NHTSA ID Number: 10156712
Manufacturer Communication Number: SIL 3-EP-16
TSB/Document Date: 2019-04-08
Summary
Announces the availability the alternating current (AC) Busbar Assembly and AC Terminal Block Inside the Dual Power Inverter Module 2 (DPIM2)
Copyright © 2016 Allison Transmission, Inc. All Rights Reserved.
SIL 3EP16
January, 2016
Page 18 of 31
Figure 27. HVIL Switch Location
4. Carefully remove the AC Busbar Assembly by slightly lifting upward then outward from the AC Lug Box
(refer to Figure 28).
CAUTION: Do not allow the AC Busbar Assembly to strike the HVIL Switch during the removal process.
Figure 28. Removal of AC Busbar Assembly
Copyright © 2016 Allison Transmission, Inc. All Rights Reserved.
SIL 3EP16
January, 2016
Page 19 of 31
5. Using an 11mm hex socket, remove the two (2) M5 BCA Standoffs (refer to Figure 29).
Figure 29. BCA Standoff Locations
6. Using a Torx PlusTM T25 bit, remove the two (2) M5x22mm screws (refer to Figure 30).
Figure 30. Location of M5x22mm Screws
7. Using a Torx PlusTM T25 bit, remove the two (2) M5x18mm screws and carefully remove the AC Terminal
Block through the main cover opening (refer to Figure 31).
Copyright © 2016 Allison Transmission, Inc. All Rights Reserved.
SIL 3EP16
January, 2016
Page 20 of 31
Figure 31. AC Terminal Block Mounting Screw Locations
Section 4: Installation of the New AC Terminal Block and AC Busbar Assembly
1. Install the new AC Terminal Block into its proper location. Apply one drop of Loctite® 425 or 242 thread
locking compound to the ends of the external threads of the two (2) M5x18mm screws. Using a Torx PlusTM
T25 bit, install the two (2) M5x18mm screws (refer to Figure 32). Torque the two (2) M5x18mm screws to
3.13.5 N∙m (27.430.9 lb in).
Figure 32. AC Terminal Block Mounting Screw Locations
2. Using a Torx PlusTM T25 bit, install the two (2) M5x22mm screws (refer to Figure 33). Torque the two (2)
M5x22mm screws to 3.13.5 N∙m (27.430.9 lb in).
Copyright © 2016 Allison Transmission, Inc. All Rights Reserved.
SIL 3EP16
January, 2016
Page 21 of 31
Figure 33. AC Terminal Block Mounting Screw Locations
3. Apply one drop of Loctite® 242 thread locking compound to the end of the external threads of the M5
BCA Standoff. Using an 11mm hex socket, install the two (2) M5 BCA Standoffs (refer to Figure 34). Torque
the two (2) M5 BCA Standoffs to 3.13.5 N∙m (27.430.9 lb in).
Figure 34. BCA Standoff Locations
4. Carefully install the AC Busbar Assembly into AC Lug Box (refer to Figure 35).
CAUTION: Do not allow the AC Busbar Assembly to strike the HVIL Switch during the installation process.
Copyright © 2016 Allison Transmission, Inc. All Rights Reserved.
SIL 3EP16
January, 2016
Page 22 of 31
Figure 35. Installation of AC Busbar Assembly
5. Install the HVIL switch connector (refer to Figure 36).
Figure 36. HVIL Switch Location
Copyright © 2016 Allison Transmission, Inc. All Rights Reserved.
SIL 3EP16
January, 2016
Page 23 of 31
6. Install and finger tighten the three (3) M8 AC lug bolts (refer to Figure 37).
Figure 37. AC Lug Bolts
7. Apply one drop of Loctite® 425 or 242 thread locking compound to the end of the external threads of the six
(6) M5x22mm screws. Using a Torx PlusTM T25 bit, install the six (6) M5x22mm screws (refer to Figure 38).
Torque the six (6) M5x22mm screws to 3.13.5 N∙m (27.430.9 lb in.).
NOTE: Install all screws before torquing to ensure that the holes line up.
NOTE: Exercise special care to not pinch any wires when components are installed and screws are
torqued.
Copyright © 2016 Allison Transmission, Inc. All Rights Reserved.
SIL 3EP16
January, 2016
Page 24 of 31
Figure 38. Mounting Screw Locations
Section 5: Installation of BCA Card Mounting Shelf
1. Feed all tie wraps through the BCA Card Mounting Shelf (refer to Figure 39).
Figure 39. BCA Card Mounting Shelf Tie Wrap Location
Copyright © 2016 Allison Transmission, Inc. All Rights Reserved.
