2012FA06C
October, 2012
Product Code(s): 63
Page 1 of 4
SUBJECT:

C5 Clutch Compressive Fatigue Inspection

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 friction plate. Field Action 2012FA06C is an inspection process to define
remaining clutch life by comparing the friction clutch plates to the duty cycle of the C5 clutch.
This Field Action vehicle population will be determined by the Allison Transmission, Inc. Service Manager for each
region. This Field Action will expire on January 31, 2013.

Service Procedure:
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. Connect Allison DOC® to the vehicle being
inspected and collect static data. Create a file for each bus inspected to save all the necessary claim information and
the Static Data File. The Static Data File must be attached to each inspection warranty claim for it to be approved.
NOTE: Do not load the updated calibration until the static data has been saved.

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 friction clutch 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 / FA0003EN

347558

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

2012FA06C
October, 2012
Product Code(s): 63
Page 2 of 4

Figure 1.
If the C5 clutch friction plates look acceptable, then tie the plates together and mark with the serial number
and identification so the Static Data File can be traced to these C5 clutch friction plates. A Return Materials
Authorization (RMA) will need to be created and the C5 clutch friction plates need to be sent to Allison Transmission
Global Headquarters (shipping information included on the (RMA) template below).
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.
Using Allison TCM Reflash (Production Calibration Configuration System (PCCS)), load an updated calibration
into the Transmission Control Module (TCM) per Field Action 2012FA06B. If performing both 2012FA06B and
2012FA06C at the same time, two separate claims are required.

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.
Below is the claim submittal information for the inspection if C5 clutch friction plates DO NOT show signs of
compressive fatigue:
Claim Type

4

Special Activity Indicator

2012FA06C

Primary Failed Part

70

Complaint Code

AT02

Failure Code

CC03

Attachments

Static Data File must be attached to the warranty claim for approval

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

2012FA06C
October, 2012
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

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 C5 clutch friction plates DO show signs of compressive
fatigue and debris inside the transmission:
Claim Type

4

Special Activity Indicator

2012FA06C

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

00094006

0.5

Back Flush/Clean Cooler

00095205

1.5

Dyno Test

Labor Operation

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)

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

2012FA06C
October, 2012
Product Code(s): 63
Page 4 of 4

Net Items:
If travel expense is required to complete this Field Action, it must be justified on the warranty claim. Each warranty
claim can include up to 21 liters of TES 295 transmission fluid. The freight invoice for each RMA should be attached
to each claim for approval. 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.

RETURN MATERIAL AUTHORIZATION
ALLISON TRANSMISSION DIVISION
REFERENCE NO. 2012FA06C
DATE:
SHIP TO:

SHIPPER:

Allison Transmission, Inc.
4700 W. 10th Street
Dock 33, Stop 70

CONTACT:

Indianapolis, IN 46222

PHONE #:

Attn:

DOES THIS RETURN CONTAIN ANY ITAR CONTROLLED MATERIAL OR INFORMATION?

Wais Mardanzi

YES

NO

If yes, contact the Allison Transmission Export Compliance Administrator for shipping authorization (317-242-3197)
QUANTITY
6

PART

DESCRIPTION and TRANSMISSION MODEL, TRANSMISSION ASSEMBLY NUMBER,

NUMBER

and TRANSMISSION SERIAL NUMBER

29537393

C5 Clutch Friction Plate

REASON FOR RETURN: 2012FA06C
Awaare Claim Number

Note: Static Data File must be attached to the claim for approval

VIN
Serial Number
RO Number
Bus Number
COMMENTS:

NOTE: ALL UNITS MUST BE CLEANED BEFORE THEY ARE SENT TO ATD. ALL EXPOSED
IRON PARTS MUST BE LIGHTLY OILED OR HAVE A PRESERVATIVE APPLIED
IMPORTANT: A COPY OF THIS COMPLETED FORM MUST BE INSIDE AND OUTSIDE OF THE SHIPPING CONTAINER.
AUTHORIZATION AND DOCUMENTATION WILL BE SHIPPED BACK TO THE SENDER FREIGHT COLLECT. ANY SUPPORT
DOCUMENTATION (PRIOR HISTORY, ETC.) SHOULD BE ATTACHED TO SHIPMENT.

PLEASE DISTRIBUTE THIS FORM AS FOLLOWS:
Fax or E-Mail to:
Fax#
Fax#
Fax#
Fax#

_____________
_____________
_____________
_____________

E-Mail
E-Mail
E-Mail
E-Mail

_________________
_________________
_________________
_________________

Copyright © 2012 Allison Transmission, Inc. All Rights Reserved