Dodge G360 Transmission

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Convert your Dodge G360 to an Allison

Transform Your Drive: Making the Switch to an Allison 1000PK Transmission

Configure your truck

Introducing the ultimate upgrade for your vehicle: the Dodge G360 to Allison 1000PK transmission conversion. Designed for unparalleled performance and durability, this conversion transforms your driving experience, offering smoother gear shifts, enhanced fuel efficiency, and exceptional towing capabilities. Ideal for Dodge truck owners who demand nothing short of the best, this conversion provides the legendary reliability and performance that Allison transmissions are renowned for. Whether you’re tackling tough terrain, hauling heavy loads, or simply seeking a more responsive and satisfying drive, the G360 to Allison 1000PK conversion is the game-changing solution you’ve been waiting for. Upgrade today and experience the difference of world-class engineering at your fingertips.

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G360 Transmission: An Overview, Key Features, and Common Concerns

Overview of the G360 Transmission

The Dodge G360 is a five-speed manual transmission designed by Getrag and used exclusively in Dodge Ram 2500 and 3500 trucks, typically paired with Cummins diesel engines, from 1989 to 1993. Renowned for its strength and durability, the G360 was designed to handle the substantial torque produced by the Cummins engine, making it ideal for heavy-duty applications, from towing hefty payloads to challenging off-road terrain.

With its fully synchronized gears, the G360 provides smooth and precise shifting, allowing drivers to have a greater level of control over their vehicle’s performance and fuel efficiency. Its robust construction, featuring a cast iron case and generous use of bearings instead of bushings, speaks to the transmission’s durability and functionality. The G360’s gear ratio spread is designed for a perfect balance, offering a low first gear for heavy hauling and a tall fifth gear enabling fuel-efficient highway cruising.

In today's world, where manual transmissions are becoming increasingly rare in trucks, the G360 holds a special appeal. It is a nod to a time when driving a truck was a more tactile and engaging experience. For those who value this direct connection between driver and vehicle, and who are willing to forgo the convenience of an automatic, the G360 remains a respected and sought-after choice.

G360 Features

The Dodge G360 transmission, built for heavy-duty Ram trucks, is celebrated for its ability to handle high-torque applications due to its strong and durable design. Here are some of its key features:

  • High Torque Capacity: Engineered specifically for heavy-duty applications, the G360 is designed to handle substantial levels of torque, making it ideal for towing and hauling substantial loads.
  • Fully Synchronized Gears: The G360 features fully synchronized gears, which facilitates smoother and more precise shifting, enhancing the driving experience.
  • Durable Construction: With its cast iron case and extensive use of bearings, the G360 is built to withstand the rigors of heavy-duty truck use, promising longevity and reliability.
  • Optimal Gear Ratio Spread: The G360's gear ratios are intelligently spaced, allowing for powerful low-end torque for hauling, while still enabling fuel-efficient highway travel.
  • Clutch Engagement: The G360 typically employs a robust clutch setup, which provides strong and reliable engagement, critical for heavy-duty applications.
  • Engaging Driving Experience: As a manual transmission, the G360 offers drivers a more tactile and connected driving experience that automatic transmissions often can't replicate.
  • Aftermarket Support: Its longevity in the market has led to robust aftermarket support for the G360, including a variety of parts and upgrade options that allow owners to customize and improve their transmission's performance.

In summary, the Dodge G360 is a robust, reliable, and engaging manual transmission, designed to meet the demands of heavy-duty truck applications with its unique blend of strength, durability, and driver control.

G360 Common Issues and Signs of Failures

While the Dodge G360 transmission was designed for durability and performance in heavy-duty applications, it is not without its potential issues. As with any mechanical component, wear and tear over time can lead to problems. Here are some common issues associated with the G360 transmission, along with signs that it might be failing:

  • Synchro Wear: Over time, the synchronizers, which help the gears in the transmission mesh smoothly, can wear down. This can lead to hard shifting, grinding noises when changing gears, and potentially gears popping out of place.
  • Input Shaft Wear: The input shaft can suffer from wear, especially under heavy loads. Signs of a failing input shaft might include noisy operation in certain gears or difficulty engaging gears.
  • Bearing Failures: The G360's bearings can wear out over time. This typically results in noisy operation, including whining or grinding sounds.
  • Oil Contamination and Lubrication Issues: Proper lubrication is critical for the G360. If incorrect or contaminated fluid is used, it can lead to accelerated wear and potential failure. Signs of this might include noisy operation, hard shifting, and excessive heat.
  • Weak Fifth Gear Nut: A known issue with some G360 transmissions is the fifth gear nut loosening and backing off. This can lead to fifth gear becoming inoperative and may cause additional damage if not addressed promptly.
  • Clutch Problems: Due to the heavy-duty applications this transmission is often subjected to, the clutch can wear out or fail, resulting in difficulty shifting, complete loss of drive, or a soft or spongy clutch pedal.
  • Shift Fork Wear: The shift forks, which are used to engage the various gears, can wear or break. This typically results in difficulty shifting into or staying in certain gears.
  • Case Flex and Cracking: Under extremely heavy loads, the case of the G360 can flex, which may lead to misalignment of internal components and potential cracking of the case itself. This is generally accompanied by leaking fluid and noisy operation.
  • Overheating: Heavy towing and hauling can lead to excessive heat, which is a common killer of transmissions. Overheating can lead to warped components, fluid breakdown, and eventual transmission failure.
  • Gears or Shaft Breakage: Under extreme stress, particularly in situations of shock loading (sudden application of high torque), the gears or shafts inside the G360 may break. This will result in a sudden loss of drive and likely loud noises from the transmission.

