2012FA06D Service Bulletin/Repair Instructions

2012FA06D

May, 2013

Product Code(s): 63

Page 1 of 4

SUBJECT:
Calibration Update for Improved C5 Clutch Operation with C5 Clutch Friction Plate Replacement
MODELS AFFECTED:
1000 and 2000 Series Transmissions
VOCATIONS AFFECTED:
Non Shift Energy Management (SEM)/Low Range Torque Protection (LRTP) Transit

Bus with 2010 Uprate Controls Operating in the United Kingdom/Republic of Ireland
Introduction:

Allison Transmission, Inc. has identiﬁed an issue which could limit the life of the C5 clutch in 1000/2000 Series

Transit Bus vocations. A higher C5 pressure strategy was implemented with the 2010 Uprate Controls which, over

time, may cause friction material loss on the C5 clutch friction plate.

To increase customer enthusiasm, Allison Transmission, Inc. is implementing this Field Action to prevent premature

C5 clutch failures. A newly released calibration will lower the C5 pressure strategy, while insuring proper torque

capacity. The C5 clutch friction plates will be replaced in transmissions with mileage over 40,000 miles at the time

the recalibration was completed.

The affected population of non SEM/LRTP Transit Bus vehicles begins with the ﬁrst production 2010 Uprate units

and ends when the new calibration was released on September 18th, 2012.

This Field Action will expire on November 1, 2014.
Service Procedure:

Only Allison 1000/2000 Series trained technicians are to perform this Field Action at authorized 1000/2000

service outlets. Collect all necessary vehicle information needed to complete a standard warranty claim: Vehicle

Identiﬁcation Number (VIN), Serial Number (S/N), bus number, correct mileage, etc.

Remove the transmission from vehicle. Remove the pan and suction ﬁlter from the transmission. Split the suction

ﬁlter apart and inspect for C5 clutch debris in the pan and ﬁlter media. Refer to Figure 1 for an example of debris. If

C5 clutch debris is found, then continue the disassembly. Rebuild the transmission using the instructions provided

in the 1000/2000 Product Families 2010 Uprate Service Manual (SM5818EN).

If C5 clutch debris is not found, then disassemble the transmission using the instructions provided in the 1000/2000

Product Families 2010 Uprate Service Manual (SM5818EN) to replace only the C5 clutch friction plates. It is

necessary to partially disassemble the transmission to allow for proper selective reaction plate selection in the

C5 clutch.
JC / FA0005EN
402986
Copyright © 2013 Allison Transmission, Inc. All Rights Reserved.
2012FA06D

May, 2013

Product Code(s): 63

Page 2 of 4
Figure 1.

Install new C5 clutch friction plates, measure for proper selectable C5 reaction plate and reassemble the unit per

1000/2000 Product Families 2010 Uprate Service Manual (SM5818EN). Reinstall the transmission in the vehicle. If

recalibration described in 2012FA06B has not yet been completed then reﬂash the updated/newest version of the

original calibration as follows:

• Record an Allison DOC® snapshot to save original Customer Modiﬁable Constants (CMC) values.

• Use Allison TCM ReﬂashTM (Production Calibration Conﬁguration System (PCCS)) to request an

updated/newest version of the original calibration.

• Recalibrate Transmission Control Module (TCM).

• Verify that CMCs are set to original values.
Claim Submittal Information:

Reimbursement of expenses should be requested via a Claim Type 4 with a Primary Failed Part (PFP) of 70 if

no damage to the C5 is observed or PFP of 29537393 for a C5 clutch friction plate failure. Multiple claims per

Serial Number (S/N) will be accepted if the recalibration is not performed at the same time as the C5 clutch

friction plate replacement.

Below is the claim submittal information for the inspection if the C5 clutch friction plates DO NOT show signs

of compressive fatigue:

Claim Type
4
Special Activity Indicator
2012FA06D
Primary Failed Part
70
Complaint Code
AT02
Failure Code
CC03
Copyright © 2013 Allison Transmission, Inc. All Rights Reserved.
2012FA06D

May, 2013

Product Code(s): 63

Page 3 of 4

Product Code 63

Labor Operation Code
Labor Hours
94000065
6.5
R&R Transit Bus 1K/2K
00095211
3.0
Partial Trans Overhaul
00095205
1.5
Dyno Test
00094006
0.5
Back Flush/Clean Cooler
00096400
0.5
Final Test Drive Vehicle
Labor Operation
Table 1. Parts Covered to Perform C5 Replacement

Part Description*
Qty
Part Number
1
29536478
Gasket, Main Housing, Separator Plate
1
29536941
Gasket, Rear Cover
6
29537393
C5 Clutch Friction Plate
1
29536379
Seal Assembly, Oil
1
29536847
Bolt, 1/2­20 Flange Hd
1
29536848
Washer, Sealing
6
23049056
Bolt, M10 x 1.5 x 15 Flange Hd
2
29536781
O­ring, 23.47 mm ID
* May require C5 Clutch Reaction, Selective (Quantity 1)
Below is the claim submittal information for the inspection if the C5 clutch friction plates DO show signs of

compressive fatigue and debris inside the transmission.

Claim Type
4
Special Activity Indicator
2012FA06D
Primary Failed Part
29537393
Complaint Code
AT02
Failure Code
CC03
Product Code 63

Labor Operation Code
Labor Hours
94000065
6.5
R&R Transit Bus 1K/2K
00095200
8.4
Transmission Overhaul
00095205
1.5
Dyno Test
00094006
0.5
Back Flush/Clean Cooler
00096400
0.5
Final Test Drive Vehicle
Labor Operation
Copyright © 2013 Allison Transmission, Inc. All Rights Reserved.
2012FA06D

May, 2013

Product Code(s): 63

Page 4 of 4

Table 2. Parts Covered to Overhaul if a C5 Failure Occurs

Part Description*
Qty
Part Number
1
29547606
Seal & Gasket Kit
6
29537393
C5 Clutch Friction Plate
1
29542824
Filter, Suction, Deep Pan
1
29539579
Filter, Control Main
1
Various
Converter Assembly
1
29536847
Bolt, 1/2­20 Flange Hd
1
29536848
Washer, Sealing
6
23049056
Bolt, M10 x 1.5 x 15 Flange Hd
2
29536781
O­ring, 23.47 mm ID
* May require C5 Clutch Reaction, Selective (Quantity 1)
Net Items:

If travel expense is required to complete this Field Action, it must be justiﬁed on the warranty claim. Each C5 clutch

replacement warranty claim can include up to 21 liters of TES 295 transmission ﬂuid. Any additional parts, labor

or travel deemed necessary to complete this Field Action must be completely described in detail in the claim

narrative; if not, they will be deducted from the claim.
Copyright © 2013 Allison Transmission, Inc. All Rights Reserved.

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