NHTSA ID Number: 10179944
Manufacturer Communication Number: 60-TR-81EN Rev J
TSB/Document Date: 2020-09-21
Summary
Service information related to measurements and inspections for tolerances to ensure proper balance between the engine and transmission mating components
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TSB/Document ID: 60-TR-81EN Rev J
Replacement Service Bulletin Number:
MFR Communication Date: 2020-08-13
MFR Internal Campaign ID/Software Version:
Communication Type: Service Bulletin/Repair Instructions
NHTSA Components: POWER TRAIN
MFR Component System:
MFR Component Subsystem:
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Revisions to this document are noted
by a stripe in the left-hand margin
SUBJECT:
SIL 60-TR-81, Rev. J
August 13, 2020
Page 1 of 18
Engine/Transmission Adaptation Requirements
H 40/50 EPTM, 1000 SeriesTM, 2000 SeriesTM, 3000 SeriesTM, 4000 SeriesTM, TC10®,
AT 500, MT 600, and HT 700 Series Transmissions
VOCATIONS AFFECTED:
Transmission performance may be adversely affected by improper tolerances existing between engine to
transmission mating components. The drive connection between the engine and transmission converter must
transmit engine power, properly locate and pilot the torque converter, and aid in controlling the forward thrust of
the converter in H 40/50 EPTM, 1000 SeriesTM, 2000 SeriesTM, 3000 SeriesTM, 4000 SeriesTM, TC10®, AT 500,
MT 600 and HT 700 models. Experience has shown these requirements can best be satisfied with a flexplate
drive connection.
Vibration, converter section oil leaks, a worn front bushing or bearing, and/or a worn engine crankshaft thrust
bearing are frequently the result of exceeding recommended tolerances in engine to transmission mating
components. When these conditions are encountered, certain important measurements should be investigated
before installing a repaired or new transmission.
These measurements are summarized below and are further detailed on the following pages. The Adaptation
Requirements Checksheets specify the tolerance by transmission model. Figure 1 illustrates the typical tooling
required for these measurements and Figures 2 through 11 explain the measurements in more detail and show
examples of each measurement as it is being performed.
Summary of Measurements and Inspections:
Component or Subassembly
Required Inspections
Flywheel Housing
Bore Diameter
Bore Eccentricity
Face Squareness
Crankshaft Hub and/or Adapter
Converter Pilot Diameter
Face Squareness
Eccentricity
Flexplate
Check for Radial Cracks
Check for Elongated Mounting Holes
Check for Any Signs of Distress and/or Wear
Mounted Flexplate
Axial Location
Flatness
SL5897EN
5236400
Copyright © 2020 Allison Transmission, Inc. All Rights Reserved.
SIL 60-TR-81, Rev. J
August 13, 2020
Page 2 of 18
Copyright © 2020 Allison Transmission, Inc. All Rights Reserved.
SIL 60-TR-81, Rev. J
August 13, 2020
Page 3 of 18
Copyright © 2020 Allison Transmission, Inc. All Rights Reserved.
SIL 60-TR-81, Rev. J
August 13, 2020
Page 4 of 18
Figure 1. This is a typical set of tooling used to determine the adaptation requirements of an AT 500 series transmission.
Figure 2. This illustrates measurement of the flywheel
housing bore diameter using an inside caliper.
Figure 3. This illustrates measurement of the eccentricity of
the flywheel housing bore using a dial indicator. Securely
fasten the base of the dial indicator support extension to
the crankshaft hub. Rotate the crank shaft so that the dial
indicator will sweep the entire flywheel housing bore. Record
the maximum and minimum readings. The difference in these
readings should not be greater than the tolerances specified
on the adaptation checksheet.
Copyright © 2020 Allison Transmission, Inc. All Rights Reserved.
SIL 60-TR-81, Rev. J
August 13, 2020
Page 5 of 18
Figure 4. This illustrates measurement of the squareness
of the flywheel housing face using a dial indicator. The
dial indicator must be securely fastened to the crankshaft
hub. While pressing the crankshaft rearward to remove all
crankshaft end play, rotate the crankshaft so that the dial
indicator sweeps the entire surface of the flywheel housing
face. Record the maximum and minimum readings. The
difference in these two readings should not be greater than
the tolerance specified on the adaptation checksheet.
Figure 5 and 6. These illustrations demonstrate the use of an inside micrometer to measure the pilot diameter of the
converter hub.
Figure 7. This illustrates measurement of the squareness of
the crankshaft hub face. Securely fasten the base of the dial
indicator to the flywheel housing and adjust the indicator to
measure the outer edge of the crankshaft hub face. While
pressing the crankshaft rearward to remove all crankshaft
end play, rotate the crankshaft so the dial indicator sweeps
the entire diameter of the crankshaft hub face. Record the
maximum and minimum readings. The difference in these two
readings should not be greater than the tolerance specified
on the adaptation checksheet. Remember, this tolerance is
given as T.I.R. per inch of diameter or T.I.R. per 25 mm of
diameter, so multiply the tolerance from the checksheet by
the diameter at which the reading is taken.
Copyright © 2020 Allison Transmission, Inc. All Rights Reserved.
SIL 60-TR-81, Rev. J
August 13, 2020
Page 6 of 18
Figure 8. In this example, the crankshaft hub eccentricity is
measured. With the dial indicator fastened to the flywheel
housing, rotate the crankshaft so the indicator sweeps
the entire inside diameter of the crankshaft hub. Note the
maximum and minimum readings. The difference of these
readings should not be greater than the tolerance specified
on the adaptation checksheet.