It is worth noting that regular maintenance, including proper lubrication with the correct transmission fluid and timely replacement of worn components, can significantly extend the life of a G360 transmission and prevent many of these issues.

When experiencing any of these symptoms, it is advisable to consult with a professional mechanic or transmission specialist to diagnose and address the problem before it leads to a complete transmission failure.

Your Guide to Rebuilding, Replacing, and Upgrading to an Allison Transmission

Rebuild, Replace, Converting to an Allison

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Convert to Allison
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Converting to an Allison 1000PK Transmission

Converting from the Dodge G360 to an Allison 1000PK transmission is a complex process, requiring careful planning, specialized tools, and expertise in transmission swaps. The conversion encompasses more than just the physical transmission. Here's an outline of the steps involved:

  1. Research and Planning

    • Determine the compatibility of the Allison 1000PK with your vehicle's engine and drivetrain.
    • Ensure you have access to any necessary custom parts or kits designed for this conversion.
    • Compile a comprehensive list of parts and tools required for the job.
  2. Acquire Necessary Parts

    • Purchase the Allison 1000PK transmission.
    • Acquire a new or modified bell housing compatible with your engine.
    • Obtain a suitable transmission control module (TCM) for the Allison.
    • Get any required wiring harnesses, adapters, and connectors.
    • Source an upgraded or suitable transmission cooler.
  3. Removal of G360

    • Disconnect the battery.
    • Drain the transmission fluid.
    • Disconnect the transmission linkage, driveshaft, and any associated wiring or hydraulic connections.
    • Remove the G360 transmission from the vehicle.
  4. Preparation and Modification

    • Check the vehicle's transmission tunnel for adequate space. Modify or fabricate as necessary to accommodate the Allison 1000PK.
    • If the existing motor mounts, crossmembers, or transmission mounts are incompatible, install or fabricate new ones.
  5. Install the Allison 1000PK

    • Position the new transmission using a transmission jack and bolt it to the engine using the appropriate bell housing.
    • Ensure all connections are secure, including any mechanical linkage or hydraulic lines, if applicable.
  6. Electronics and Wiring

    • Install the TCM in an appropriate location, typically within the vehicle's cabin or engine bay.
    • Route and connect the wiring harness, ensuring all connections are secure.
    • Integrate the Allison's electronics with the vehicle's existing electrical system, making certain the TCM communicates correctly with the engine control unit (ECU).
  7. Cooling System Installation

    • Install the transmission cooler, ensuring it’s adequately positioned for airflow.
    • Connect the transmission cooling lines between the Allison 1000PK and the cooler.
  8. Drive Shaft and Final Connections

    • Depending on the length adjustment requirements, either modify the existing driveshaft or obtain a custom one.
    • Install the driveshaft, ensuring it's correctly aligned and securely connected at both ends.
  9. Fluids and Testing

    • Fill the Allison 1000PK with the recommended transmission fluid.
    • Reconnect the battery.
    • Start the vehicle and test all gear positions for correct operation.
    • Take the vehicle for a test drive, ensuring the transmission shifts smoothly and the TCM functions correctly.
  10. Final Adjustments

    • After the test drive, check for any leaks, noises, or irregularities.
    • Make any necessary adjustments to the linkage, wiring, or other components.

Documentation and Legal Considerations:

  • Ensure all changes to the vehicle are documented for future reference or resale.
  • Check with local regulations to ensure the conversion is compliant with emissions, safety, or other legal requirements.

Due to the complexity of this conversion, it's highly recommended to work with a mechanic or shop that has experience with transmission swaps, particularly from manual to automatic systems. Properly executed, this conversion can result in a vehicle that harnesses the reliability and performance of the Allison 1000PK.

