155 311 41.04 42.27 43.50
160 320 36.65 37.74 38.84
TEMPERATURE VERSUS RESISTANCE (SPEED
SENSOR)
Temperature Temperature Minimum Resistance Nominal Resistance Maximum Resistance
°C °F k ohms k ohms k ohms
-25 -13 1.93 2.14 2.36
0 32 2.16 2.40 2.64
25 77 2.34 2.60 2.86
50 122 2.61 2.90 3.20
75 167 2.84 3.16 3.47
100 212 3.07 3.41 3.75
125 257 3.30 3.67 4.03
150 302 3.48 3.87 4.26

WORKHORSE CUSTOM CHASSIS
Service Manual
2007 W Series
SECTION
7.2
PAGE
10 Automatic Transmission – Allison
2007 W Series Chassis
© 2006 Workhorse Custom Chassis — All Rights Reserved
WSM082106
TEMPERATURE VERSUS RESISTANCE (SOLENOID)
Sump Temperature Sump Temperature Pressure Control Solenoids 1, 2, and TCC
Resistance
Shift Solenoids 1, 2, and 3 Mod Main Solenoid
°C °F ohms ohms ohms
0 32 4.5 20.0 20.0
20 68 5.5 22.0 22.0
40 104 6.5 24.5 24.5
80 176 7.5 27.0 27.0
120 248 8.5 29.5 29.5
PRESSURE SWITCH MANIFOLD (PSM) LOGIC
Range Pressure Switch 1 - N/O Pressure Switch 2 - N/O Pressure Switch 3 - N/O Pressure Switch 4 - N/C
Switch
Status
Scan Tool
Status
Switch
Status
Scan Tool
Status
Switch
Status
Scan Tool
Status
Switch
Status
Scan Tool
Status
R Open HIGH* Closed LOW Closed LOW Closed LOW
N Closed LOW Closed LOW Closed LOW Open HIGH
1 Open HIGH Closed LOW Open HIGH Open HIGH
2 OpenHIGHOpenHIGHOpenHIGHOpenHIGH
3 Closed LOW Open HIGH Open HIGH Open HIGH
4 Closed LOW Open HIGH Closed LOW Open HIGH
5 Open HIGH Open HIGH Closed LOW Open HIGH
6 Open HIGH Open HIGH Closed LOW Open HIGH
N/C = Normally Closed
N/O = Normally Open
* Pressure switch 1 (PS1) reverts to the Closed/LOW state with throttle applied in REVERSE.

WORKHORSE CUSTOM CHASSIS
Service Manual Automatic Transmission – Allison
2007 W Series
© 2006 Workhorse Custom Chassis — All Rights Reserved
SECTION
7.2
PAGE
11
2007 W Series Chassis
WSM082106
TRANSMISSION INTERNAL MODE SWITCH LOGIC
Range A B C P
P OFF ON ON OFF
R OFF OFF ON ON
N ON OFF ON OFF
D ON OFF OFF ON
*M OFF OFF OFF OFF
1 OFF ON OFF ON
*L1 OFF OFF OFF OFF
*L2 OFF OFF OFF OFF
*L3 OFF OFF OFF OFF
*L4 OFF OFF OFF OFF
*L5 OFF OFF OFF OFF
*L6 OFF OFF OFF OFF
ON = Open Circuit
OFF = Grounded Circuit
*M mode allows TAP Up/TAP Down feature functionally between 1st through 6th ranges.
SOLENOID AND CLUTCH CHART (NORMAL MODE)
Solenoid and Clutch Chart (Normal Mode)
Range
Status
Logic
State
Clutch to
Line
Pressure Control Solenoids Shift Solenoids TCC
Sol.
PCS1 PCS2 SS1 SS2 SS3
Steady State R -- De-energized; Low and Reverse
Clutch Applied
Energized; 3rd, 5th, and Reverse
Clutch Applied
ON ON ON OFF
Garage Shift R-N -- De-energizing; Low and Reverse
Clutch Applied
Energizing; 3rd, 5th, and
Reverse Clutch Trimming Off
ON ON ON OFF
Garage Shift N-R -- De-energizing; Low and Reverse
Clutch Trimming On
Energizing; 3rd, 5th, and
Reverse Clutch Trimming On
ON ON ON OFF
Steady State N or P -- De-energized; Low and Reverse
Clutch Applied
De-energized; Exhausted ON ON ON OFF
Upshift N-1 -- De-energized; Low and Reverse
Clutch Applied
Energized; 1-2-3-4 Clutch
Trimming On
ON ON ON OFF

