BD Diesel 1064702 Auto Trans Assembly Installation

BD Diesel 1064702 Auto Trans Assembly Installation
6 November 2006
GMC/Chevy Allison Performance Transmission
1
BD PERFORMANCE TRANSMISSION
Allison Installation Instructions
1064702
1064722
2WD Transmissions
2000-2003 LB7
2004-2005 LLY
1000
1000
1064704
1064724
4WD Transmissions
2000-2003 LB7
2004-2005 LLY
1000
1000
Please read the instructions and disclaimer before beginning installation.
BD Engine Brake Inc.
Plant Address: #A10 – 33733 King Road, Abbotsford, BC, Canada V2S 7M9
US Shipping: #88 – 446 Harrison St., Sumas, WA, USA 98295 | US Mailing Address: P.O. Box 231, Sumas, WA, USA, 98295
Phone#: (604) 853-6096 | Fax: (604) 853-8749 | Web: www.dieselperformance.com
6 November 2006
GMC/Chevy Allison Performance Transmission
2
REMOVAL:
1) Park the vehicle, apply the park brake, and open the hood.
2) Record your sound system and clock preset settings (if desired) and disconnect both negative
cables on the batteries.
3) Remove the transmission dipstick.
4) With the vehicle safely supported on an overhead hoist, remove the transmission pan drain
plug and drain the fluid.
5) Remove both front skid plates for easy access to components.
6) Remove both bolts (15mm hex socket or wrench) holding the starter in place and with rope or
wire, secure the starter up and out of the way on the frame. This allows for access to the
torque converter/flex plate bolts through the starter opening. NOTE: The starter wires do not
have to be disconnected to perform this operation.
7) Torque Converter (TC) removal procedure:
a. Locate the transmission/bell housing window at the lower left corner.
b. View the converter and flex drive plate through this window.
c. Use a 1 ½” box end wrench on the crankshaft front damper bolt to turn the crankshaft
until the flex plate holes come into view as seen through the window from below. This
indicates a removal point.
d. Shine a flashlight through the right side frame and suspension members to locate the
converter mounting bolts through the starter mounting opening.
e. As each mounting bolt is lined up, apply a small paint pen dot to the front damper, and
one dot to an adjacent stationary surface. This allows for easy re-assembly as the dots
may be lined up while turning the crank from the front.
f. Remove each of the six mounting bolts (15mm hex head bolts with 5/16” allen head
socket as well) using an extra long extension and ratchet extending clear through to the
front of the engine. NOTE: A magnet may be required to extract the bolts once they are
removed because of their location within the recess of the ring gear plate.
g. The converter should now be unbolted from the flex plate within the bell housing
enclosure.
h. During re-assembly, using the same long extension but using a 5/16” Allen head socket
may better control the converter mounting bolts
8) Remove both front and rear drive shafts and tape some plastic over the transfer case rear boot
to keep fluid from leaking during its removal.
9) Remove all wiring harnesses and shift linkages with their respective hold down devices and
swing them carefully to the left of the transmission and strap them temporarily to the frame.
10) Position a suitable transmission jack under the flat area of the pan, ensuring the transmission
is secured to the jack. Be careful, as the transmission weights over 300lbs.
11) Locate the two oil cooler tube fittings on the right side of the transmission, then pop the ring
back on the fitting and pull the snap/lock ring from its slot. Use a catch tray when unseating the
BD Engine Brake Inc.
Plant Address: #A10 – 33733 King Road, Abbotsford, BC, Canada V2S 7M9
US Shipping: #88 – 446 Harrison St., Sumas, WA, USA 98295 | US Mailing Address: P.O. Box 231, Sumas, WA, USA, 98295
Phone#: (604) 853-6096 | Fax: (604) 853-8749 | Web: www.dieselperformance.com
6 November 2006
GMC/Chevy Allison Performance Transmission
3
pipes to collect draining fluid and use cap plugs on pipes and fittings to keep dirt from entering.
12) Lift the transmission slightly and remove the rear cross-member.
13) Remove the nuts (15mm) holding the transfer case to the transmission and slide the transfer
case off its mounting studs. Rotate it counterclockwise within the frame and front suspension
torsion bar beam until it clears and can be removed by lowering it.
NOTE: This allows the torsion beam, torsion bars, and accompanying components to be left
undisturbed.
14) Remove all transmission-to-engine bell housing fasteners, taking note of their locations and
type as some are 15mm hex head cap screws and others are 15mm “stud” bolts. Ensure all
fasteners are removed, especially the one at the 12 o’clock position at the top of the unit.
15) Roll the transmission assembly backwards, then lower and remove the assembly from under
the vehicle.
16) Using two of the 15mm “stud” bolts at opposite sides (180° apart) of the torque converter,
gently pull the converter out of the transmission while holding the studs for control with a drain
pan beneath to catch any fluid. The converter may be placed face down to further drain fluid if
desired.
INSTALLATION:
Installation is the reverse of the removal procedure. Refer to the next page for proper tightening
specifications.
BD Engine Brake Inc.
