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Allison Transmission Plant Tour

How The 1000 Series Is Made

Mike McGlothlin
Aug 1, 2011
The modern-diesel era is slowly phasing out the manual transmission. And not just in the pickup world, but in the medium-duty segment as well. With ever- improving lockup torque converters, electronic valve bodies, built-in tow-haul modes, hybrid technology, and better all-around efficiency—automatic transmissions are the future.
Photo 2/26   |   allison Transmission Tour completed Transmission
One company that has been at the forefront of perfecting automatic transmission technology, for applications in America and around the globe, is Allison Transmission. With its roots in providing quality, reliability, durability, vocational value, and outstanding customer service, it’s no wonder why thousands of fleet owners, much of the public transportation industry, and off-highway operators prefer the Allison name. Whether it’s a 1000 series dwelling in a school bus, a 3000 series helping a fire truck pump water, or a 4000 series handling oilfield duty, you know the brand.
One hundred years after Jim Allison helped found Indianapolis Motor Speedway and 65 years since Allison entered the transmission industry, we found ourselves at its historic Indianapolis headquarters watching its commercial-duty line of transmissions being manufactured. Follow along as we take you through the Allison 1000 assembly process and show you what we experienced during our ride-and-drive tour at Allison’s demonstration track.
1000/2000 Series Gear Ratios:
All 1000-series transmission gear ratios consist of:
First 3.10:1
Second 1.81:1
Third 1.41:1
Fourth 1.00:1
Fifth 0.71:1
Sixth 0.61:1
Reverse 4.49:1
Photo 3/26   |   1000/2000 Series Common Applications: School buses Shuttle buses Tour buses Motorhomes Specialty vehicles
However, Highway, Pupil Transport, Rugged Duty, Emergency Vehicle, Motorhome, and Specialty versions of some 2000-series transmissions come equipped as follows:
First 3.51:1
Second 1.90:1
Third 1.44:1
Fourth 1.00:1
Fifth 0.74:1
Sixth 0.64:1
Reverse 5.09:1
Allison In Action
Prior to our assembly plant tour, the folks at Allison let us experience some of its products firsthand when we got to drive a few medium- and heavy-duty vehicles. The Freightliner Coronado SD dump truck shown here was equipped with a DD15 Detroit Diesel 15.0L engine (460hp, 1,850-lb-ft version) and an Allison 4500RDS (Rugged Duty Series) transmission. Loaded up with rock and grossing 70,000 pounds, we drove the truck up and down a steep, 25 percent grade several times.
Photo 23/26   |   allison Transmission Tour dump Truck Side Shot
Starting from a dead stop at the bottom of the loose-rock grade, we slowly (and effortlessly) ascended the hill. Halfway up the grade, we let off the accelerator, held the brake, and then went back to the accelerator. With very slight throttle input, we found the truck would hold its position on the hill with no brakes required.
Photo 24/26   |   allison Transmission Tour dump Truck Rear Three Quarter
One option that sets Allison apart and is offered with many of its transmissions (including the 4500RDS we operated) is a prognostics feature. By being calibrated for the vehicle’s specific operating requirements, service intervals can be forecasted and various transmission parameters monitored. Things like oil level, oil life, filter life, and overall transmission health are consistently analyzed, and the operator is alerted when the unit needs to be serviced.
Rugged Duty Series Transmission
Allison offers a Rugged Duty Series (RDS) version of its transmissions in every series (1000, 2000, 3000, and 4000). Typical vehicle applications for the Rugged Duty Series include: dump trucks, equipment haulers, heavy equipment transport, concrete mixers, snow removal vehicles, wreckers, refuse/waste vehicles, and many more. The 4500RDS, which would be found in the dump truck we drove, is shown in this photo.
Photo 25/26   |   allison Transmission Tour allison 4500rds
4500RDS Specs
Application: Max Input Power: Max Input Torque:
On/Off Highway 565 hp 1,650 lb-ft (1,850 lb-ft w/SEM)
Refuse 500 hp 1,550 lb-ft
Specialty PTO 565 hp 1,650 lb-ft (1,770 lb-ft w/SEM)
HET 600 hp 1,650 lb-ft (1,850 lb-ft: available in Second–Sixth gear)
Photo 26/26   |   To give you an idea just how large some of the components found in Allison’s 4000- series transmissions are, we snapped this photo of the output shaft. When compared to the 4000 tour hosts’ shoes, you get a sense of the general makeup of a 4000: massive shafts, huge geartrain components, a 180-pound torque converter, and an overall dry weight of 830 (for a basic model) to 970 pounds (with PTO and auxiliary braking retarder included).
SEM: Shift Energy Management (limits engine torque output during shifts)
HET: Heavy Equipment Transport


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