SIL 3EP16
January, 2016
Page 25 of 31
2. Place the BCA Mounting Shelf onto the side of DPIM chassis as shown in Figure 40.
Figure 40. BCA Mounting Shelf (GATE Drive Card Cable Connectors Shown Circled)
3. Connect three (3) GATE Drive Card Connectors to three (3) GATE Drive Cards (refer to Figure 41) and
install the cable strain relief caps.
Figure 41. GATE Drive Card Cable Connector Installation (BCA Card Cable Connector Shown for Clarity)
Copyright © 2016 Allison Transmission, Inc. All Rights Reserved.
SIL 3EP16
January, 2016
Page 26 of 31
4. Move BCA Mounting Shelf to its final location. Using a Torx PlusTM T25 bit, install the seven (7) M5x14mm
screws that secure the BCA Mounting Shelf (refer to Figure 42). Torque the seven (7) M5x14mm screws to
3.13.5 N∙m (27.431.0 lb in.).
Figure 42. BCA Mounting Shelf Fastener Locations
5. Install five (5) wire harness connectors to circuit card surface mount connectors (refer to Figure 43,
Figure 44, and Figure 45).
Copyright © 2016 Allison Transmission, Inc. All Rights Reserved.
SIL 3EP16
January, 2016
Page 27 of 31
Figure 43. Wire Harness Connector Installation (4 Locations)
Figure 44. 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 © 2016 Allison Transmission, Inc. All Rights Reserved.
SIL 3EP16
January, 2016
Page 28 of 31
CAUTION: Permanent damage to the H 40/50 EP Drive UnitTM or DPIM can occur if the current sensor
harnesses are plugged into the wrong connectors.
Figure 45. Wire Harness Connector Installation
6. Install NEW wire ties as required to retain the wire harnesses (refer to Figure 46).
Figure 46. Wire Tie Locations
Copyright © 2016 Allison Transmission, Inc. All Rights Reserved.
SIL 3EP16
January, 2016
Page 29 of 31
Section 6: 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 47.
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 47. 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 48.
Figure 48. 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 3.13.5 N∙m (2731 lb in). Refer to Figure 49 for
fastener sizes and locations.
Copyright © 2016 Allison Transmission, Inc. All Rights Reserved.
SIL 3EP16
January, 2016
Page 30 of 31
Figure 49. HVIL Circuit Card – Fastener Sizes/Locations
5. Install the two (2) wire ring terminals onto the studs at locations shown in Figure 50. Using an 8mm socket,
install four (4) M5 nut/washer assemblies onto the studs as shown in the same figure. Torque the nuts
to 3.13.5 N∙m (2731 lb in).
Figure 50. 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 47 and Figure 51 for
wire tie locations.
Figure 51. HVIL Circuit Card – Two (2) Wire Tie Locations
Copyright © 2016 Allison Transmission, Inc. All Rights Reserved.
SIL 3EP16
January, 2016
Page 31 of 31
7. Install new Cover Gasket P/N 29540714. Using a Torx Plus™ T25 bit, install and finger tighten the twentysix
(26) M5x18mm machine screws that secure the Main Cover to the DPIM Housing as shown in Figure 52.
Torque the screws to 3.13.5 N∙m (2731 lb in).
Figure 52. DPIM Main Cover
NOTE: For additional information refer to H 40/50 EP SystemTM Service Manual SM3602EN Appendix E.
8. Complete the DPIM check sheet again to verify the repair before installing the DPIM on the bus.
Copyright © 2016 Allison Transmission, Inc. All Rights Reserved.
DC
Terminal
Block
DC Lug
Box
AC Lug Box
Inverter B
AC Lug Box
Inverter A
AC Terminal
Block (x2)
AC Busbar (x6)
DC Busbar
Level 3
Current
Sensor (x6)
Level 1
BCA Card
Inverter B
BCA Card
Inverter A
X-Capacitor
(x18)
HVIL
Circuit
Board
HVIL
Switch
NOTE: This illustration is to be used for identifying the name and location
of components within the Dual Power Inverter Module 2 (DPIM2). It is not
intended to be used for disassembly and assembly procedures.
HVIL
Switches
Copyright 2014 Allison Transmission, Inc. All Rights Reserved.
