The Allison 1000 PTO opening is a common leak point and a key upgrade location for utility trucks. Here is what you need to know.
What the PTO opening is
- Power Take-Off port on the Allison 1000
- Allows external accessory drive
- Used for snow plows, dump trucks, work trucks
- Cover-plated from factory on most trucks
Common PTO cover problems
Leak from cover gasket:
- Most common Allison leak
- Cover gasket degrades over 80k+ miles
- Fluid drips from PTO area
Stripped cover bolts:
- Aluminum case threads
- Easy to over-torque
- Sometimes requires helicoil
Internal damage from no-cover operation:
- Running without cover damages internals
- Always cover the port
Replacement parts
PTO cover only:
- OEM cover + gasket: $30-$60
- Aftermarket: $20-$40
- HD aluminum cover: $40-$80
Full PTO drive gear kit:
- Drive gear + idler + bearings
- $150-$300
- Required for active PTO use
Always replace:
- PTO cover gasket
- Cover bolts (10mm M8x1.25)
- Inspect threads for damage
Install
- Drain trans (or just pan if just cover)
- Remove 6 bolts from PTO cover
- Pull cover and old gasket
- Inspect drive gear teeth (if equipped)
- Clean mating surface
- Install new gasket, new cover
- Torque to 33 ft-lb in cross pattern
Adding active PTO
What you need:
- PTO drive gear kit (~$200)
- Active PTO unit (Chelsea, Muncie, etc.)
- External controls + wiring
- Trans cooler upgrade (recommended)
Cost:
- PTO unit: $1,200-$2,500
- Install labor: $400-$800
- Drive gear kit: $150-$300
- Total: $1,750-$3,600
When NOT to add PTO
- Tuned high-HP Duramax
- Adds rotational load on already-stressed clutches
- Increases heat generation
Related work worth doing at same time
- External cooler line inspection
- Filter replacement
- Fluid service (TES-295)
Need Allison 1000 PTO cover, gasket, or full rebuild kit? Shop our Allison catalog. PTO covers, gaskets, rebuild kits, HD parts. Free shipping over $70.
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