WORKHORSE CUSTOM CHASSIS
Service Manual
2007 W Series
SECTION
7.2
PAGE
12 Automatic Transmission – Allison
2007 W Series Chassis
© 2006 Workhorse Custom Chassis — All Rights Reserved
WSM082106
Solenoid and Clutch Chart (Normal Mode)
Range
Status
Logic
State
Clutch to
Line
Pressure Control Solenoids Shift Solenoids TCC
Sol.
PCS1 PCS2 SS1 SS2 SS3
Downshift 1-N -- De-energized; Low and Reverse
Clutch Applied
Energized; 1-2-3-4 Clutch
Trimming Off
ON ON ON OFF
Steady State 1 1-2-3-4
Clutch
De-energized; Low and Reverse
Clutch Applied
De-energized; 2-6 Clutch
Exhausted
OFF ON OFF OFF
Upshift 1-2 1-2-3-4
Clutch
Energized; Low and Reverse
Clutch Trimming Off
Energized; 2-6 Clutch Trimming
On
OFF ON OFF OFF
Downshift 2-1 1-2-3-4
Clutch
Energized; Low and Reverse
Clutch Trimming On
Energized; 2-6 Clutch Trimming
Off
OFF ON OFF OFF
Steady State 2 1-2-3-4
Clutch
Energized; 3rd, 5th, and Reverse
Clutch Exhausted
Energized; 2-6 Clutch Applied OFF OFF OFF OFF
Upshift 2-3 1-2-3-4
Clutch
De-energized; 3rd, 5th, and
Reverse Clutch Trimming On
De-energized; 2-6 Clutch
Trimming Off
OFF OFF OFF OFF
Downshift 3-2 1-2-3-4
Clutch
De-energized; 3rd, 5th, and
Reverse Clutch Trimming Off
De-energized; 2-6 Clutch
Trimming On
OFF OFF OFF OFF
Steady State 3 1-2-3-4
Clutch
De-energized; 3rd, 5th, and
Reverse Clutch Applied
De-energized; 4-5-6 Clutch
Exhausted
ON OFF OFF OFF
Upshift 3-4 1-2-3-4
Clutch
Energized; 3rd, 5th, and Reverse
Clutch Trimming Off
Energized; 4-5-6 Clutch Trimming
On
ON OFF OFF ON
Downshift 4-3 1-2-3-4
Clutch
Energized; 3rd, 5th, and Reverse
Clutch Trimming On
Energized; 4-5-6 Clutch Trimming
Off
ON OFF OFF OFF
Steady State 4 4-5-6
Clutch
Energized; 3rd, 5th, and Reverse
Clutch Exhausted
Energized; 1-2-3-4 Clutch
Applied
ON OFF ON ON
Upshift 4-5 4-5-6
Clutch
De-energized; 3rd, 5th, and
Reverse Clutch Trimming On
De-energized; 1-2-3-4 Clutch
Trimming Off
ON OFF ON ON
Downshift 5-4 4-5-6
Clutch
De-energized; 3rd, 5th, and
Reverse Clutch Trimming Off
De-energized; 1-2-3-4 Clutch
Trimming On
ON OFF ON ON
Steady State 5 4-5-6
Clutch
De-energized; 3rd, 5th, and
Reverse Clutch Applied
De-energized; 2-6 Clutch
Exhausted
OFF OFF ON ON
Upshift 5-6 4-5-6
Clutch
Energized; 3rd, 5th, and Reverse
Clutch Trimming Off
Energized; 2-6 Clutch Trimming
On
OFF OFF ON ON
Downshift 6-5 4-5-6
Clutch
De-energized; 3rd, 5th, and
Reverse Clutch Trimming On
De-energized; 2-6 Clutch
Trimming Off
OFF OFF ON ON
Steady State 6 4-5-6
Clutch
Energized; 3rd, 5th, and Reverse
Clutch Exhausted
Energized; 2-6 Clutch Applied OFF OFF ON ON