Levels of Assembly
DPIM2
C
A
B
B
Level 2
Gate Drive
Cards
Inverter B
Phase
Phase
Gate Drive
Cards
Inverter A
Level 4
DC Capacitor SKiM Module/IGBT
(x9)
Cards Inverter B
SKiM Module/IGBT
Cards Inverter A
Encoder
Motor B
Phase
Phase
HVIL Support
Discharge
Resistor
DC Choke
Encoder
Motor A
A
C
AC Bus Bar
Inverter B
Phase
Phase
AC Bus Bar
Inverter A
GN7499EN
201405
Signal
Interface
- 💯【Conta.ct us for Support Directly】If you met any...
- 🔥🔥🔥【2026 AUTEL FLAGSHIP MK900BT MK900-BT, NEW...
- 🚗【3000+ ACTIVE TESTS (50➡3000+), SAME AS MS...
- 🚗【40+ HOT SERVICES FOR 150 MAKES (28+➡40+)】Full...
- 🚗【OE ALL SYSTEM DIAGNOSE, AUTO SCAN 2.0: SCAN LICENSE...
- 📌【We are Here for You】Dear valued customer, please be...
- 🚀【5X Faster Next-Level Hardware, Same as MK900/ MX...
- 🔥【3000+ Active Tests = MK900/MK900BT but...
- 📢【2026 U.S. Version, All-in-One as MK808S/ MK808Z...
- 🔥【28+ Hot Services for 150+ Brands】Same as MaxiCOM...
If the PDF is very large, it may not load in the preview below.
Some older TSBs had multiple PDFs — visit the NHTSA Website to view all PDFs.
If the TSB PDF does not show, download or view it on the NHTSA Website.
Click on the (+) Plus Sign
Then Click on Associated Document(s)
Search NHTSA Database for Recalls
Search NHTSA Database for Vehicle Investigations
View Latest Vehicle Investigations
Search NHTSA Database for Vehicle Complaints
View Latest Vehicle Complaints
TSB/Document ID: SIL 3-EP-16
Replacement Service Bulletin Number:
MFR Communication Date: 2016-01-28
MFR Internal Campaign ID/Software Version:
Communication Type: Service Bulletin/Repair Instructions
NHTSA Components: ELECTRICAL SYSTEM
MFR Component System:
MFR Component Subsystem:
Previous TSB | Next TSB |
- [Notice] When you receive a used device, it may be a customer return resold by Amazon without inspection. You can exchange it for a new one through Amazon. As this situation is unavoidable, we sincerely apologize. For any issues, contacting us via Amazon's "Messages" is the best way. THINKSCAN 689BT Bidirectional Scan Tool Can Be Used Immediately After It is Turned On, Without Complicated Registration Process, Which is More Convenient & Quick.
- Full Bi-Directional Control & 3000+ Active Tests: Take control and test components like actuators, fuel injectors, relays, and cooling fans in real time. You’ll quickly see if the problem is in the part itself or the control module — saving you hours of guesswork and frustrating trial-and-error.
- Advanced ECU Coding Capabilities: Handle module matching and hidden feature activation with confidence. When you replace an ECU or want to customize settings, this obd2 scanner diagnostic bi directional tool gives you the professional-level capabilities you need without the dealership price tag.
- 34+ Useful Reset and Maintenance Functions: Complete everyday service tasks smoothly with a wide range of helpful reset and maintenance functions. Whether you’re keeping up with regular upkeep or tackling a specific job, this scanner makes maintenance simpler and less stressful for both DIYers and pros.
- Comprehensive Full System Diagnostics: Diagnose every major system — Engine, Transmission, ABS, SRS, TPMS, and more — all in one place. Finally stop wondering if you’re missing something important; get the full picture and clear codes with ease.
