NHTSA ID Number: 10075606
Manufacturer Communication Number: SIL 10-1K2K-09 D
TSB/Document Date: 2016-07-07
Summary
SUMMARY TO BE PROVIDED ON A FUTURE DATE.
Revisions to this document are noted
by a stripe in the lefthand margin
SUBJECT:
SIL 101K2K09, Rev. D
November, 2015
Product Code(s):
Page 1 of 62
2010 Uprate Hardware Modifications
MODELS AFFECTED:
1000 and 2000 Product Families Transmissions
SERIAL NUMBERS AFFECTED:
S/N 6310972823 (First 2010 Uprate S/N)
S/N 6310988346 (Final Pre 2010 Uprate S/N)
Introduction
Hardware modifications occurred for the 2010 Uprate at the start of production (12/09) for the 1000 and 2000
Product Families Transmissions equipped with Allison 4th Generation Controls. Changes have been implemented
in the Torque Converter, Planetary Gear, Rear Cover, Oil Pan, Oil Pump and Control Valve groups.
Some of the parts detailed in this SIL were early released into production starting in July of 2009. These parts were
previously described in the 2010 1K2K Hardware Early Release SIL 161K2K09.
This former design, Pre 2010 Uprate with the early release 2010 Uprate parts will be produced until the second
quarter of 2010.
Additional information detailing 2010 Uprate changes and Allison 4th Generation Controls are available in the
following publications:
• WATCH 396
• SIL 131K2K09
• www.allisontransmission.com
SD / SL5805EN
2982712
Copyright © 2015 Allison Transmission, Inc. All Rights Reserved.
SIL 101K2K09, Rev. D
November, 2015
Product Code(s):
Page 2 of 62
Torque Converter (21 Group)
Table 1. Torque Converter
Part Name
Pre 2010 Uprate P/N
2010 Uprate P/N
Description of Change
Torque Converter TC 211
29549522
29546573
New TCC design. Is not
interchangeable backwards
Torque Converter TC 210
29549521
29546574
New TCC design. Is not
interchangeable backwards
Torque Converter TC 221
29549519
29546576
New TCC design. Is not
interchangeable backwards
Torque Converter TC 222
29549520
29546575
New TCC design. Is not
interchangeable backwards
Interchangeability:
All models of the current 2010 Uprate Torque Converters listed in Table 1 are not interchangeable with the
former Pre 2010 Uprate design.
Parts Modifications:
The 2010 Uprate Torque Converters include a dual friction lockup clutch and are distinguished from the Pre2010
Uprate Torque Converter by the Swedge Marks on the Torque Converter front cover as seen in Figure 1.
Service Parts Information:
The former Pre 2010 have been cancelled for production and maintained for service. The former Pre 2010 Uprate
Torque Converters and the current 2010 Uprate Torque Converters will be available for order from the Allison PDC.
Copyright © 2015 Allison Transmission, Inc. All Rights Reserved.
SIL 101K2K09, Rev. D
November, 2015
Product Code(s):
Page 3 of 62
Figure 1. Torque Converter
Copyright © 2015 Allison Transmission, Inc. All Rights Reserved.
SIL 101K2K09, Rev. D
November, 2015
Product Code(s):
Page 4 of 62
Main Case (01 Group)
Table 2. Main Case
Part Name
Pre 2010 Uprate P/N
2010 Uprate P/N
Description of Change
C3/C4 Piston
29543321
29546697
Orifice size change and new design
C3/C4 Spring/
Plate Assembly
29542192 / 29542191
29546698
Integral spring assembly
C3/C4 Friction
Plates
29531049 (C3 requires 4)
(C4 requires 5)
29546270 (C3 requires 4)
(C4 requires 6)
Friction plates are a wave plate
design of narrower thickness.
Increased number of friction plates
are required for C4.
C3/C4 Reaction
Plates
29531048 (C3 requires 3)
(C4 requires 4)
29546701 (C3 requires 4)
(C4 requires 6)
Quantity change required for C3/C4
Clearance for integral spring assembly
C3 Backing Plate
Assembly
29535648
29546702
Thicker
C4 Backing Plate
29535640
29546271
Thinner
Interchangeability:
Current 2010 Uprate parts listed in Table 2 are not interchangeable backwards with the Pre 2010 Uprate parts with
the exception of the C3/C4 Reaction Plates P/N 29546701.
Parts Modifications:
The C3/C4 Clutch Reaction Plate, Friction Plate, Backing Plates and spring assembly modifications have been
made to increase clutch capacity for the 2010 Uprate transmission increased torque ratings. These changes are
also calibration sensitive.