WORKHORSE CUSTOM CHASSIS
Service Manual Automatic Transmission – Allison
2007 W Series
© 2006 Workhorse Custom Chassis — All Rights Reserved
SECTION
7.2
PAGE
13
2007 W Series Chassis
WSM082106
SOLENOID AND CLUTCH CHART (TOW/HAUL)
Solenoid and Clutch Chart (Tow/Haul)
Range
Status
Logic
State
Clutch to
Line
Pressure Control Solenoids Shift Solenoids TCC
Sol.
PCS1 PCS2 SS1 SS2 SS3
Steady State R -- De-energized; Low and Reverse
Clutch Applied
Energized; 3rd, 5th, and Reverse
Clutch Applied
ON ON ON OFF
Garage Shift R-N -- De-energizing; Low and Reverse
Clutch Applied
Energizing; 3rd, 5th, and Reverse
Clutch Trimming Off
ON ON ON OFF
Garage Shift N-R -- De-energizing; Low and Reverse
Clutch Trimming On
Energizing; 3rd, 5th, and Reverse
Clutch Trimming On
ON ON ON OFF
Steady State N or P -- De-energized; Low and Reverse
Clutch Applied
De-energized; Exhausted ON ON ON OFF
Upshift N-1 -- De-energized; Low and Reverse
Clutch Applied
Energized; 1-2-3-4 Clutch Trimming
On
ON ON ON OFF
Downshift 1-N -- De-energized; Low and Reverse
Clutch Applied
Energized; 1-2-3-4 Clutch Trimming
Off
ON ON ON OFF
Steady State 1 1-2-3-4
Clutch
De-energized; Low and Reverse
Clutch Applied
De-energized; 2-6 Clutch Exhausted OFF ON OFF OFF
Upshift 1-2 1-2-3-4
Clutch
Energized; Low and Reverse Clutch
Trimming Off
Energized; 2-6 Clutch Trimming On OFF ON OFF OFF
Downshift 2-1 1-2-3-4
Clutch
Energized; Low and Reverse Clutch
Trimming On
Energized; 2-6 Clutch Trimming Off OFF ON OFF OFF
Steady State 2 1-2-3-4
Clutch
Energized; 3rd, 5th, and Reverse
Clutch Exhausted
Energized; 2-6 Clutch Applied OFF OFF OFF ON
Upshift 2-3 1-2-3-4
Clutch
De-energized; 3rd, 5th, and Reverse
Clutch Trimming On
De-energized; 2-6 Clutch Trimming
Off
OFF OFF OFF ON
Downshift 3-2 1-2-3-4
Clutch
De-energized; 3rd, 5th, and Reverse
Clutch Trimming Off
De-energized; 2-6 Clutch Trimming
On
OFF OFF OFF ON
Steady State 3 1-2-3-4
Clutch
De-energized; 3rd, 5th, and Reverse
Clutch Applied
De-energized; 4-5-6 Clutch
Exhausted
ON OFF OFF ON
Upshift 3-4 1-2-3-4
Clutch
Energized; 3rd, 5th, and Reverse
Clutch Trimming Off
Energized; 4-5-6 Clutch Trimming On ON OFF OFF ON
Downshift 4-3 1-2-3-4
Clutch
Energized; 3rd, 5th, and Reverse
Clutch Trimming On
Energized; 4-5-6 Clutch Trimming Off ON OFF OFF ON
Steady State 4 4-5-6
Clutch
Energized; 3rd, 5th, and Reverse
Clutch Exhausted
Energized; 1-2-3-4 Clutch Applied ON OFF ON ON

