manual for automatic 5 sp allison - Diesel Truck Forum - TheDieselGarage.com
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post #1 of 8 (permalink) Old 01-31-2010, 10:06 PM Thread Starter
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manual for automatic 5 sp allison

I am looking for a repair manual for an automatic 5 sp allison with transfer case. I need to do some repairs on the transfer case and would like to look at a manual before I attempt this feat. Thanks.

03 Chevy Silverado 2500 HD, K/N intake, PPE boost fooler, Edge hot juice w/monitor, 4" MBRP turbo back exhaust, Line X bed lining, B/W turnover hitch, Merchant Automotive xfer case pump upgrade
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post #2 of 8 (permalink) Old 02-01-2010, 11:56 PM
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what do you need to do to the transfer case?

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post #3 of 8 (permalink) Old 02-02-2010, 12:12 AM
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ATSG Website
http://atsg.com/cart/index.php?p=cat...ison&x=83&y=11

or

Makco
http://www.bulkpart.com/Merchant2/me...=&Store_Code=2

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post #4 of 8 (permalink) Old 02-03-2010, 12:29 PM Thread Starter
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I am figuring a bearing has gotten really sloppy and is almost shot allowing the gear or chain inside to rub the side of the housing causing a hole in the side about 2cm big. I can grab the drive shaft near the extension housing and move it a little(up and down) so something isn't right inside.

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post #5 of 8 (permalink) Old 02-03-2010, 04:57 PM
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You have pump rub! The wear clip has rubbed a hole in the magnesium case. Somewhat common.

Eric has an affordable fix.

http://www.merchant-automotive.com/t...pgradekit.aspx

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post #6 of 8 (permalink) Old 02-04-2010, 10:37 AM Thread Starter
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Quote:
Originally Posted by BombDocDiesel View Post
You have pump rub! The wear clip has rubbed a hole in the magnesium case. Somewhat common.

Eric has an affordable fix.

http://www.merchant-automotive.com/t...pgradekit.aspx
Thank you sooooo much, never would have thought of looking there. Now it's the only place I will look for parts. That is exactly what it is. Good description of problem right next to the parts. Awesome!!

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post #7 of 8 (permalink) Old 02-04-2010, 01:16 PM Thread Starter
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With this running low on fluid what would be the possible issues that will most likely need addressed? Do you think all the bearings need replaced, planetary gear or others? I will need to order all the stuff before I dig into it so I only have to do it once. one thing I noticed when I placed it in 4X4 after about 10 sec in motion there was a thunking noise that acted like a bad u-joint but both were replaced already and in good shape. Does that sound like something with planetary unit?

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post #8 of 8 (permalink) Old 02-04-2010, 03:24 PM
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Most people can fix the pump rub and keep going. I recommend switching to 5w-30 or 0w-30 synthetic motor oil in cases. ATF has great hydraulic pressure and heat transfer properties but a transfer cases needs lubrication.

If you drain and remove the case and put it through it's range by hand, if it feels loose or grinds you may need to replace the bearings. I would contact SoGrand https://www.thedieselgarage.com/forums/member.php?u=309 I went trhough him when I needed parts and he was great to work with.

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