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Allison Transmission service
You can get MOST of the fluid out of the auto tranny yourself. I don't have an Allison but I have a PSD and this is the way I did it. Mine also didn't require changing the screen so no pan drop was needed. I disconnected one of the return lines to the tranny and slipped a clear plastic hose over it. I then clamped that hose to a large bucket. Run the truck until you see some are bubbles in the hose,( a few seconds... maybe 10-20) shut it down. Add tranny fluid equal to what came out. Repeat until you have added and removed the ammount the tranny holds. I went a little extra just to be sure I got all the old out. With synthetics that could be expensive to use extra just to insure a good flush.
The process is pretty much the same as the flush machines at Jiffy lube. You will get 90% out and you will see the nice color the fluid has.
This where I got the idea.
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Allison Transmission service
I used the regular transmission fluid not synthetic. I ran about 4 quarts extra through just to get a good flush. It still cost under 30 dollars to do and at least I know it was done right with quality fluids unlike the quicky lube joints  I change the fluid every 20-25K and it looks almost as good going out as it did going in. Cheap insurance.
I did the Dana 80 rear-end in my truck I used that aerosol can gasket maker (Black Magic?) that comes in the Cheeze Wiz type can. 2 years and still holding strong. Used a stiff nylon brush paint remover attachment on the end of a cordless drill to scrape off the old gasket.
For the front diff. I just suctioned it and added fluid, it looked new anyway. Used a stiff nylon brush paint remover attachment on the end of a cordless drill to scrape off the old gasket.
Guess you might be changing the transfer case fluid also. That was easy, top plug for filling bottom plug for draining. Don't know about Chevy but on the Ford you need to fashion a "funnel" out of aluminum foil to stop the transfer case fluid from landing on the skid plate.
Chief,
you are right about the mess...I made one. If you had 2 people it would be a snap and this wouldn't have happened. They can start and stop the truck and you can make sure you hit the pail and it doesn't overflow. I had to run a line over to the drivers side and sit 1/2 out of the seat while I monitored the flow.
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Allison Transmission service
Oh, yeah I forgot the 50 hr service. Here's' how it came out, the first price is the JD and the second is what I would have paid for like substitutes of good quality.
JD Plus 50 15-40 7.50 gallon Delo 400 6.50
JD (fleetguard) hydr. filter 17.00 Wix or Hastings 23.00
JD (Fleetguard) oil filter 5.99 Mobil 1 11.99
JD Lo-Vis hydraulic fluid 35.00 five gallons Others? 25.00
So Chief, it was just about a wash and I got all JD parts so nobody can argue I didn't use the right stuff. Don't think my other choices would have been any lessor in quality but why mix and match when the dealer had it all under one roof. Also they have a record of all my purchese under my account in case I have a catastrophic failure and maintenance is called into question. You can't be too safe 
The synthetic choice was made for me when my JD dealer laughed and said he can't get any Synthetic 0-40 it is sold out. Says he's been having a problem getting that and another oil they use in big tractors. So next oil change I'll switch to 0-40. Would have been nice to have it for the cold winter but I'm sure my tractor will survive
As we discussed I plan on doing the fluid/filter changes at the beginning of every spring season even if I don't make the 200 hours.
I also have some kind of suction gun I got from an autoparts store years ago. In a pinch( when I lose the right tool) I have also used those hand operated suction pumps that you use to fill kerosene heaters.
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Allison Transmission service
No that form a gasket makes a perfect seal. All you do is apply it, let it set according to directions (5 minutes?) and then put the cover on. It is just starting to get a little firm and then the even pressure of tightening all bolts a little at a time creates the gasket. I think it is better, I have never had a problem and I can't say the same for some of those cheap gaskets some companies make. I think I read on another forum that Dana does make a gasket for the Dana 80 but in the Ford application they use gasket maker.
Whatever rearend the Chevy has I can't see you having any problem with the gasket maker. I am suprised the fluid was gunky especially in the front as most of us don't use 4 wheel THAT often and really beat on the front end. You MUST BE deep in the woods I wouldn't worry too much I remeber some guys making comments that their factory Ford fluid was green nasty looking stuff.
Don't forget your limited slip fluid if the rear end calls for it. I use the Dodge stuff after several people on the Ford truck forum said the thought it was better than the Ford stuff. No chatter when turning they said.
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Allison Transmission service
I don't want to steer you wrong. My Chevy van does not have LS so I don't know. Maybe with the synthetic they call for you don't need the limited slip additive. I can remeber some Ford guys saying that they ran Amsoil synthetic rear-end fluid and with it you didn't need LS additive.
I can only say my Ford called for synthetic AND additive. I am sure another Chevy owner will have the answer.
Sorry
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That's what I thought Chief. i rmembered the AMsoil not needing it.
I love the looks you get at the local supermarket parking lot when you go and do the figure 8's With these trucks an airport might be better, darn turning radius is HUGE.
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