2012FA06A
October, 2012
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 SEM/LRTP Transit Bus

Introduction:
Allison Transmission, Inc. has identified an issue which could limit the life of the C5 clutch in 2100 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 also be replaced.
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 April 30, 2013.

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. Disassemble the transmission using the instructions provided in the
1000/2000 Product Families 2010 Uprate Service Manual (SM5818EN) to inspect the C5 clutch friction plates.
It is necessary to fully disassemble the transmission to allow for proper selective reaction plate selection in
the C5 clutch.
Inspect the C5 clutch friction plates. If compressive fatigue is present (refer to Figure 1) and C5 clutch friction plate
debris has contaminated the transmission, then continue the disassembly. Rebuild the transmission, replace the
torque converter and flush the transmission cooler.

JC / FA0001EN

347760

Copyright © 2012 Allison Transmission, Inc. All Rights Reserved.

2012FA06A
October, 2012
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.
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 Reflash (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

2012FA06A

Primary Failed Part

70

Complaint Code

AT02

Failure Code

CC03

Copyright © 2012 Allison Transmission, Inc. All Rights Reserved.

2012FA06A
October, 2012
Product Code(s): 63
Page 3 of 4
Product Code 63
Labor Operation Code

Labor Hours

00096501

1.0

Reflash TCM with new Calibration
Identification Number (CIN)

94000065

6.5

R&R Transit Bus 1K/2K

00095211

4.0

Partial Trans Overhaul

00095205

1.5

Dyno Test

Labor Operation

Table 1. Parts Covered to Perform C5 Inspection
Part Description*

Qty

Part Number

1

29536478

Gasket, Main Housing, Separator Plate

1

29536941

Gasket, Rear Cover

6

29537393

C5 Clutch Friction Plate

* 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

2012FA06A

Primary Failed Part

29537393

Complaint Code

AT02

Failure Code

CC03

Product Code 63
Labor Operation Code

Labor Hours

00096501

1.0

Reflash TCM with new CIN

94000065

6.5

R&R Transit Bus 1K/2K

00095200

8.4

Transmission Overhaul

00094006

0.5

Back Flush/Clean Cooler

00095205

1.5

Dyno Test

Labor Operation

Copyright © 2012 Allison Transmission, Inc. All Rights Reserved.

2012FA06A
October, 2012
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

* Other applicable parts as necessary, such as 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. It is expected
that the authorized Allison Transmission service outlet will make every attempt to optimize travel expense by
performing multiple recalibrations per trip. 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 © 2012 Allison Transmission, Inc. All Rights Reserved.