NHTSA ID Number: 10152812
Manufacturer Communication Number: SIL 27-EP-18EN
TSB/Document Date: 2019-02-19
Summary
Announces the availability of the DC busbar and procedures for replacing the DC busbar located inside the DPIM2
SIL 27-EP-18
January, 2019
Page 17 of 38
Figure 24. GATE Drive Card Locking Tab Locations
NOTE: If the spring pin sticks to the underside of the card, do not attempt to dislodge the spring from the
card until the card has been completely removed. No loose pins should be left in the DPIM.
4. Verify that all fifteen (15) spring pins are still present in each SKiM module (refer to Figure 25).
Copyright © 2019 Allison Transmission, Inc. All Rights Reserved.
SIL 27-EP-18
January, 2019
Page 18 of 38
Figure 25. SKiM Spring Pins Locations
5. If any spring pins are stuck to the bottom of the card (refer to Figure 26), remove them from the solder pad
taking care not to bend or lose the pin. Reinstall the spring pin into the corresponding hole in the SKiM
module (refer to Figure 25).
Figure 26. Spring Pins Stuck to GATE Drive Card Solder Pads
6. Using a 4mm hex key, remove the six (6) black M6x10mm screws from each SKiM Module (refer to
Figure 27).
Copyright © 2019 Allison Transmission, Inc. All Rights Reserved.
SIL 27-EP-18
January, 2019
Page 19 of 38
Figure 27. SKiM Module Fastener Locations
7. Using a 4mm hex key, remove the three (3) silver M6x12mm screws from each SKiM Module (refer to
Figure 28).
Figure 28. SKiM Module Fastener Locations
8. Remove all eighteen (18) capacitors from the six (6) SKiM modules and set them aside (refer to Figure 29).
Copyright © 2019 Allison Transmission, Inc. All Rights Reserved.
SIL 27-EP-18
January, 2019
Page 20 of 38
Figure 29. Capacitor Removal
9. Remove the DC choke and set it aside (refer to Figure 30).
Figure 30. Choke Removal
Copyright © 2019 Allison Transmission, Inc. All Rights Reserved.
SIL 27-EP-18
January, 2019
Page 21 of 38
Section 4: DC Busbar Removal
1. Remove the eighteen (18) white protective caps from the capacitor studs (refer to Figure 31).
Figure 31. Protective Cap Removal
2. Using a 13mm hex socket, remove the eighteen (18) 8mm hex nuts, the eighteen (18) lock washers, and the
eighteen (18) flat washers from the capacitor studs (refer to Figure 32).
Copyright © 2019 Allison Transmission, Inc. All Rights Reserved.
SIL 27-EP-18
January, 2019
Page 22 of 38
Figure 32. Capacitor Stud Hardware Removal
3. Lift the DC Busbar up evenly and off the capacitor studs. Use care to prevent any debris from falling into the
DPIM during removal.
4. With the DC Busbar removed and wearing the electrostatic discharge wrist strap, use a vacuum to remove
any dust, dirt, or debris from the DPIM. Save any loose hardware parts that may be under the DC busbar in
between the capacitors (refer to Figure 33).
Copyright © 2019 Allison Transmission, Inc. All Rights Reserved.
SIL 27-EP-18
January, 2019
Page 23 of 38
Figure 33. Loose Hardware Under DC Busbar (White Cap)
Copyright © 2019 Allison Transmission, Inc. All Rights Reserved.
SIL 27-EP-18
January, 2019
Page 24 of 38
Section 5: Installation of DC Busbar
1. Align the DC busbar over the capacitor studs and evenly lower the DC busbar onto the capacitors. Ensure
that the tabs are aligned with the SKiM modules and the DC Busbar is positioned properly.
CAUTION: Remove any debris that may have been created when installing the DC Busbar onto the
capacitor studs. Any conductive material left in the DPIM could cause permanent damage to the DPIM.
2. Install eighteen (18) flat washers onto the capacitor studs. If there is a burr sticking up from the flat washer,
install the side with the burr face-down against the DC busbar (refer to Figure 34) to prevent the burr from
coming loose in the DPIM.
Figure 34. Burr on Flat Washer
3. Install eighteen (18) lock washers and 8mm hex nuts onto the capacitor studs. Using a 13mm hex socket
and starting at the center studs, torque the eighteen nuts to 6.8-7.9 N∙m (60-70 lb in) in an expanding
pattern (refer to Figure 36).
CAUTION: Failure to properly torque the capacitor nuts could cause permanent damage to the DPIM.
Copyright © 2019 Allison Transmission, Inc. All Rights Reserved.
