Banks Performance Transmission Parts Installation

Banks Performance Transmission Parts Installation
Owner’sManual
with Installation Instructions
Banks Billet
Torque Converter
TM
2001-2008 Chevy/GMC Duramax Allison
Transmission
THIS MANUAL IS FOR USE WITH KITS 72510
>>
General Installation Practices
1. Familiarize yourself with the installa-
tion procedure by reading the installation
manual before starting work.
2. Throughout this manual, the left side
of the vehicle refers to the driver’s side,
and the right side refers to the passenger’s side.
3. Disconnect the negative (ground)
cable from the battery (or batteries, if
there are two) before beginning work.
4. Route and tie wires and hoses
7. Installing the Banks Torque Convert-
er requires removal of the transmission
from the vehicle. Heavy tooling such as
a transmission jack and an automotive
hoist or ample-height jack stands are
required. Professional installation by a
properly equipped shop is recommended. Failure to follow all installation
instructions during Torque Converter
install can result in bodily injury and/or
expensive damage to the transmission
and surrounding components.
a minimum of 6 inches away from
exhaust heat, moving parts and sharp
edges. Clearance of 8 inches or more is
recommended where possible.
8. The transmission and torque con-
5. During installation, keep your work
9. Before installing the Banks Torque
area and tools clean to avoid possible
entry of dirt into the drivetrain.
6. When raising the vehicle, support it
on properly weight-rated safety stands,
ramps or a commercial hoist. Follow
the manufacturer’s safety precautions.
Take care to balance the vehicle to
prevent it from slipping or falling. When
using ramps, be sure the front wheels
are centered squarely on the topsides.
When raising the front of the vehicle,
set the parking brake and block the
rear wheels. When raising the back of
the vehicle, be sure the vehicle is on
level ground and the front wheels are
securely blocked.
verter must be removed as an assembly to avoid damage to the converter
drive plate, pump bushing and oil seal.
Converter, verify that your transmission is in good operating condition.
Transmission problems such as harsh
or delayed engagement when shifting into Drive or Reverse, no Drive or
Reverse range, erratic shifting, grating
or scraping noises, or lack of up and/
or downshifting can lead to torque converter damage. If necessary, have your
transmission repaired or overhauled
before installing the converter.
>>
Caution! Do not use floor jacks to
support the vehicle while working under it. Do not support the
vehicle using concrete blocks,
masonry or any other item not
intended specifically for this use.
2
96732 v.2.0
Tools Required:
•3 ⁄ 8 ” and 1 ⁄ 2 ” drive ratchets with
metric sockets including 1 ⁄ 2 ” and
3 ⁄ 8 ” drive extension
Highly recommended
tools and supplies:
• Penetrating oil or light lubricant
spray
• Metric combination or open-end
wrenches
• Transmission fluid filter
• Standard and Phillips head
screwdrivers
• Torsion Bar Removal Tool (Kent
Moore PN J36202)
• Standard and needle-nose pliers
• Transmission pan gasket
• Clean shop towels or rags
• Transmission hoist
• Floor jack
• C-clamp
• Drain pan
• GM Goodwrench DEXRON® VI ATF
fluid (See manufacturers
recommendations for your specific
model)
Notice To Installer:
Banks recommends replacing your
transmission fluid, transmission fluid
filter and transmission pan gasket.
Failure to service transmission may
result in torque converter damage.
• 320-400 grit sandpaper
• Measuring ruler
• Pry bar or channel lock pliers
• Grease pen
• Inch-pound and foot-pound torque
wrenches
96732 v.2.0
3
General Figure 1
Description
4
Description
1
Torque Converter
8
Transmission Oil Pan
2
Turbine Shaft
9
Input speed sensor
3
Drive Shaft Output
10
Turbine speed sensor
4
Torque Converter Housing
11
Output speed sensor
5
Fuel Line Retaining nut
12
Park/neutral position Switch
6
Fill tube
13
Main electrical connector
7
Transmission Cooler Lines
96732 v.2.0
96732 v.2.0
5
Installation procedure
Torque Converter
Removal
1. Disconnect the negative
BY A JACK. SEVERE INJURY MAY
RESULT.