WORKHORSE CUSTOM CHASSIS
Service Manual
2007 W Series
SECTION
7.2
PAGE
14 Automatic Transmission – Allison
2007 W Series Chassis
© 2006 Workhorse Custom Chassis — All Rights Reserved
WSM082106
Solenoid and Clutch Chart (Tow/Haul)
Range
Status
Logic
State
Clutch to
Line
Pressure Control Solenoids Shift Solenoids TCC
Sol.
PCS1 PCS2 SS1 SS2 SS3
Upshift 4-5 4-5-6
Clutch
De-energized; 3rd, 5th, and Reverse
Clutch Trimming On
De-energized; 1-2-3-4 Clutch
Trimming Off
ON OFF ON ON
Downshift 5-4 4-5-6
Clutch
De-energized; 3rd, 5th, and Reverse
Clutch Trimming Off
De-energized; 1-2-3-4 Clutch
Trimming On
ON OFF ON ON
Steady State 5 4-5-6
Clutch
De-energized; 3rd, 5th, and Reverse
Clutch Applied
De-energized; 2-6 Clutch Exhausted OFF OFF ON ON
Upshift 5-6 4-5-6
Clutch
Energized; 3rd, 5th, and Reverse
Clutch Trimming Off
Energized; 2-6 Clutch Trimming On OFF OFF ON ON
Downshift 6-5 4-5-6
Clutch
De-energized; 3rd, 5th, and Reverse
Clutch Trimming On
De-energized; 2-6 Clutch Trimming
Off
OFF OFF ON ON
Steady State 6 4-5-6
Clutch
Energized; 3rd, 5th, and Reverse
Clutch Exhausted
Energized; 2-6 Clutch Applied OFF OFF ON ON
SHIFT SPEED (1-2 AND 2-3 SHIFTS)
1-2 Shift Output Shaft RPM 2-3 Shift Output Shaft RPM
Engine % of TPS 12 25 50 100 12 25 50 100
Mode
L18 8.1L Normal 462 636 1040 1300 867 1127 1792 2312
L18 8.1L Tow/Haul 722 722 1040 1300 1445 1445 1792 2370
SHIFT SPEED (3-4, 4-5, 5-6 AND CT DOWNSHIFTS)
3-4 Shift Output
Shaft RPM
4-5 Shift Output
Shaft RPM
5-6 Shift Output
Shaft RPM
Closed Throttle Downshift Output
Shaft RPM
6-5 5-4 4-3 3-2 2-1
Engine %ofTPS12255012255012255000000
Mode
L18 8.1L Normal 1185 1474 2370 1647 2081 3237 2451 2451 3488 1994 1517 1243 766 202
L18 8.1L Tow/Haul 2023 1965 2399 2875 2774 3352 2976 3038 3756 2514 2167 1532 1040 202

WORKHORSE CUSTOM CHASSIS
Service Manual Automatic Transmission – Allison
2007 W Series
© 2006 Workhorse Custom Chassis — All Rights Reserved
SECTION
7.2
PAGE
15
2007 W Series Chassis
WSM082106
RANGE REFERENCE
Range Park Reverse Neutral OD D 2 1
Gear N R N 1st 2nd 3rd 4th 1st 2nd 3rd 1st 2nd 1st 2nd
**1-2 Shift Solenoid ON ON ON ON OFF OFF ON ON OFF OFF ON OFF ON OFF
**2-3 Shift Solenoid OFF OFF OFF OFF OFF ON ON OFF OFF ON OFF OFF OFF OFF
Fourth Clutch -- -- -- -- -- -- A -- -- -- -- -- -- --
Overrun Clutch -- -- -- --------AAAAAAA
Overdrive Roller
Clutch
H H H HHHORAAAAAAA
Forward Clutch -- -- -- AAAAAAAAAAA
Direct Clutch -- A -- -- -- A A -- -- A -- -- -- --
Front Band -- -- -- -- -- -- -- -- -- -- -- A -- A
Intermediate Sprag
Clutch
-- -- -- * H OR OR * H OR * H * H
Intermediate Clutch -- -- -- -- A A A -- A A -- A -- A
Lo Roller Clutch -- -- -- H OR OR OR H OR OR H OR H OR
Rear Band -- A -- ------------------A--
A = Applied
H = Holding
OR = Overrunning
* = Holding, but not effective
ON = The solenoid is energized
OFF = The solenoid is de-energized
** = The state of the solenoid follows a shift pattern, which depends upon vehicle speed and throttleposition. The
pattern does not depend upon the selected gear.