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G360 Rebuild

Rebuilding the Dodge G360 Transmission

Rebuilding a G360 transmission is a detailed process that involves careful planning, specific tools, and extensive knowledge of transmission systems. The goal is to restore the transmission to optimal performance. Here's an outline of the steps involved:

  1. Preparation and Assessment

    • Obtain a factory service manual specific to the G360 transmission for guidance and specifications.
    • Compile a comprehensive list of tools and parts you will need for the rebuild.
    • Assess the condition of your G360 transmission to determine the extent of the rebuild required.
  2. Disassembly

    • Carefully disassemble the G360 transmission, keeping track of all components and their orientation.
    • Clean all components thoroughly and inspect for wear or damage.
    • Organize and label parts to ensure proper reassembly.
  3. Inspection and Parts Replacement

    • Inspect all gears, bearings, synchros, and seals for wear. Replace components as necessary.
    • Check shafts for straightness and surfaces for wear or pitting.
    • Replace any worn or damaged components with new or quality used parts.
  4. Reassembly

    • Following the service manual, meticulously reassemble the G360 transmission with the new and inspected components.
    • Ensure that all components are installed in their correct orientation and order.
    • Apply the appropriate lubricants and sealants as you reassemble the unit.
  5. Final Inspection and Adjustment

    • After reassembly, double-check your work to ensure everything is in its correct place and adjusted according to specifications.
    • Rotate the shafts and shift through the gears to ensure smooth and proper operation.
  6. Installation

    • Reinstall the rebuilt G360 transmission into the vehicle.
    • Reconnect all linkages, driveshafts, and other components.
  7. Fluids and Testing

    • Fill the G360 with the recommended transmission fluid.
    • Test the transmission for correct operation in all gears and ranges.
    • Perform a test drive to ensure that the rebuilt transmission operates smoothly and without noise.
  8. Final Adjustments and Break-in

    • After the test drive, check for leaks or issues.
    • Make any necessary final adjustments and follow any break-in procedures recommended in the service manual.

Documentation:

  • Keep detailed records of all work performed and parts replaced during the rebuild for future reference or resale.

Rebuilding a G360 transmission is a complex task, requiring a high level of mechanical knowledge and attention to detail. It’s strongly advised to work with a professional mechanic experienced in transmission rebuilds or to have the rebuilt transmission inspected by a professional before returning the vehicle to regular service.

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Replace G360

Replacing the Dodge G360 Transmission

Replacing a G360 transmission is a significant task that involves removing the existing unit and installing a new or refurbished one. Here's an outline of the steps involved:

  1. Preparation and Assessment

    • Research and ensure that the replacement transmission is compatible with your vehicle's make, model, and engine configuration.
    • Compile a comprehensive list of tools and parts you will need for the replacement.
    • Ensure a safe and clean workspace for the replacement procedure.
  2. Removal of the Old G360 Transmission

    • Disconnect the battery.
    • Drain the transmission fluid from the existing unit.
    • Remove the shift lever, linkage, driveshaft, and any associated wiring or hydraulic connections.
    • Support the engine and carefully remove the old G360 transmission from the vehicle.
  3. Installation of the New or Rebuilt G360 Transmission

    • Prepare the replacement transmission by ensuring it is clean, intact, and filled with the appropriate fluid.
    • Carefully align the replacement transmission with the engine and install using a transmission jack, ensuring all connections are secure.
    • Install the bell housing, ensuring it is properly torqued to specification.
  4. Reconnecting Components

    • Reinstall the shift lever and linkage, ensuring they are adjusted and operate smoothly.
    • Reconnect the driveshaft, ensuring it's correctly aligned and securely connected at both ends.
    • Reconnect any wiring or hydraulic connections associated with the transmission.
  5. Fluids and Testing

    • Fill the new or rebuilt G360 transmission with the recommended transmission fluid.
    • Reconnect the battery.
    • Start the vehicle and test all gear positions for correct operation.
    • Take the vehicle for a test drive, ensuring the transmission shifts smoothly.
  6. Final Adjustments and Inspection

    • After the test drive, check for any leaks, noises, or irregularities.
    • Make any necessary adjustments to the linkage, fluid levels, or other components.

Documentation and Legal Considerations:

  • Ensure all changes to the vehicle are documented for future reference or resale.
  • Check with local regulations to ensure the replacement is compliant with emissions, safety, or other legal requirements.

Due to the complexity of replacing a transmission, it is highly recommended to work with a mechanic or shop that has experience with such procedures. Properly executed, this replacement can restore your vehicle to optimal transmission performance and extend its service life.

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Benefits of converting to an Allison 1000PK Transmission

Converting a Dodge G360 transmission to an Allison 1000PK is a significant undertaking, but it can offer a range of benefits for drivers seeking enhanced performance, reliability, and other advantages. Below are some key benefits of making this conversion:

Enhanced Durability and Reliability

The Allison 1000PK is known for its exceptional durability and is built to handle heavy-duty applications. It is designed to endure substantial stress, making it a reliable choice for those who use their vehicle for towing or hauling heavy loads.