2. Raise the vehicle high enough to
remove the transmission and support
it securely with properly weight-rated
safety stands, ramps or a commercial
hoist. Take care to balance the vehicle
to prevent it from slipping or falling.
When using ramps, be sure the wheels
are centered squarely on the topsides.
Set the parking brake and securely
block the wheels that are on the
ground.
4. To avoid pump seal damage dur-
(ground) cable from the battery (if there
is more than one battery, disconnect
both negative cables). Secure the cable
so it cannot accidentally come in contact with the post.
CAUTION: DO NOT WORK UNDER
ANY VEHICLE SUPPORTED ONLY
Figure 2
6
96732 v.2.0
3. Carefully remove the Banks Torque
Converter from the shipping container.
Be careful not to damage the shipping
container as it will be used to return
the factory torque converter to Gale
Banks Engineering.
ing converter installation, inspect the
Banks Torque Converter hub and hub
drive notches for sharp edges, burrs,
scratches or nicks. It may be necessary to polish hub and/or notches with
320/400 grit sandpaper and crocus
cloth.
CAUTION: Make sure to cover the
drive hub entry with a clean rag
to prevent any contaminants from
entering the torque converter.
Clean any contaminants from
the converter hub and hub drive
notches off before installing the
torque converter into the transmission or damage may result.
5. Remove the factory front catalytic
converter hanger pin from the Exhaust
hanger rubber grommet. See Figure 2.
Note: Loosen the exhaust clamps and
disconnect the exhaust components
to ease the removal of the hanger pin
from the rubber grommet and to make
room for starter and transmission
removal.
Note: Spray lubricant may assist in
hanger pin removal.
6. Remove the Exhaust hanger from
the right side of the transmission.
7. Torsion Bar Removal
A. Install the Torsion Bar Removal
Tool to the Adjustment Arm and the
Cross Member. See Figure 3.
Note: There is a notch on top of the
Cross Member to properly sit the
Removal Tool.
Figure 3
96732 v.2.0
7
Figure 4
B. Increase the tension on the
Adjustment Arm until the load is
removed from the Adjustment bolt
and Adjuster nut.
F. Remove the Torsion Bars and
Adjustment Arms from the vehicle.
Note: Mark the position of the Torsion Bars as the left and right bar
are different.
G. Remove the Cross Member bolts
from the weld nuts and remove the
member by lifting and moving it to
the rear of the vehicle.
C. Remove the Adjustment bolt and
Adjuster nut.
-Important- Mark the location of
the Adjustment bolt and Adjuster
nut before removing to help with
alignment during re-installation.
D. Remove the Removal Tool to allow the Torsion Bar to unload.
E. Remove the Adjustment Arm by
sliding the Torsion Bar forward until
it clears the Cross Member.
Note: To provide better access to the
starter, the right front wheel and wheel
housing may be removed.
Note: Once the Torsion Bar is removed, the Adjustment Arm is free
to move, take care to support the
Adjustment Arm.
9. Rotate the crankshaft bolt in front of
8
96732 v.2.0
8. Remove the starter motor to access
converter bolts. Retain the hardware
for reassembly.
the engine with a large 36mm wrench
to access the torque converter bolts
thru the starter opening. Remove
torque converter bolts. See Figure 4.
Figure 5
Note: Only rotate the engine clockwise.
Rotating the engine counterclockwise
may loosen the crankshaft balancer
bolt.
10. Mark the rear propeller shaft and
axle yokes for assembly alignment,
then disconnect and remove the propeller shaft. (It is common for transmission fluid to drain from the rear of the
transmission after driveshaft removal.)
11. For 4 x 4 models - Mark the
front propeller shaft and axle yokes for
assembly alignment, then disconnect
the front propeller shaft from the front
axle pinion yoke.
12. Remove the fuel line retainer bolts
on the driver side of the transmission.
13. Disconnect the park/ neutral posi-
tion switch, turbine speed sensor, and
the output and input speed sensor wire
connectors. Disconnect the transmission main electrical connector. Secure
all wires away from transmission.
14. Disconnect the shift cable from
the selector lever ball stud and remove
the cable from the bracket. Secure
cable away from transmission.