SIL 27-EP-18
January, 2019
Page 25 of 38
Figure 35. DC Busbar Torque Pattern
4. Install eighteen (18) white protective caps over the capacitor studs (refer to Figure 36).
Figure 36. Protective Cap Installation
Copyright © 2019 Allison Transmission, Inc. All Rights Reserved.
SIL 27-EP-18
January, 2019
Page 26 of 38
5. Install the DC choke as shown in Figure 37 below. The choke must be installed with the arrow pointing
toward the DC lug box and the arrow label facing up.
Figure 37. DC Choke Installation
Copyright © 2019 Allison Transmission, Inc. All Rights Reserved.
SIL 27-EP-18
January, 2019
Page 27 of 38
Section 6: Installation of GATE Drive Cards
NOTE: Prior to installing the GATE drive card, ensure all fifteen (15) spring pins are properly located
(refer to Figure 42 ).
Figure 38. SKiM Spring Pins Locations
1. Position the eighteen (18) capacitors on the SKiM Modules. Apply one drop of Loctite® 425 or 242
threadlocking compound to the ends of the external threads of each silver M6x12mm screw. Using a 4mm
hexkey, install the eighteen (18) M6x12mm screws (refer to Figure 39). Torque the screws to 6.8-7.3 N∙m
(60.2-64.6 lb in.).
Copyright © 2019 Allison Transmission, Inc. All Rights Reserved.
SIL 27-EP-18
January, 2019
Page 28 of 38
Figure 39. SKiM Module Capacitor Installation
Loctite®
2. Apply one drop of
425 or 242 thread locking compound to the ends of the external threads of each
black M6x10mm screw. Using a 4mm hex key, install the thirty-six (36) M6x10mm screws to the SKiM
Module (refer to Figure 40). Torque the screws to 6.8-7.3 N∙m (60.2-64.6 lb in.).
Figure 40. SKiM Module Fastener Locations
3. Position each GATE Drive Card over the locating hubs on the SKiM module (refer to Figure 41). Carefully
press each GATE Drive Card straight down over the ten (10) white locking tabs (refer to Figure 42) so
the card is fully seated.
NOTE: There are 6 locating hubs on the SKiM module; two (2) on each end of the SKiM module and
two (2) in the center.
Copyright © 2019 Allison Transmission, Inc. All Rights Reserved.
SIL 27-EP-18
January, 2019
Page 29 of 38
CAUTION: Failure to mount the card on the locating hubs correctly can prevent the card from seating
completely causing the card to flex which can cause damage.
Figure 41. Locating Hub Identification on SKiM Module
Figure 42. GATE Drive Card Locking Tab Locations
4. Place the two (2) grounding brackets into position on each of the SKiM modules. Using a Torx Plus® T10 bit,
install the four (4) M3x8mm (fine thread) screws to each GATE Drive Card (refer to Figure 43). Torque all
twelve (12) M3x8mm (fine thread) screws to 0.6-0.8 N∙m (5.3-7.1 lb in.).
Copyright © 2019 Allison Transmission, Inc. All Rights Reserved.
SIL 27-EP-18
January, 2019
Page 30 of 38
Figure 43. GATE Drive Card Fastener Locations (M3x8mm Fine Thread) – Quantity 12
5. Using a Torx Plus® T8 bit, install the twelve (12) M3x8mm (coarse thread) screws to each GATE Drive Card
(refer to Figure 44). Torque all seventy-two (72) M3x8mm (coarse thread) screws to 0.3-0.6 N∙m (2.7-5.3
lb in.).
Copyright © 2019 Allison Transmission, Inc. All Rights Reserved.
SIL 27-EP-18
January, 2019
Page 31 of 38
Figure 44. GATE Drive Card Fastener Locations (M3x8mm Coarse Thread – Quantity 72)
Copyright © 2019 Allison Transmission, Inc. All Rights Reserved.
SIL 27-EP-18
January, 2019
Page 32 of 38
Section 7: Installation of BCA Card Mounting Shelf
1. Feed all tie wraps through the BCA Card Mounting Shelf (refer to Figure 45).
Figure 45. BCA Card Mounting Shelf tie Wrap Location
2. Place the BCA Mounting Shelf onto the side of DPIM chassis as shown in Figure 46.
Figure 46. BCA Mounting Shelf (GATE Drive Card Cable Connectors Shown Circled)
Copyright © 2019 Allison Transmission, Inc. All Rights Reserved.
SIL 27-EP-18
January, 2019
Page 33 of 38
3. Connect three (3) GATE Drive Card Connectors to three (3) GATE Drive Cards (refer to Figure 47) and
install the cable strain relief caps.
