SIL 101K2K09 Rev Service Bulletin/Repair Instructions

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

12 3

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