RevMax Allison 1000 Signature Series Installation Instructions

Fluid Capacity

RevMax performance transmissions require the use of "DEXRON 3" fluid. Transmissions are shipped empty due to DOT and freight regulations.

Fluid amounts may vary slightly year to year. It is crucial to check the fluid level frequently during the first few weeks of operation. This ensures that any air pockets are worked out, resulting in an accurate fluid level reading.

Typically, the fluid amount is between 17-20 quarts when using RevMax deep transmission pans. This can vary depending on the vehicle year and if a larger transmission cooler is installed. *PLEASE CHECK FLUID OFTEN FOR THE FIRST COUPLE WEEKS* to ensure the transmission fluid level is perfect.

Torque Specifications

Pre-Installation and Drive Learning Procedures

CAUTION: Prior to Installation

NOTE: The installation and drive learning process typically takes 2-3 days. During this period, towing, hauling, or rough driving is not permitted.

Before removing the original transmission, set your programmer or tuner to the STOCK power level. All relearn procedures must be performed at stock power levels; never increase power during the relearn process.

Connect to the TCM with a scanner and perform the transmission relearn and re-adaptation process. This currently requires a Tech II or equivalent scan tool. Ensure the scanner successfully completes the relearn procedure. If the TCM does not relearn successfully, stop immediately, turn off the engine, and contact RevMax before proceeding. The truck cannot be driven until the relearn is completed, not even for short distances.

For the initial test drive, do not exceed 30% throttle or 2000 RPM. Allow the transmission to shift through all gears up to sixth and back down to first at least 25 times. Applying full power during this phase can lead to immediate transmission failure, for which you will be responsible for repair charges.

Begin the initial drive learn cycle. Maintain throttle input below 50% at all times during this cycle. Drive the truck for a MINIMUM of 2-3 days. The truck must be allowed to rest overnight to experience both HOT and COLD engine and transmission temperature cycles. During this period, it is recommended to accumulate a MINIMUM of 200 miles of STOP-and-GO driving. Highway driving does not contribute to the drive learn process.

PART B: Changing Vehicle Power Levels or Re-flashing with New Tuning

This issue can arise when using tuners to flash the engine with custom tuning, or anytime the ECM is re-flashed with factory or aftermarket tuning.

When the transmission's adaptive settings are reset, it becomes out of sync with the controller. The transmission has accumulated a certain amount of wear, but the controller may not reflect this accurately. This mismatch can lead to incorrect timing during shifts, causing clutch engagement issues that may result in a flare or a bind during shifts. At light throttle, the transmission can relearn these adaptives over several light throttle up-shift and down-shift sequences (less than 30% throttle). This process typically takes a few dozen sequences.

However, if the truck is driven aggressively after a re-flash while the transmission is out of sync, it can cause significant wear. In extreme cases, a single aggressive shift can destroy the transmission. The greater the power and throttle input, the more severe the potential issue.

Installation Steps

1. C2 Clearance

   Step 1: Begin by stacking the steel and friction clutches. Alternate between a steel plate and a friction clutch, starting with a steel plate. There are 7 steel plates and 7 friction clutches.

   Image shows stacking clutches.

   Step 2: Install the snap ring after the last steel plate to enable clearance measurement.

   Image shows installing a snap ring.

   Step 3: To determine clearance, place a dial indicator on the middle of the top steel plate. Pull up on the entire pack/stack; the gauge will indicate the clearance. Note: The C2 clearance should be .065" to .085".

   Image shows measuring clearance with a dial indicator.

   Step 4: Air check the C2 to confirm the piston is applying and there are no leaks. After completion, remove all C2 clutch plates and steels.

   Image shows air checking the C2 assembly.

2. C1 Clearance

   Step 5: Next, stack the C1 clutch pack. Start with the selectable apply plate. 5-speed models use a .219" plate, while 6-speed models use a .087" plate.

   NOTE: These instructions are based on the 6-speed style transmission.

   NOTE: The .219" thick C1 apply plate is for early model 5-speed transmissions. For these, you will only stack 7 steel and friction plates because the apply plate is thicker.

   Step 6: Install the thin apply plate. Begin by stacking one inner spline clutch with the friction clutch facing up, then an outer friction clutch facing up. Alternate each inner and outer clutch until you have stacked 8 of each.

   Image shows stacking C1 clutch components.

3. C1 and C2 Final Assembly

   Step 7: Add the pressure plate followed by the thick snap ring. Do not install the spiral snap ring at this time.

   Image shows adding pressure plate and thick snap ring.