- Top Reasons to Choose the D7S OBD2 Scanner: XTOOL D7S car scan tool, an upgrade of XTOOL D7, offers comprehensive features for automotive technicians, workshops, and DIY enthusiasts 1. Upgraded Hardware: 2+64GB memory, rear camera, intuitive interface, foldable bracket 2. Complete Diagnostics: FCA
Autoauth, OE-level all system scan, 39+ maintenance services, 4K+ bidirectional, CANFD/DoIP protocol 3. Advanced Capabilities: ECU coding, PMI functions 4. Wide Compatibility: Support 10,000+ models, covering 99% vehicle brands 5. Multi-language: Available in 22+ languages, No IP Restrictions 6. 3-Year Updates: Save 300 bucks on software updates for the latest features and optimizations - 2026 Upgraded D7S Car Scanner Features: The newly 2026 D7S V2.0 scanner for car brings exciting features for advanced vehicle diagnostics and enhanced user experience 1. FCA AutoAuth: Now supports FCA SGW module for Chrysler, for Jeep, for Dodge (2018+), for Fiat (2017+), enabling faster vehicle communication without gateway restrictions 2. PMI (Offline ECU Programming): Allows for Ford, for Lincoln, and for Mazda ECU programming for new modules 3. Optimized Diagnostic Report 2.0: Personalized reports with logos and customer info for auto shops. Note: Compatibility varies by cars, please check before order
- Cost-effective ECU Coding Scan Tool for Specific Brands: Enhance your vehicle's performance with XTOOL D7S! This obd2 scanner all systems bidirectional offers advanced capabilities at an affordable price, supports online for BMW, for Benz and offline for BENZ, for MIT, along with PMI functions for Ford, for Mazda, and for Lincoln
. Ideal for technicians and DIY enthusiasts, this automotive scanner diagnostic tool optimizes vehicle performance and enhances the driving experience. Note: Not for all cars and modules, please send car VIN to check the compatibility before purchase - OE All System Diagnostic & 8 Pids Graphing: XTOOL D7S is a comprehensive all system bi directional obd2 scanner that delivers dealer-level diagnostics, completely controlling over your vehicle’s performance and health. This automotive scan tool can read and clear DTCs, view live data and ECU information, retrieve freeze frames, and perform active tests and full obd2 functions. This bi-directional scan tool can can identify your vehicle's make, model, and year information with just one click and show up to 8 PIDs live data with options for CSV viewing, playback, and recording for in-depth analysis. It is easy-to-use for both professionals and beginners, helping pinpoint issues efficiently
- 3 Years Software Update, Value for Money: With 3 years of software updates and 22+ languages(no IP restrictions), XTOOL D7S auto scanner code scanner ensures ongoing compatibility for the latest car models and improved diagnostic functions. This all system vehicle diagnostic scanner comes with a 30-day return policy and a 24-month repair for dependable performance. XTOOL are dedicated to your satisfaction, so enjoy seamless support and lifetime expert assistance. Should you encounter any issues or concerns, don’t hesitate to reach out XTOOL. D7S with newest update with 22 languages freely transfer without authorization, check details from setting-language or from XTOOL
- 【✅Compared to BOSSCOMM IF742, IF745 Offers Full-System Diagnostics】The BOSSCOMM IF745 car diagnostic scanner is an upgraded model of IF742. In addition to supporting all OBD2 Code Reader functions and 6 reset options (ABS/EPB/SAS/BMS/Oil/Throttle), it expands diagnostics from 4 systems (Check Engine/ABS/SRS/Transmission) to vehicle All systems, including Steering, Suspension, and Body Electronics. This provides deeper, more comprehensive diagnostic capabilities.
- 【✨10 OBD2 Functions】The BOSSCOMM IF745 scan tool’s DTC Lookup instantly translates fault codes into user-friendly explanations, its I/M Readiness feature streamlines emissions testing with a single tap, and Freeze Frame lets you pinpoint the exact moment of a fault for in-depth root-cause diagnosis. Combined with a live data dashboard and advanced diagnostics (O2S, OBMon, EVAP), it delivers comprehensive insights for confident troubleshooting.
- 【✨Deep Diagnostics for All Vehicle System Modules】Beyond code reading/clearing and ECU information retrieval, our all-in-one data stream feature lets you inspect all current fault codes and their locations across the vehicle’s systems. This vehicle code reader helps you turn off dashboard warning lights and perform a comprehensive self-check of your car at home—no more back-and-forth trips to the repair shop or hefty inspection fees.
- 【✨6 Essential Resets: ABS Bleeding, Oil, EPB, SAS, Throttle, BMS】The BOSSCOMM IF745 obd2 scanner diagnostic tool swiftly purges air from brake lines to restore braking sensitivity, fine-tunes maintenance cycles to eliminate false alerts, resolves parking brake issues with one-click control, recalibrates steering sensors for stability, optimizes engine idling/acceleration for smoother performance, and deeply resets battery systems to extend lifespan and range via precise parameter adjustments.❗NOTE: Does NOT support bidirectional control, coding, or programming.
- 【✨10,000+ Car Models, AutoVIN, 13 Languages】The BOSSCOMM IF745 vehicle scanner diagnostic tool covers 73+ global car brands and offers support in 13 languages, making it perfect for DIYers, auto mechanics, or as a thoughtful gift. With a single-click AutoVIN feature, it instantly retrieves vehicle serial numbers, streamlining diagnostics for users globally. This adaptable tool balances user-friendliness with precision, catering to both personal and professional requirements.✅Unsure about compatibility? Compatibility will vary on vehicles' model and year, pls reach us via 📧 [email protected] 📧 before purchase.
This product presentation was made with AAWP plugin.