Service Parts Information:
The former Pre 2010 Uprate parts have been cancelled for production and maintained for service, except for
C3/C4 Reaction Plates P/N 29531048, which will be completely cancelled but can be replaced by the current
2010 Uprate C3/C4 Reaction Plates P/N 29546701. All other former Pre 2010 Uprate parts will be available
for order from the Allison PDC,
CAUTION: The current 2010 Uprate parts listed in Table 2 (Main Case) can be physically installed in
Pre 2010 Uprate transmissions. However, a mix of pre2010 Uprate and 2010 Uprate parts will cause
transmission damage.
Copyright © 2015 Allison Transmission, Inc. All Rights Reserved.
SIL 101K2K09, Rev. D
November, 2015
Product Code(s):
Page 5 of 62
Figure 2. C3/C4 Piston
Copyright © 2015 Allison Transmission, Inc. All Rights Reserved.
SIL 101K2K09, Rev. D
November, 2015
Product Code(s):
Page 6 of 62
Figure 3. C3/C4 Spring Plate Assembly
Copyright © 2015 Allison Transmission, Inc. All Rights Reserved.
SIL 101K2K09, Rev. D
November, 2015
Product Code(s):
Page 7 of 62
Figure 4. C3/C4 Friction Plate
Copyright © 2015 Allison Transmission, Inc. All Rights Reserved.
SIL 101K2K09, Rev. D
November, 2015
Product Code(s):
Page 8 of 62
Figure 5. C3/C4 Reaction Plate
Copyright © 2015 Allison Transmission, Inc. All Rights Reserved.
SIL 101K2K09, Rev. D
November, 2015
Product Code(s):
Page 9 of 62
Figure 6. C3 Backing Plate Assembly
Copyright © 2015 Allison Transmission, Inc. All Rights Reserved.
SIL 101K2K09, Rev. D
November, 2015
Product Code(s):
Page 10 of 62
Figure 7. C4 Backing Plate
Copyright © 2015 Allison Transmission, Inc. All Rights Reserved.
SIL 101K2K09, Rev. D
November, 2015
Product Code(s):
Page 11 of 62
Converter Housing (34 Group)
Table 3. Converter Housing
Part Name
Pre Jan 2010 P/N
Jan 2010 P/N
Description of Change
Converter Housing
SAE #3 (#12)
29536810
29547463
SAE #12 Integral Cooler Ports
Converter Housing
SAE #3 (#8)
29538610
29547463
SAE #12 Integral Cooler Ports
Converter Housing
SAE #2
29536710
29547462
SAE #12 Integral Cooler Ports
Cooler Manifold
29536297
N/A
No longer part of integral converter housing
Cooler Manifold Gasket
29531189
N/A
No longer part of integral converter housing
Cooler Manifold
Channel Plate
29531190
N/A
No longer part of integral converter housing
Interchangeability:
All models of the current 2010 Uprate Converter Housings listed in Table 3 are interchangeable backwards
providing the, "to and from", transmission cooler lines can be adapted to fit (if required).
Parts Modifications:
The Converter Housing Cooler Manifold has been removed from the 2010 Uprate design making transmission
cooler ports integral to the Converter Housing.
Service Parts Information:
The Converter Housing is a use stock change. Once stock is depleted the 2010 Uprate parts will be available for
order from the Allison PDC. The Cooler Manifold, Cooler Manifold Gasket and Cooler Manifold Channel Plate have
been cancelled from production, maintained for service, and are available for purchase from the Allison PDC.
Copyright © 2015 Allison Transmission, Inc. All Rights Reserved.
SIL 101K2K09, Rev. D
November, 2015
Product Code(s):
Page 12 of 62
Figure 8. Converter Housing SAE #3 (#12 Cooler Ports)
Copyright © 2015 Allison Transmission, Inc. All Rights Reserved.
SIL 101K2K09, Rev. D
November, 2015
Product Code(s):
Page 13 of 62
Figure 9. Converter Housing SAE #3 (#8 Cooler Ports – Former and #12 Cooler Ports – Current)
Copyright © 2015 Allison Transmission, Inc. All Rights Reserved.
SIL 101K2K09, Rev. D
November, 2015
Product Code(s):
Page 14 of 62
Figure 10. Converter Housing SAE #2
Copyright © 2015 Allison Transmission, Inc. All Rights Reserved.