Improved Fuel Efficiency

The Allison 1000PK features a more advanced and efficient design compared to the G360, potentially leading to better fuel economy. Its locking torque converter and higher overdrive gear can reduce engine RPM at highway speeds, saving fuel.

Ease of Use and Comfort

Switching from a manual G360 to an automatic Allison 1000PK can make driving more convenient and comfortable, especially in stop-and-go traffic or over long distances. The automatic shifting eliminates the need for constant manual gear changes, reducing driver fatigue.

Enhanced Towing and Hauling Capabilities

The Allison 1000PK is designed for heavy-duty use and can provide improved towing and hauling capabilities. It features strong gears and is designed to handle high torque outputs, making it ideal for towing trailers, boats, or other heavy loads.

Increased Vehicle Value

A well-executed conversion to an Allison 1000PK could potentially increase the value of your vehicle. It signifies an upgrade to a newer, more robust and efficient transmission system, which could be a selling point for future buyers.

Adaptability and Customization

The Allison 1000PK can be paired with various aftermarket components, allowing for a high degree of customization. Owners can fine-tune their setup for specific performance characteristics, whether they prioritize fuel efficiency, towing capacity, or high-speed performance.

Lower Maintenance Costs

In many cases, the Allison 1000PK can be more robust and require less frequent repair and maintenance than the G360. Its robust design and construction mean that, once installed, it could result in lower long-term maintenance costs.

What's included in an Allison Conversion kit?

We provide everything you will need to get the swap done right

Duramax with Allison Transmission
    • Kit Includes
    • Transmission
      Torque Converter
      Wiring Harness
      Flex Plate adapter
      Transfer Case
      Mounting Kit
      Cooling Kit
      Digital Display
      Allison TCM
      CAC TCM
Allison 1000PK Transmission

Allison 1000PK Transmission

Upgrade your vehicle's capabilities with the esteemed Allison 1000PK Transmission. You have the option to either include this component in your kit purchase or use your own pre-acquired Allison 1000PK transmission. To cater to your needs, we also provide transmission rebuilding services. Explore a comprehensive selection of other Allison transmissions here that we can expertly convert.

How to determine the Right Torque Converter

Maximizing Performance: Using Tire Diameter and Gear Ratio Calculations to Choose the Ideal Torque Converter

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How to determine the right torque converter

FAQ'S

Converting your Dodge Ram's transmission to an Allison can result in numerous benefits including improved durability, enhanced towing capability, increased fuel efficiency, and smoother gear shifts, thus optimizing your vehicle's performance.

Most Dodge Ram models can benefit from an Allison transmission conversion, but it's advisable to consult with a specialist to ensure compatibility with your specific model.

Yes, with the right adapters, your existing Dodge Ram transfer case can be utilized in an Allison conversion.

The Allison 1000 series is a popular choice for Dodge Ram vehicles due to its reliability and performance, but the best option depends on your particular needs and vehicle model.

The conversion process involves removing your Dodge Ram's current transmission, fitting the Allison transmission with the necessary adapters, and installing it. The wiring harness, TCM, and other components are also adjusted accordingly.

Yes, an Allison transmission is designed to provide smoother shifts, increased durability, and better fuel efficiency, all of which contribute to improved vehicle performance.

An Allison conversion kit typically includes components such as the transmission (if chosen), TCM, torque converter, wiring harness, adapters, and other necessary parts for the conversion.

You have the option to either provide your own Allison transmission or include it with your conversion kit purchase.

While it's possible for experienced individuals to do the conversion, it's generally recommended to hire a professional to ensure the job is done correctly and safely.

The conversion time can vary based on the vehicle and the specific conversion kit. On average, it might take a few days to complete.

An Allison conversion could affect your vehicle's warranty depending on the specific terms of your warranty agreement. We recommend checking with your warranty provider before proceeding with the conversion.

If you face any problems after the conversion, it's best to contact your conversion specialist for troubleshooting assistance or potential service needs.

Yes, an Allison transmission from another vehicle can be used, provided it's compatible with your Dodge Ram model. Ensure to consult with your conversion specialist before proceeding.

Yes, we do offer rebuilding services for Allison transmissions, ensuring your transmission is operating at peak performance.

The cost can vary significantly depending on the specific Allison model, whether you're providing the transmission or purchasing it as part of the kit, and any additional services required. Please contact us directly for a more precise estimate.

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Financing Available

Financing is available, so that you can get on the road faster

3524 Garcon Point Road

Milton, FL 32583

caconversions@gmail.com

(865) 253-1133