   Step 8: To determine C1 clearance, place the dial indicator on the middle of the top plate. Air check the C1 clutch pack with air pressure into the indicated hole (See Step 8 photo). NOTE: The C1 clearance is .105" to .125".

   Image shows dial indicator location and air checking C1 clutch pack.

   Step 9: Once you have final clearances for C1 & C2, begin the final assembly. Start by placing the spiral snap ring over the thick snap ring. Then, place the thrust bearing on top of your input shaft.

   Image shows installing spiral snap ring and thrust bearing.

   Step 10: Place the C1 hub. Ensure it is seated properly over the entire C1 clutch stack. Place the C1 thrust bearing onto the C1 hub.

   Image shows placing C1 hub and thrust bearing.

   Step 11: Place the C2 hub on top of the bearing. Restack your C2 clutches, starting with a steel plate and then a friction clutch, alternating back and forth.

   Image shows placing C2 hub and restacking C2 clutches.

   Step 12: Install the P1 planetary drive flange and P1 planetary snap ring.

   Image shows installing P1 planetary drive flange and snap ring.

4. C3 Clearance

   Step 13: Start by applying assembly gel to both the bore for the piston and the piston itself. Gently install the piston into the bore, being careful not to cut the seal.

   NOTE: The C3 piston has a bleed hole. The bleed hole must be positioned at the 12 o'clock location.

   Image shows applying gel and installing C3 piston.

   Step 14: Once the piston is in place, start with the C3 apply plate. Place all 5 steel plates on top of the apply plate, followed by all 6 friction clutches on top of the steel plates. Finish with the C3 pressure plate and snap ring. This is a preliminary stackup for checking clearance.

   Image shows stacking C3 components for clearance check.

   Step 15: Next, check the C3 stack clearance. It should be .040" to .060" clearance between the pressure plate and the snap ring.

   Image shows checking C3 stack clearance.

   Step 16: After confirming C3 clearance, remove the C3 snap ring, pressure plate, clutches, steels, and the apply plate.

5. C4 Clearance

   Step 17: Next, place the C3 pressure plate back into the case with the C3 snap ring. Apply assembly gel to the piston bore and piston, then gently install the piston into the bore, avoiding seal damage.

   Image shows reinstalling C3 pressure plate and snap ring.

   Step 18: Once the piston is in place, start with the C4 apply plate, followed by all 6 friction clutches. Then, place all 5 steel plates on top of the friction clutches. This is a preliminary stackup for checking clearance.

   NOTE: The C4 piston has a bleed hole. The bleed hole must be positioned at the 12 o'clock location.

   Image shows stacking C4 components for clearance check.

   Step 19: Place the C4 pressure plate and install the snap ring on top.

   Image shows placing C4 pressure plate and installing snap ring.

   Step 20: Next, check the C4 stack clearance. It should be .040" to .060".

   Image shows checking C4 stack clearance.

   Step 21: After confirming C4 clearance, remove the C4 snap ring, pressure plate, clutches, steels, and the apply plate.

   Image shows removing C4 components after clearance check.

6. C3 and C4 Final Assembly

   Step 22: Install the holding plate for the intermediate shaft.

   NOTE: The holding plate is mandatory and can be purchased at: http://adaptacase.com/t-44587ac.html

   Image shows installing the holding plate.

   Step 23: With the holding plate in place, place the P1 ring gear. This will sit on top of the C3 pressure plate that is already installed.

   Image shows placing P1 ring gear.

   Step 24: Next, place the P1 spacer that comes with the C3 kit onto the P1 planetary. Then, add the P1 factory plastic spacer. NOTE: Ensure the spacer is aligned with the notches.

   Image shows installing P1 spacer and aligning notches.

   Step 25: Place the P1 planetary onto the P1 ring gear.

   Image shows placing P1 planetary onto ring gear.

   Step 26: Attach the 3 factory return springs to the new apply plate by snapping them into place. Install the apply plate with springs, aligning the alignment hole to the piston bleed hole. NOTE: You must align the 12 o'clock alignment hole to the 12 o'clock piston hole. There is only one area on the apply plate that will align correctly between the springs.

   Image shows attaching return springs and aligning apply plate.

7. Further Assembly Steps

   Step 27: Place the C4 apply plate with attached return springs, followed by 5 steel plates and 6 friction clutches, alternating clutch then steel. The stack should end with a friction clutch on top. Ensure all friction and steel plates (oil holes and slots) align with the 12 o'clock bleed hole in the case (very important).

   Image shows stacking C4 components with springs.

   Step 28: Next, add the C4 pressure plate and the 2 snap rings. The thin snap ring goes first, followed by the thick snap ring. NOTE: The C4 typically has 2 snap rings. Earlier models may have a spiral snap ring, while later models have a standard upper snap ring.