Figure 47. GATE Drive Card Cable Connector Installation (BCA Card Cable Connector Shown for Clarity)
4. Move BCA Mounting Shelf to its final location. Using a Torx Plus® T25 bit, install the seven (7) M5x14mm
screws that secure the BCA Mounting Shelf (refer to Figure 48). Torque the seven (7) M5x14mm screws to
3.1-3.5 N·m (27.4-31.0 lb in.).
Figure 48. BCA Mounting Shelf Fastener Locations
5. Install five (5) wire harness connectors to circuit card surface mount connectors (refer to Figure 49,
Figure 50, and Figure 51).
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SIL 27-EP-18
January, 2019
Page 34 of 38
Figure 49. Wire Harness Connector Removal (4 Locations)
Figure 50. Current A, Current B, and Current C Locations
NOTE: Each current sensor phase (A, B, and C) MUST be plugged into the appropriate connector
(CURR A, CURR B, CURR C).
Copyright © 2019 Allison Transmission, Inc. All Rights Reserved.
SIL 27-EP-18
January, 2019
Page 35 of 38
CAUTION: Permanent damage to the H 40/50 EPTM Drive Unit or DPIM can occur if the current sensor
harnesses are plugged into the wrong connectors.
Figure 51. Wire Harness Connector Installation
6. Install NEW wire ties to retain the wire harnesses (refer to Figure 52).
Figure 52. Wire Tie Locations
Copyright © 2019 Allison Transmission, Inc. All Rights Reserved.
SIL 27-EP-18
January, 2019
Page 36 of 38
Section 8: Installation of HVIL Circuit Card and Main Cover
1. Insert one (1) new wire tie into the new HVIL Circuit Card at the same location as shown in Figure 53.
NOTE: To ease assembly, the new wire tie must be inserted through the hole in the circuit card prior to
installation in the DPIM Housing.
Figure 53. HVIL Circuit Card – Wire Tie Location
2. Install HVIL Circuit Card into the DPIM Housing.
NOTE: Ensure that the wire harnesses and individual wires are NOT pinched under the circuit card
during installation.
3. Connect the three (3) wiring harness connectors at locations shown in Figure 54.
Figure 54. HVIL Circuit Card – Three (3) Harness Connector Locations
4. Using a Torx Plus® T25 bit, install and finger tighten the ten (10) M5 screws that secure the HVIL Circuit
Card to the DPIM Housing. Torque all M5 screws to 3.1-3.5 N·m (27-31 lb in). Refer to Figure 55 for
fastener sizes and locations.
Copyright © 2019 Allison Transmission, Inc. All Rights Reserved.
SIL 27-EP-18
January, 2019
Page 37 of 38
Figure 55. HVIL Circuit Card – Fastener Sizes/Locations
5. Install the two (2) wire ring terminals onto the studs at locations shown in Figure 56. Using an 8mm socket,
install four (4) M5 nut/washer assemblies onto the studs as shown in the same figure. Torque the nuts
to 3.1-3.5 N·m (27-31 lb in).
Figure 56. HVIL Circuit Card – Four (4) Mounting Nut/Washer Locations (M5)
6. Secure wiring with new wire ties and clip excess length as required. Refer to Figure 53 and Figure 57 for
wire tie locations.
Figure 57. HVIL Circuit Card – Two (2) Wire Tie Locations
Copyright © 2019 Allison Transmission, Inc. All Rights Reserved.
SIL 27-EP-18
January, 2019
Page 38 of 38
NOTE: Verify that all eighteen (18) white protective caps are installed over the capacitor studs in the
center of the DPIM. Reinstall or replace any missing caps as necessary.
7. Install new Cover Gasket P/N 29540714, included in Electronic Service Kit P/N 29556119. Using a Torx
Plus® T25 bit, install and finger tighten the twenty-six (26) M5x18mm machine screws that secure the Main
Cover to the DPIM Housing as shown in Figure 58. Torque the screws to 3.1-3.5 N·m (27-31 lb in).
Figure 58. DPIM Main Cover
NOTE: For additional information refer to H 40/50 EPTM System Service Manual SM3602EN Appendix E.
8. Complete the DPIM check sheet again to verify the repair before installing the DPIM on the bus.
Torx Plus® is a registered trademark of Acument Intellectual Properties, LLC.
Loctite® is a registered trademark of Henkel IP & Holding GmbH.
Copyright © 2019 Allison Transmission, Inc. All Rights Reserved.
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TSB/Document ID: SIL 27-EP-18EN
Replacement Service Bulletin Number:
MFR Communication Date: 2019-01-13
MFR Internal Campaign ID/Software Version:
Communication Type: Service Bulletin/Repair Instructions
NHTSA Components: ELECTRICAL SYSTEM
MFR Component System:
MFR Component Subsystem:
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