SIL 20-WT-01 Rev Service Bulletin/Repair Instructions

Revisions to this document are noted

by a stripe in the left-hand margin
SUBJECT:
SIL 20-WT-01, Rev. B

August 16, 2019

Product Code(s): 66 and 65

Page 1 of 2
Filter Cover Bolt Hole Repair Kit
MODELS AFFECTED:
All 3000 and 4000 Series Product Families Transmission Models
Introduction:

To facilitate the repair of the filter cover bolt threads in the main case a Filter Cover Bolt Hole Repair Kit, J-42385-AT

has been released. The kit can be used for thread repair with any 3000 and 4000 Product Families model. The kit

allows the threads to be repaired in or out of chassis. The kit utilizes a solid, thin-walled, self-locking steel bushing

insert to repair the filter cover bolt threads in the main housing of the transmission. The thread inserts repair the

filter cover bolt threads to their original thread specification of an M10 x 1.5.

The Filter Cover Bolt Hole Repair Kit contains:

• Template J-42385-230 (Main Filter)
• Insert Driver J-42385-233
• Template J-42385-234 (Lube Filter)
• Tap Wrench 510260
• Two (2) Alignment Pins J-42385-308
• Six (6) M10 Retaining Bolts 206158
• M10 Step Drill J-42385-231
• Driver Oil J-42385-110
• Tap J-42385-232

• 60 Inserts J-42385-514, the kit contains six (6) packets of ten (10) M10 x 1.5 x 24.5
The kit contains 60 inserts and 1 bottle of oil. Additional inserts and oil can be purchased through Bosch

Automotive Service Solutions LLC.

Bosch Automotive Service Solutions LLC

28635 Mound Road

Warren, MI 48092-3499

US and CANADA: 1-866-621-2128

INTERNATIONAL: 1-507-455-7223

FAX: 1-800-578-7375

https://allison.service-solutions.com

3000 and 4000 series transmissions have been manufactured with two versions of filter cover bolt patterns. It

is important to first determine which version is being repaired before proceeding. Transmissions manufactured

MC / SL5350EN
4650277
Copyright © 2019 Allison Transmission, Inc. All Rights Reserved.
SIL 20-WT-01, Rev. B

August 16, 2019

Product Code(s): 66 and 65

Page 2 of 2

prior to 2002 have M10 x 1.50 tapped holes in the main housing that accept the filter cover bolts directly. Around

late 2002 the main housing configuration was changed with the addition of factory installed helicoil inserts in the

filter cover bolt patterns.

It is necessary to first inspect the housing being repaired to determine if factory installed helicoil inserts are

present. The instruction sheet included in the Filter Cover Bolt Hole Repair Kit, J-42385-AT has been modified to

include two separate repair processes, one for housings without helicoil inserts and a second for housings with

helicoil inserts. Use the applicable process for the housing being repaired.

WARNING: For housings without factory installed helicoil inserts, prior to beginning the repair, the filter

cover bolt holes must be inspected to assure the M10 Step Drill (J-42385-231) can properly prepare the

hole for thread cutting with the Tap J-42385-232. If any of the filter cover bolt holes are found oversized

the transmission main housing must be replaced.
WARNING: For housings with factory installed helicoil inserts, it is important to remove the helicoil inserts

from all holes before cutting the needed countersink with the M10 Step Drill J-42385-231. The countersink

is needed for proper installation of the Thread Repair Kit inserts. The Allison factory installed helicoil

inserts use the same hole and thread size as the Thread Repair Kit inserts – so the kit’s J-42385-232

Tap should not be run afterward. When cutting the countersink with the step drill, take care to avoid

damaging the existing threads with the drill.

Field Repair Procedures:

The two attached Instruction Sheets (with & without factory installed helicoils) must be used to facilitate the repair

of the filter cover bolt threads in the main housing.
Copyright © 2019 Allison Transmission, Inc. All Rights Reserved.
Automotive Service Solutions

J-42385-AT Filter Cover Bolt Hole Repair Kit (Without Helicoils)

Allison Transmission

Step 1
Step 8
Remove control module

from the transmission.

Refer to appropriate

service manual for correct

removal procedure.
Step 2
Step 3
Align the fixture using two

alignment pins. Secure

the plate with three

attachment bolts.
Step 4
Step 4
LUBE
MAIN
MAIN
Step 9
J-42385-308
Step 10
Inspect the insert for

correct installation. It must

be flush or below the base

surface.
J-42385-232
Step 5
Remove fixture. Verify

holes are free of chips or

debris.
Step 7
Step 7
Kit Contains
Part Number
Driver Oil

Drill Fixture- Main

Step Drill Bit

Tap

Driver

Drill Fixture- Lube

Alignment Pin

Thread Inserts (bag of 10)

Tap Wrench

Attachment Bolts
J-42385-110

J-42385-230

J-42385-231

J-42385-232

J-42385-233

J-42385-234

J-42385-308

J-42385-514

510260

206158
.

.

IMPORTANT

.

• Cutting fluid, such as WD40 or equivalent, is recommended for all drilling and tapping operations.

• Driver oil J-42385-110 must be used on the insert driver

• After each cutting operation, clean out metal ships using compressed air

• Do not allow metal chips to enter the transmission. Cover and clean components as necessary
Qty.