WORKHORSE CUSTOM CHASSIS
Service Manual
2007 W Series
SECTION
7.2
PAGE
16 Automatic Transmission – Allison
2007 W Series Chassis
© 2006 Workhorse Custom Chassis — All Rights Reserved
WSM082106
LINE PRESSURE
Range Line Pressure @ 600 RPM Line Pressure @ 2100 RPM
Forward Converter - Torque Converter Clutch Not Applied 700- 380 kPa (101-200 PSI) 1 515-1 795 kPa (220-260 PSI)
Forward Lockup - Torque Converter Clutch Applied N/A 1 000-1 170 kPa (145-170 PSI)
Reverse 700-1 380 kPa (101-200 PSI) 1 515-1 795 kPa (220-260 PSI)
Neutral/Park 590-720 kPa (85-105 PSI) 1 515-1 795 kPa (220-260 PSI)
SPECIAL TOOLS
Illustration Tool Number/ Description
Scan Tool
J 5959
Dial Indicator Clamp and Adjuster
J 7872
Magnetic Base Dial Indicator
J 8092
Universal Driver Handle - 3/4 in - 10
J 21366
Torque Converter Retaining Strap

WORKHORSE CUSTOM CHASSIS
Service Manual Automatic Transmission – Allison
2007 W Series
© 2006 Workhorse Custom Chassis — All Rights Reserved
SECTION
7.2
PAGE
17
2007 W Series Chassis
WSM082106
J 21369-F
Torque Converter Leak Test Fixture
J 24204-2
Bar and Stud Assembly
J 24420-B
Universal Puller
J 24446
Rear Bearing Installer
J 24459-5
Spring Compressor Adapter
J 26941
Bushing and Bearing Remover 3-4 in
J 33163 Valve Tray Set
J 36850
Transjel® Lubricant

WORKHORSE CUSTOM CHASSIS
Service Manual
2007 W Series
SECTION
7.2
PAGE
18 Automatic Transmission – Allison
2007 W Series Chassis
© 2006 Workhorse Custom Chassis — All Rights Reserved
WSM082106
J 39200
Digital Multimeter (DMM)
J 43763
Torque Converter Leak Test Plug
J 43764
Torque Converter End Play Gage
J 43765
Stator Shaft Installer/Remover
J 43767
Tone Wheel Staker
J 43768
Tone Wheel Driver
J 43770
Main Lube, Converter Relief Valve
Spring Compressor
J 43771
Pump Bushing Removal and
Installation Tool

WORKHORSE CUSTOM CHASSIS
Service Manual Automatic Transmission – Allison
2007 W Series
© 2006 Workhorse Custom Chassis — All Rights Reserved
SECTION
7.2
PAGE
19
2007 W Series Chassis
WSM082106
J 43772
Torque Converter Seal Installer
J 43773
Valve Spring Compressor
J 43774
Stator Shaft Bushing Installer
J 43775
Oil Pump Cover Needle Bearing
Installer
J 43778
Clutch Bushing Installer
J 43779
Locating Pin Installer
J 43780
Transmission Case Locating Pin
Installer
J 43781
Input Carrier Bushing Remover/
Installer

WORKHORSE CUSTOM CHASSIS
Service Manual
2007 W Series
SECTION
7.2
PAGE
20 Automatic Transmission – Allison
2007 W Series Chassis
© 2006 Workhorse Custom Chassis — All Rights Reserved
WSM082106
J 43782
Rear Seal Installer
J 43785
Intermediate Bushing Remover/
Installer
J 43791
Output/Turbine Shaft Bushing Installer
J 43797
Output Carrier Bearing Race Installer
J 43909
Manual Shift Shaft Seal Installer
J 43910
Output Bearing Puller Leg Set
J 43911
Manual Shift Shaft Seal Remover
J 44247
Internal Wiring Harness Installer