Allison 5sp: tools needed to rebuild a 1000 4X4

[THEFERMANATOR]

What special tools are required to properly rebuild an ALLISON 1000 out of a 2001 3500 4X4? I'm considering putting in a SC4 into mine before I swap it into my SUBURBAN since it has 162K on it from the 3500 in a work truck. SUNCOAST reccomended a SC4 and 1056 converter for mine, and there website lists it for just under $2800. Unfortunately I'm outside of driving range of MIKE L, or else I would take it to him. I've built a few 4L60E's in the past and got by with just a couple of tools I made myself. I know I could build one, I just don't know if I want mine to be my learning experience or not. I called up the local shop to me that has been doing SUNCOAST's stuff for a LONG time, and they quoted me $3997 to build mine if I brought it to them. This included a SC4 and a 1056 converter with a 2 year unlimited warranty(except for hard parts), basically a SC5 but including a converter. trying to decide if it's worth buying any special tools to build just one or not.

The 95 SUBURBAN will weigh in right around 6500-6700 pounds, and I will be putting 3.42 gears in it for mostly highway cruising. I'm sure the SC4 will be overkill as I don't plan on going wild, I just want it to last for a LONG time.

 

[Cougar281]

Main tools needed are an adapter to hold the Alli up on an engine stand (I had mine made at a local metal shop for $85) and a spring compressor for the C1/C2 assembly (I made mine with soem threaded rod, two nuts and PVC couplers :rofl. A good set of snap-ring pliers would be a good idea too. I picked up a set at Harbor freight that just barely cut it. Then I got a HUGE set at Cummins Tools (more or less the same as HF) for $16. worked like a charm for the larger snap rings.

 

[motohed]

nothing out of the ordinary as far as i can remember. it was pretty easy.

 

[Bentley]

Snap ring pliers need to be like these...
http://buy1.snapon.com/catalog/item...4&group_ID=768&store=snapon-store&dir=catalog
They make them so easy! If you get a smaller pair you will struggle with them!

 

[TNRGreene]

What special tools are required to properly rebuild an ALLISON 1000 out of a 2001 3500 4X4? I'm considering putting in a SC4 into mine before I swap it into my SUBURBAN since it has 162K on it from the 3500 in a work truck. SUNCOAST reccomended a SC4 and 1056 converter for mine, and there website lists it for just under $2800. Unfortunately I'm outside of driving range of MIKE L, or else I would take it to him. I've built a few 4L60E's in the past and got by with just a couple of tools I made myself. I know I could build one, I just don't know if I want mine to be my learning experience or not. I called up the local shop to me that has been doing SUNCOAST's stuff for a LONG time, and they quoted me $3997 to build mine if I brought it to them. This included a SC4 and a 1056 converter with a 2 year unlimited warranty(except for hard parts), basically a SC5 but including a converter. trying to decide if it's worth buying any special tools to build just one or not.

The 95 SUBURBAN will weigh in right around 6500-6700 pounds, and I will be putting 3.42 gears in it for mostly highway cruising. I'm sure the SC4 will be overkill as I don't plan on going wild, I just want it to last for a LONG time.

Cool another Fla boy here.

 

[THEFERMANATOR]

I talked to the local SUNCOAST shop and he said there were a couple of seal installers that were required to put one together. And what about the nut on the output shaft? It looks like a spindle nut, only smaller. I'm probably going to give MIKE L a call and see what he thinks I should put in this tranny as well.

 

[Cougar281]

Snap ring pliers need to be like these...
http://buy1.snapon.com/catalog/item...4&group_ID=768&store=snapon-store&dir=catalog
They make them so easy! If you get a smaller pair you will struggle with them!

That's pretty much the same thing I got @ Cummins tools, just not Snap-On.

I talked to the local SUNCOAST shop and he said there were a couple of seal installers that were required to put one together. And what about the nut on the output shaft? It looks like a spindle nut, only smaller. I'm probably going to give MIKE L a call and see what he thinks I should put in this tranny as well.

Forgot the output nut; I got my socket at Orielley's IIRC. It's pretty much a 4-prong spindle nut socket.

 

[bullfrogjohnson]

Why are yall taking the output nut off? I have always just taken the whole tail section off as one unit. Unless you are putting a billet shaft in.

 

[Mike L.]

Why are yall taking the output nut off? I have always just taken the whole tail section off as one unit. Unless you are putting a billet shaft in.

I agree.

 

[bullfrogjohnson]

I agree.