Plant Address: #A10 – 33733 King Road, Abbotsford, BC, Canada V2S 7M9
US Shipping: #88 – 446 Harrison St., Sumas, WA, USA 98295 | US Mailing Address: P.O. Box 231, Sumas, WA, USA, 98295
Phone#: (604) 853-6096 | Fax: (604) 853-8749 | Web: www.dieselperformance.com
6 November 2006
GMC/Chevy Allison Performance Transmission
4
Fastener Tightening Specifications
Application
Control Module Cover to Radiator Shroud Bolts
Control Valve Assembly to Main Housing Bolts
Converter Housing to Front Support Assembly Bolts
Detent Lever Retaining Nut
Detent Spring Assembly to Main Valve Body Bolts
Filler Tube Bracket to Transmission Nuts
Fuel Line Bracket to Transmission Nut
Fuel Line Retainer to Transmission Bolts
Heat Shield to Transmission Bolts
Heat Shield to Transmission Nut
Hydraulic Connector Assembly
Input Speed Sensor to Torque Converter Housing Bolt
Main Pressure Tap Plug
Oil Cooler Line Clip to Oil Pan Nut
Oil Cooler to Radiator Brace Bolts
Oil Pan Drain Plug
Oil Pan to Main Housing Bolts
Output Speed Sensor to Rear Cover Bolt
PNP Switch to Main Housing Bolts
Pressure Switch Assembly to Main Valve Body Bolts
PTO Cover(s) to Main Housing Bolts
Shift Cable Bracket to Transmission Bolts
Shift Cable Support to Steering Column Brace Bolt
Shift Lever to Shift Selector Shaft Nut
Shipping Bracket to Torque Converter Housing Bolts
Shipping Bracket to Torque Converter Lug Bolts
Torque Converter to Flywheel Bolts
Torque Converter Housing Inspection Cover to Transmission Bolts
Transmission Mount to Adapter Bolts (4WD)
Transmission Mount to Transmission Bolts (2WD)
Transmission Mount to Transmission Support Nuts
Transmission Support to Frame Nuts and Bolts
Turbine Speed Sensor to Main Housing Bolt
Wire Harness/Vent Tube Bracket to Transmission Nut
Yoke Assembly to Output Shaft Bolt
Specification
Metric
Imperial
9 N·m
80 lb in
12 N·m
108 lb in
56 N·m
41 lb ft
29 N·m
21 lb ft
12 N·m
108 lb in
18 N·m
13 lb ft
18 N·m
13 lb ft
2.5 N·m
22 lb in
17 N·m
13 lb ft
25 N·m
18 lb ft
25 N·m
18 lb ft
12 N·m
108 lb in
12 N·m
108 lb in
9 N·m
80 lb in
12 N·m
106 lb in
35 N·m
26 lb ft
27 N·m
20 lb ft
12 N·m
108 lb in
27 N·m
20 lb ft
12 N·m
108 lb in
43 N·m
32 lb ft
25 N·m
18 lb ft
10 N·m
89 lb in
24 N·m
18 lb ft
27 N·m
20 lb ft
27 N·m
20 lb ft
27 N·m
20 lb ft
10 N·m
89 lb in
47 N·m
35 lb ft
50 N·m
37 lb ft
40 N·m
30 lb ft
70 N·m
52 lb ft
12 N·m
108 lb in
18 N·m
13 lb ft
123 N·m
91 lb ft
BD Engine Brake Inc.
Plant Address: #A10 – 33733 King Road, Abbotsford, BC, Canada V2S 7M9
US Shipping: #88 – 446 Harrison St., Sumas, WA, USA 98295 | US Mailing Address: P.O. Box 231, Sumas, WA, USA, 98295
Phone#: (604) 853-6096 | Fax: (604) 853-8749 | Web: www.dieselperformance.com
6 November 2006
GMC/Chevy Allison Performance Transmission
5
BD ENGINE BRAKE, INC.
LIMITED WARRANTY STATEMENT
BD Engine Brake, Inc. (BD) warrants to the original purchaser that any parts purchased shall be free from defects
in material and workmanship. BD limits the liability to the repair or replacement, at BD's option, of any warrantable
product returned prepaid with a complete service history and proof of purchase. A valid proof of purchase is a dated bill of
sale. Repaired or replaced product will be returned to the customer freight collect. Accepted warranty units, which have
been replaced, become the sole property of BD.
A Return Material Authorization (RMA) number, obtained in advance from a BD customer service representative,
must accompany product, returned prepaid by the purchaser, for warranty determination. BD will be the final authority on
all warranty decisions.
This parts warranty shall terminate at the end of 12 months or 24,000 miles in service with original user,
whichever comes first. Labor costs incurred by the removal and replacement of a BD Performance Converter while
performing warranty work, will be covered for 12 months at authorized centers with prior approval. Until the product has
been approved at the original installing dealer or at one of our distributors, the consumer should cover these costs.
NOT COVERED UNDER THIS WARRANTY
This warranty shall not apply to any unit that has been improperly stored or installed; or to misapplication,
improper operation conditions, accidents, or neglect, or which has been improperly repaired or altered or otherwise
mistreated by the owner or his agent.
The nature of this product is PERFORMANCE and is designed to perform at above OEM specifications. This
product was designed with this in mind and should NOT be used in RACING and/or HIGH HORSEPOWER applications
and will only be considered for warranty on vehicles with a maximum of 450 REAR WHEEL HORSEPOWER. Using this
product on vehicles with a higher rating will cause premature failure and therefore BD will not consider such claims. BD
reserves the right to void the transmission warranty if a BD torque converter is not used throughout the warranty period of
the transmission.
Except as set forth in our parts outline, BD disclaims any implied warranties of merchantability and fitness for a
particular purpose. BD also disclaims any liability for incidental or consequential damages including but not limited to,
repair labor, rental vehicles, hotel cost or any other inconvenience cost. This warranty is in lieu of all other warranties or
guaranties, either expressed or implied, and shall not extend to any consumer or to any person other than the original
purchaser residing within the boundaries of the continental U.S. or Canada.
BD Engine Brake Inc.
Plant Address: #A10 – 33733 King Road, Abbotsford, BC, Canada V2S 7M9
US Shipping: #88 – 446 Harrison St., Sumas, WA, USA 98295 | US Mailing Address: P.O. Box 231, Sumas, WA, USA, 98295
Phone#: (604) 853-6096 | Fax: (604) 853-8749 | Web: www.dieselperformance.com
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