SIL 101K2K09, Rev. D
November, 2015
Product Code(s):
Page 15 of 62
Output Shaft Assembly (39 Group)
Table 4. Output Shaft Assembly
Part Name
Pre 2010 Uprate P/N
29536845
Output Shaft Assembly
2010 Uprate P/N
29546744
*
Description of Change
Lube orifice size change
*This part was early released into production in July 2009. See SIL 161K2K09
Interchangeability:
CAUTION: 2010 Uprate shaft parts must be used as a set. Replacing individual shafts with 2010 Uprate
shaft parts to service Pre 2010 Uprate transmissions, so that a mix of Pre 2010 Uprate and 2010 Uprate
shafts are operating together, may cause transmission damage.
2010 Uprate shafts must be operated in sets to achieve reduced spin losses and maintain balanced lube pressure.
The set includes Ground Sleeve, Turbine Shaft Assembly, Main Shaft, and Output Shaft Assembly.
Parts Modifications:
The lube hole is step drilled to reduce the diameter of the lube orifice.
Service Parts Information:
All Pre 2010 Uprate shafts will be completely cancelled from production and maintained for service. The Pre 2010
Uprate shafts will be available for purchase from the Allison PDC.
Copyright © 2015 Allison Transmission, Inc. All Rights Reserved.
SIL 101K2K09, Rev. D
November, 2015
Product Code(s):
Page 16 of 62
Figure 11. Output Shaft Assembly
Copyright © 2015 Allison Transmission, Inc. All Rights Reserved.
SIL 101K2K09, Rev. D
November, 2015
Product Code(s):
Page 17 of 62
Main Suction Filter (37 Group)
Table 5. Main Suction Filter
Part Name
Pre 2010 Uprate P/N
Suction Filter – Shallow Pan
29537965
29542833
*
Increased filtration capacity
and lower flow restriction
Suction Filter – Standard Pan
29537966
29542824
*
Increased filtration capacity
and lower flow restriction
2010 Uprate P/N
Description of Change
*This part was early released into production in July 2009. See SIL 161K2K09
Interchangeability:
The 2010 Uprate Standard Pan Suction Filter P/N 29542824 listed in Table 5 is completely interchangeable
backwards. The current Shallow Pan Suction Filter P/N 29542833 listed in Table 5 is only interchangeable
backwards to MY06 GenIV Controls. For more information please reference SIL 12–1K2K–10.
Parts Modifications:
The 2010 Uprate suction filters have been redesigned to accommodate the 2010 Uprate valve body configuration.
Refer to Figure 12 and Figure 13.
Service Parts Information:
The former Standard Pan Suction Filter, P/N 29537966, has been completely cancelled. The current Standard
Pan Suction Filter, P/N 29542824, is available for purchase from the Allison PDC. Both the former Shallow Pan
Suction Filter, P/N 29537965, and the current Shallow Pan Suction Filter, P/N 29542833, will be available for
purchase from the Allison PDC.
Copyright © 2015 Allison Transmission, Inc. All Rights Reserved.
SIL 101K2K09, Rev. D
November, 2015
Product Code(s):
Page 18 of 62
Figure 12. Suction Filter Shallow Pan
Copyright © 2015 Allison Transmission, Inc. All Rights Reserved.
SIL 101K2K09, Rev. D
November, 2015
Product Code(s):
Page 19 of 62
Figure 13. Suction Filter Standard Pan
Copyright © 2015 Allison Transmission, Inc. All Rights Reserved.
SIL 101K2K09, Rev. D
November, 2015
Product Code(s):
Page 20 of 62
Rotating Clutch With and Without PTO (14 group)
Table 6. Rotating Clutch with and without PTO
Part Name
Pre 2010 Uprate
P/N
Clutch and Shaft Assy
— Rotating, PTO
29545811
29549726*
Housing and PTO Gear
Assembly
29542802
Clutch and Shaft Assy —
Rotating nonPTO
29545812
29549727*
Housing and Tone Wheel
Assembly
29542804
29547425
*
Reduced size lube orifice
Housing Assembly
and Bushing
29542699
29546704
*
Reduced size lube orifice
Rotating Clutch Housing
29542700
29546585
*
Reduced size lube orifice
C1 Friction Plate
29538468 (6)
29546276 (7)
Changes to accommodate increased horsepower
and torque ratings (thinner friction plate thickness)
C1 Reaction Plate
29530314 (6)
29530314 (7)
Changes to accommodate increased horsepower
and torque ratings
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TSB/Document ID: SIL 10-1K2K-09 D
Replacement Service Bulletin Number:
MFR Communication Date: 2015-11-01
MFR Internal Campaign ID/Software Version:
Communication Type: Service Bulletin/Repair Instructions
NHTSA Components: POWER TRAIN:AUTOMATIC TRANSMISSION
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