   Image shows adding C4 pressure plate and two snap rings.

   Step 29: Compress the C4 pressure plate using a bar tool and a fabricated tool similar to the one shown. Once compressed, install the 2 snap rings.

   Image shows compressing C4 pressure plate and installing snap rings.

   Step 30: Place the P1 and P2 planetary thrust bearing. The shoulder should face inward.

   Image shows placing P1 and P2 planetary thrust bearings.

   Step 31: Place your P2 planetary, followed by the P2 thrust bearing.

   Image shows placing P2 planetary and P2 thrust bearing.

   Step 32: Next, install the P2 sun gear onto your intermediate shaft and spline it into your P2 planetary.

   Image shows installing P2 sun gear onto intermediate shaft.

   Step 33: Install the P2 spacer. Align the hole on the intermediate shaft with the opening on the spacer.

   Image shows installing P2 spacer.

   Step 34: Next, place the P3 sun gear over the end of the intermediate shaft.

   Image shows placing P3 sun gear.

   Step 35: Follow with the P3 thrust bearing.

   Image shows following with P3 thrust bearing.

   Step 36: Install the C5 thick pressure plate on top of the C4 pressure plate and snap rings, followed by the friction and steel plates. Alternate, starting with the friction plate first.

   Image shows installing C5 thick pressure plate and plates.

   Step 37: Next, place the factory return spring in the case on top of the C5 stack. Spline the P3 planetary and the output shaft together, and lower the entire assembly into the C5 ring gear. The P3 planetary and output shaft should sit flush.

   Image shows placing return spring, splining P3 planetary and output shaft.

   Step 39: Put the upper shaft spacer with the selective shim on top.

   Image shows placing upper shaft spacer with shim.

   Step 40: Install the park pawl assembly.

   Image shows installing the park pawl assembly.

   Step 41: Place the C5 piston into the extension housing. Ensure both the piston housing and piston seals have assembly gel applied. NOTE: There is only one correct orientation for the piston; align the hole in the housing with the slot on the piston.

   Image shows placing C5 piston into extension housing, ensuring alignment.

   Step 42: Place the gasket on the top rear of the case, then add the extension housing. Align the dowel pin on the case with the extension housing hole. NOTE: The extension housing will not sit flat until bolted down.

   Image shows placing gasket and extension housing, aligning dowel pin.

   Step 43: Insert the extension housing bolts and secure them in a star pattern around the extension housing to ensure an even seal.

   Image shows bolting extension housing in a star pattern.

   Step 44: Install the upper shaft blocking nut with the blue seal facing up. A special socket is required for this, which can be purchased at: http://adaptacase.com/t-1000ac.html

   Image shows installing upper shaft blocking nut.

   Step 45: Flip the case so the extension housing faces the ground to access the C3 stack up. Remove the holding plate that secured the intermediate shaft.

   Image shows flipping case and removing holding plate.

   Step 46: Pull out the C3 snap ring and pressure plate. Add the C3 factory springs to the C3 apply plate, aligning the center hole at the 12 o'clock position. NOTE: The springs are designed to fit only in their correct locations.

   Image shows removing C3 components and adding springs.

   Step 47: Start the C3 stack up with a steel apply plate, factory return springs, then a friction clutch with the bleed hole at 12 o'clock. Alternate with steel and friction clutches. The stack should end with a friction clutch.

   Step 48: Place the C3 pressure plate on top of the C3 stack, followed by the snap ring.

   Image shows placing C3 pressure plate and snap ring.

   Step 49: Compress the C3 pressure plate using a bar tool and a fabricated tool similar to the one shown. Once compressed, install the C3 snap ring.

   Image shows compressing C3 pressure plate and installing C3 snap ring.

   Step 50: Next, add the input drum with your C1 and C2 stacks and place it into the case.

   Image shows adding input drum with C1 and C2 stacks.

   Step 51: Ensure it is fully seated into the P1 planetary.

   Image shows ensuring input drum is seated.

   Step 52: Place a gasket on the case before attaching your pump assembly and bell housing.

   Image shows placing gasket on case.

   Step 53: Place the pump assembly and bell housing onto the case.

   Image shows placing pump assembly and bell housing.

   Step 54: Bolt down the housing to the case, securing it in a star pattern to ensure an even seal.

   Image shows bolting housing to case.

   Step 55: Finally, check your front end play. The best method is to use a screwdriver to hold the void underneath where the input drum rests. Set your dial indicator on top of the input shaft and pry down to lift the input drum. The clearance for front end play should be .030" to .045".

   Image shows checking front end play with dial indicator. Image shows detail of checking front end play.