Thats good you agree, I was starting to think I have been foretting something

 

[TrentNell]

Thats good you agree, I was starting to think I have been foretting something

i never pull it apart either ... except for when i had to replace the extension housing , i usually just flush it real well in the solvent tank .

 

[Cougar281]

Only "gotcha" with not taking it apart would be if you need/want to replace the C5 piston seals. The problem with flushing it in the solvent tank without taking it apart is the potential for leaving excessive solvent behind the piston. Personally, I found it easier to take apart and re-assemble by putting everything together individually than trying to wrestle the P3 carrier and extension housing together. But that's my personal opinion; YMMV.

 

[bullfrogjohnson]

Only "gotcha" with not taking it apart would be if you need/want to replace the C5 piston seals. The problem with flushing it in the solvent tank without taking it apart is the potential for leaving excessive solvent behind the piston. Personally, I found it easier to take apart and re-assemble by putting everything together individually than trying to wrestle the P3 carrier and extension housing together. But that's my personal opinion; YMMV.

Yes putting back together is fun sometimes you just have to hold your tongue right

 

[THEFERMANATOR]

Well I followed cougar281's picture and made my own holder to go in my engine stand. This should be alot easier than wrestling this thing on the bench.

And a BIG thumbs up to MIKE L:thumb:. Called him this afternoon to ask his opinion on what I should put into my build. He spent a good 30 minutes listing off things I should check and what mandatory items should be replaced. Gave me a good deatiled build list and where to get certain things to get the best. I only wish it would be feasible for me to take it to him to have it done. Mike DEFINATELY knows how to keep his customers happy, AND what support is:beavisnbutthead:.

 

[Mike L.]

Well I followed cougar281's picture and made my own holder to go in my engine stand. This should be alot easier than wrestling this thing on the bench.

And a BIG thumbs up to MIKE L:thumb:. Called him this afternoon to ask his opinion on what I should put into my build. He spent a good 30 minutes listing off things I should check and what mandatory items should be replaced. Gave me a good deatiled build list and where to get certain things to get the best. I only wish it would be feasible for me to take it to him to have it done. Mike DEFINATELY knows how to keep his customers happy, AND what support is:beavisnbutthead:.

Thank you for the compliment. You are much more than capable of doing this build and conversion. I only wish that I could be a part of this as it is realy a cool transplant. I am more than willing to help you with this via long distance. Call my cell after hours or the shop in the day. Thank you for the call. :hug:

 

[rgullett83]

Thank you for the compliment. You are much more than capable of doing this build and conversion. I only wish that I could be a part of this as it is realy a cool transplant. I am more than willing to help you with this via long distance. Call my cell after hours or the shop in the day. Thank you for the call. :hug:

You cant ask for better customer service and help than that.:cool2:
I did my first alli on a saturday, and Mike ansewered all of my calls and questions with out hesitation, great vendor and great guy.

 

[Cougar281]

And a BIG thumbs up to MIKE L:thumb:. Called him this afternoon to ask his opinion on what I should put into my build. He spent a good 30 minutes listing off things I should check and what mandatory items should be replaced. Gave me a good deatiled build list and where to get certain things to get the best. I only wish it would be feasible for me to take it to him to have it done. Mike DEFINATELY knows how to keep his customers happy, AND what support is:beavisnbutthead:.

Mike's good people. He's been a BIG help to me too and tolerated my stupid questions and a duh moment or two .

One word of advice for anyone building an Allison, unless you're doing an 01 or 02: don't rely on the ATSG manual as gospel. It's 97% accurate, and VERY useful to have, but there are some differences between it and the newer Allisons that had me scratching my head for a few minutes.

 

[bullfrogjohnson]

Mike L. is the sh*t!!! I cant tell you how many times he has been there for me in a jam and I needed help.

 

[mainer]

Only "gotcha" with not taking it apart would be if you need/want to replace the C5 piston seals. The problem with flushing it in the solvent tank without taking it apart is the potential for leaving excessive solvent behind the piston. Personally, I found it easier to take apart and re-assemble by putting everything together individually than trying to wrestle the P3 carrier and extension housing together. But that's my personal opinion; YMMV.

anyone else have any comment on weather or not this is really an issue with leaving solvent in there?? also is it safe to be using mineral spirits etc as solvent?? dont want to damage anything/ dry it out by using the wrong solvent.

 

[Dazedandconfused]

Does anyone know of any other tools or items you need? What about a good VB brush set? I know there are valves that stick sometimes and was wondering what you are useing to clean the VB up with?