1 bottle

1

1

1

1

1

2

6

1

6
J-42385-514

TIME-SERT®

Inserts
J-42385-230 (Main)

J-42385-234 (Lube)
206158
J-42385-231
J-42385-233
Step 6
Lubricate the threads of the

driver tool with J-42385-110

driver oil.
LUBE
Install the insert into the hole

until it is seated in the

counterbore. Continue to

rotate the driver through the

insert. The driver will tighten

up before screwing

completely through the

insert. This is normal

because the bottom threads

of the insert are being

formed and mechanically

locked into the hole. Lightly

bottom the driver in the hole

to ensure complete

threading and insert lock-in.

Remove the driver, and the

repair is complete.
Step 10
Step 5
Use Tap J-42385-232 and

Tap Wrench 510260 to

thread new hole. Tap must

bottom to ensure thread

depth. Clean out ALL

chips or foreign material.

Retap if necessary.
3000 MH/MD 3060
J-42385-110
Use the step drill bit

J-42385-231 with an

electric drill to drill out the

damaged thread. Collar on

drill must contact the

guide. Clean out ALL chips

or foreign material.
4000 MH/HD 4060

FILTER

COVER
Step 9
Step 2
Determine correct drill

fixture for hole pattern to

be repaired (i.e. “Main

J-42385-230” or “Lube

J-42385-234”). Locate

FRONT of fixture to front

of transmission.
Step 8
Install the insert onto the

Driver Tool J-42385-233.

Do not allow oil or foreign

material to contact the

outside of the insert.
510260
WARNING: Always wear safety glasses when performing this task.

WARNING: The Allison factory installed steel inserts use the same hole

and thread size as the Thread Repair Kit inserts; however, the M10 Step

Drill J-42385-231 must be used to countersink the existing holes before the

Thread Repair inserts are installed. Take care to avoid damaging the

existing threads with the step drill when machining the countersinks.
Form No. 507330 Rev B

Litho in USA 201905
Automotive Service Solutions

J-42385-AT Filter Cover Bolt Hole Repair Kit (With Helicoils)

Allison Transmission

Step 1
Step 8
Remove control module

from the transmission.

Refer to appropriate

service manual for correct

removal procedure.
Step 1a
Step 2
Determine correct drill

fixture for hole pattern to

be repaired (i.e. “Main

J-42385-230” or “Lube

J-42385-234”). Locate

FRONT of fixture to front

of transmission.

Align the fixture using two

alignment pins. Secure

the plate with three

attachment bolts.
Step 4
MAIN
Step 9
J-42385-308
Step 10
Inspect the insert for

correct installation. It must

be flush or below the base

surface.
J-42385-232

J-42385-233
Step 5
Step 5
Clean out ALL chips or

foreign material.

Retap if necessary .
Step 6
Remove fixture. Verify

holes are free of chips or

debris.
Step 7
LUBE
MAIN
Step 10
Step 4
Use the step drill bit

J-42385-231 with an

electric drill to drill out the

damaged thread. Collar on

drill must contact the

guide. Clean out ALL chips

or foreign material.
LUBE
Install the insert into the hole

until it is seated in the

counterbore. Continue to

rotate the driver through the

insert. The driver will tighten

up before screwing

completely through the

insert. This is normal

because the bottom threads

of the insert are being

formed and mechanically

locked into the hole. Lightly

bottom the driver in the hole

to ensure complete

threading and insert lock-in.

Remove the driver, and the

repair is complete.
Step 7
Kit Contains
Part Number
Driver Oil

Drill Fixture- Main

Step Drill Bit

Tap

Driver

Drill Fixture- Lube

Alignment Pin

Thread Inserts (bag of 10)

Tap Wrench

Attachment Bolts
J-42385-110

J-42385-230

J-42385-231

J-42385-232

J-42385-233

J-42385-234

J-42385-308

J-42385-514

510260

206158
Lubricate the threads of the

driver tool with J-42385-110

driver oil.

IMPORTANT

• Cutting fluid, such as WD40 or equivalent, is recommended for all drilling and tapping operations.

• Driver oil J-42385-110 must be used on the insert driver.

• After each cutting operation, clean out metal ships using compressed air.

• Do not allow metal chips to enter the transmission. Cover and clean components as necessary.
Qty.

1 bottle

1

1

1

1

1

2

6

1

6
J-42385-514

TIME-SERT®

Inserts
J-42385-230 (Main)

J-42385-234 (Lube)
206158
J-42385-231
Step 3
3000 MH/MD 3060

FILTER

COVER
Step 9
Step 2
4000 MH/HD 4060
J-42385-110
Remove helicoils with pliers

and dispose – taking care

when doing so not to

damage the tapped holes

in the housing.
Step 8
Install the insert onto the

Driver Tool J-42385-233.

Do not allow oil or foreign

material to contact the

outside of the insert.
510260
WARNING: Always wear safety glasses when performing this task.

WARNING: The Allison factory installed steel inserts use the same hole

and thread size as the Thread Repair Kit inserts; however, the M10 Step

Drill J-42385-231 must be used to countersink the existing holes before the

Thread Repair inserts are installed. Take care to avoid damaging the

existing threads with the step drill when machining the countersinks.
Form No. 507330 Rev C

Litho in USA 201905

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