15. Disconnect transmission fluid
cooler lines by removing the retaining clips and carefully pulling the lines
out of the transmission fittings. Secure
lines away from the transmission. Plug
the cooler lines fittings in the transmission case. See Figure 5.
16. Remove the fill tube nuts from the
converter housing and pull the tube out
of the transmission. Retain fill tube Oring and hardware for re-assembly. Plug
the fill tube fitting in the transmission
case. See Figure 6.
96732 v.2.0
9
Figure 6
Figure 7
10
96732 v.2.0
17. Remove the wire harness/vent
tube bracket nut from the top of the
converter housing stud. See Figure 7.
18. Support the rear of the engine
with a jack, engine hoist or safety
stands. Raise the transmission slightly
with a transmission jack to relieve load
on the cross member support.
19. Remove the bolts securing rear
support, transmission cushion and
cross member.
WARNING: Torque Converter can
slide off the turbine shaft. Secure
the converter when removing the
transmission and torque converter assembly from the engine.
22. Lower the transmission and remove it from under the vehicle.
23. Once the transmission and torque
converter assembly are removed, place
a suitable drain pan under the converter housing end of the transmission.
20. Remove the bolts attaching the
24. Measure from the mounting lugs
cross member to the frame and remove the cross member.
on the torque converter to the transmission mounting face. See Figure 8.
21. Remove all the torque converter
housing bolts and studs and retain for
reassembly. Carefully slide the transmission and torque converter assembly
rearward. Disengage torque converter
hub from the end of the crankshaft.
-Important- The distance from the
torque converter mounting lugs to the
face on the transmission mounting
face must be recorded. This will insure
proper installation of the Banks Torque
Converter.
Figure 8
96732 v.2.0
11
Figure 9
CAUTION: Verify that the transmission is secured to the lifting
device. When torque converter is
removed, the transmission’s center of gravity will shift and transmission may become unstable.
25. Carefully slide the torque converter out of the transmission.
WARNING: Install 2 torque converter lifting handles or bolts into
2 lugs on the front of the torque
converter to prevent severe injury
and to ease remove of torque converter. See Figure 9.
Note: Inspect the oil seal on the front
pump of the transmission. If there are
signs of leakage or damage, the seal
should be replaced prior to installing
the new torque converter.
12
96732 v.2.0
26. Drain the transmission fluid and
replace transmission oil filter and transmission pan gasket.
Banks Torque Converter
Installation.
27. Lubricate the splines shaft seals
inside the torque converter housing
with factory recommend transmission
assembly lubricant to prevent damage
when installing Banks Torque Converter.
28. Lubricate the Banks converter
drive pilot hub, oil pump and the converter pilot hub by pouring one quart of
GM Goodwrench DEXRON® VI ATF fluid
into the pilot hub.
CAUTION: When installing Banks
Torque Converter, be careful not
to damage the pump gear O-ring
or Hub-Seal.
29. Align and carefully rotate the
Banks Torque Converter to engage the
turbine shaft splines to the converter
drive pilot hub. Continue rotating pushing the converter inward to engage the
stator shaft splines to the stator race
and the drive flats on the converter to
the oil pump drive gear. Be sure the
converter drive pilot hub is fully seated
in pump gears.
30. Check converter seating with a
ruler and straightedge (Figure 8).
Note: Converter is properly seated
when the distance from the lugs to the
mounting face is the same as recorded
measurement taken before removal
of factory torque converter. Refer to
measurement record in step 24.
37. Reinstall the fill tube and nuts to
the converter housing.
38. Install the park/neutral position
switch, turbine speed sensor, and the
output and input speed sensor connector. Reconnect the transmission main
electrical connector.
39. Shift the park/neutral position
switch forward to put the transmission
in the park position. Connect the shift
cable over the selector lever ball stud
and connect the cable to the bracket.
40. Rotate the crankshaft bolt in front
of the engine to install torque converter bolts thru the starter opening.
Reinstall the torque converter bolts and
torque to 44 ft-lbs.
31. Raise the transmission and align
41. Reinstall the rear propeller shaft.
32. Move the transmission towards
42. For 4x4 models - Reconnect the
the converter with the drive plate.
the engine and raise/tilt the transmission to align the converter housing with
alignment dowels.
33. Seat the front converter hub into
Be sure to realign the marks on propeller shaft and yoke.
Front propeller shaft to the front axle
pinion yoke and realign the marks on
the propeller shaft and yoke.
the crankshaft by aligning the transmission over the alignment dowels.
43. Reinstall the starter motor.
44. Reinstall cooler line bracket and
Note: Check to see if torque converter
will rotate smoothly and will not bind
with the crankshaft.
45. Torsion Bar installation
34. Install the factory bolts and studs
A. Slide the Cross Member over
the weld nuts and drop into place.
Reinstall factory bolts and tighten to
70 ft-lbs.
B. Slide the Torsion Bar into the
lower control arm. Slide the Adjustment Arm into the Cross Member.
While holding the Adjustment Arm
in place, slide the Torsion Bar from
the lower control arm rearward into
the Cross Member. Make sure the
Torsion Bar slides into the Adjustment Arm and is properly inserted.
through the converter housing and into
engine.
35. Reinstall the transmission cross
member to the vehicle frame. Lower
the transmission onto the cross member to the vehicle frame. Install and
tighten the bolts attaching the transmission mount to the cross member
cushion.
36. Reinstall the wire harness/vent
tube bracket and nut to the top of the
converter housing.
connect the cooler lines to the transmission.
96732 v.2.0
13
C. Install the Torsion Bar Removal
Tool to the Adjustment Arm and the
Cross Member. Make sure the Removal Tool sits on the notch on top
of the Cross Member. See Figure 2.
49. Verify that all previously removed
D. Add tension on the Adjustment
Arm until the Adjustment bolt and
Adjuster nut can be installed.
50. Fill the transmission with the fac-
E. Install the Adjustment bolt and
Adjuster nut and adjust the bolt and
nut to realign to the marks made
during removal process.
Note: Refer to factory recommendation on Torsion Bar adjustment.
CAUTION: DO NOT overfill transmission fluid. Fill transmission
with 6 quarts then start your
vehicle and check fluid level. Add
ATF fluid as needed.
F. Remove the Removal Tool.
46. Reinstall exhaust hanger and
reconnect the exhaust hanger pin into
the rubber grommet.
47. Reconnect exhaust components
and clamps
48. Reconnect the fuel line retainer
bolts on the driver side of transmission.
14
96732 v.2.0
components are reconnected, all tools
used are accounted for and all bolts
are tightened to manufacture specifications.
tory recommended GM Goodwrench
DEXRON® VI ATF.
51. Reconnect the battery cable(s).
52. Start the vehicle and allow
engine to reach normal operating
temperatures. With the vehicle lightly
loaded, accelerate gently and allow the
torque converter to lock and unlock a
minimum of fifteen (15) times. Monitor
transmission temperatures and stall
speed to verify the torque converter is
operating normally. Check transmission
fluid level and add ATF fluid if needed.
Installation of the Banks Torque Converter is now complete.
To receive a core charge refund,
complete the following steps
You will notice that you have been
charged a $250.00 refundable core
charge for your Banks Torque Converter. In order to receive a refund on the
core charge you must send us a good
rebuildable core. Please follow these
important instructions.
1. Do not discard or destroy the shipping container that your new torque
converter came in.
2. After installation of your new torque
converter, DRAIN ALL FLUID from your
old torque converter by allowing it to
sit upside-down in a suitable drain pan
or container overnight.
CAUTION: Failure to properly drain
the converter may result in shipping refusal or other consequences related to shipping hazardous
material.
3. Install supplied plug on old torque
converter input hub and wrap it in the
supplied plastic bag.
4. Pack the torque converter into the
Banks shipping container. If applicable,
place the foam insulation around the
torque converter to prevent damage
during shipping.
5. Reseal the shipping container. Verify
that the Torque Converter is secure in
the shipping container.
6. Locate the return shipping label
included in the Banks Torque Converter
package and affix it to the outside of
the shipping container so that it completely covers the previous shipping
label.
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