Figure 9. This illustrates measurement of the flexplate
flatness. Fasten the dial indicator to the flywheel housing and
measure only in an area adjacent to each converter mounting
hole in the flexplate. If a two-piece flexplate is being checked,
both pieces must be bolted together on the engine. Refer to
adaptation checksheet for tolerance.
Copyright © 2020 Allison Transmission, Inc. All Rights Reserved.
SIL 60-TR-81, Rev. J
August 13, 2020
Page 7 of 18
Copyright © 2020 Allison Transmission, Inc. All Rights Reserved.
SIL 60-TR-81, Rev. J
August 13, 2020
Page 8 of 18
Figure 10. In this example, converter axial location is measured. While pressing the crankshaft rearward to remove all
crankshaft end play, measure from the rear face of the flywheel housing to the rear face of the flexplate, adjacent to the
converter mounting holes. The measurement should be within the tolerance specified on the adaptation checksheet.
Copyright © 2020 Allison Transmission, Inc. All Rights Reserved.
SIL 60-TR-81, Rev. J
August 13, 2020
Page 9 of 18
Figure 11. In this example, flexplate axial location is
measured. While pressing the crankshaft rearward to remove
all crankshaft end play, measure from the rear face of the
flywheel housing to the rear face of the flexplate, adjacent to
the converter mounting holes. The measurement should be
within the tolerance specified on the adaptation checksheet.
Table 1 shows the Flexplate Adapter offsets for the 3000/4000 Product Family Transmissions. To determine
the Flywheel Housing to Flexplate offset, you will use Table 1 and the information provided in the Adaptation
Requirements Checksheets.
Copyright © 2020 Allison Transmission, Inc. All Rights Reserved.
SIL 60-TR-81, Rev. J
August 13, 2020
Page 10 of 18
Example for finding Flywheel Housing to Flexplate Nominal Offset.
Figure 1. Example for finding Flywheel Housing to Flexplate Nominal Offset
3000 SeriesTM Transmission/ AS04 342-G (MAN D0826, MAN D0836)
Flexplate deflection when mounted (0.38mm)
0.38
A
Flex Plate Adapter Offset
29.50
B
Torque Converter Cover to Converter Housing Flange face (3K)
49.87
C
Converter Housing Flange face to Engine Flywheel Housing face (adapter)
NOT SHOWN
Sum
Nominal Flywheel Hsg to Flexplate Offset (79.75 - 69.70)
Copyright © 2020 Allison Transmission, Inc. All Rights Reserved.
69.70
69.70
10.05
79.75
Table 1. Flexplate Adapter Offsets
Flex
Adapter
P/N
A
B
Flex
Adapter
Offset
TC
Cover
to Conv
Hsg.
Flange
C
Adapter Ring
P/N
Adapter Ring
Offset
Nominal
Flywheel
Hsg. Face
to Flexplate
Face mm (in)
Description
30.20
49.87
None
80.45 (3.167)
29503525
25.09
49.87
None
75.34 (2.966)
AS04-293-H - Caterpillar
3116, 3116E, 3126, C7 : 12 flexplate bolts
29511625
25.09
49.87
None
75.34 (2.966)
AS04-297-J - Caterpillar 3116, 3116E, 3126, C7 : 6 flexplate bolts
29507915
31.98
49.87
None
82.23 (3.237)
AS04-298-C - Mercedes OM366LA (173 tooth ring gear)
29508368
25.45
49.87
None
75.7 (2.98)
AS04-299-E - Mercedes OM366LA (133 tooth ring gear)
29512130
30.20
49.87
None
80.45 (3.167)
AS04-300-K - Cummins C Series (C, ISC, ISL, CG, LG) 8/10 Pitch
Ring Gear: 6 flexplate bolts w/ starter spacer....NOTE: AS04-459 and
AS04-474 reflect recommended designs for new vehicle builds.
29512880
28.40
49.87
None
78.65 (3.096)
AS04-303-G - Detroit Series 40 (1994 & later); Navistar DT466, DT570,
530, MaxxForce DT9 & DT10; Perkins Peregrine
80.45 (3.167)
AS04-304-J - Cummins B Series (B, ISB, BG, BLPG) 10/12 Pitch
Ring Gear : 6 flexplate bolts....NOTE: AS04-459 and AS04-474 reflect
recommended designs for new vehicle builds.
AS04-312-H - Detroit V92, S50, S60 Series (SAE No. 1 Hsg./ No. 1
Ring Gear Position)
29512136
30.20
49.87
None
29513053
34.38
49.87
23049392
0.00
84.63 (3.332)
29511095
34.15
49.87
23049392
0.00
84.4 (3.323)
29510822
47.66
49.87
None
97.91 (3.855)
29520757
50.13
49.87
None
100.38
(3.952)
29511095
34.15
49.87
None
84.4 (3.323)
29516147/
29513023
36.00
49.87
29513023
42.00
44.25 (1.742)
AS04-323-F - Iveco Cursor 8 (F2B) - SAE No.1 Housing / No.1 Ring
Gear Position
29522215
30.25
49.87
29524800
22.76
57.74 (2.273)
AS04-324-G - Mercedes OM900, MBE900 (SAE No. 2 Hsg. / Mercedes
Flywheel)
AS04-314-D - Detroit V92, S50, S60 Series (SAE No. 1 Housing / No. 2
Ring Gear Position)
AS04-315-G - Detroit V92, S50, S60 Series (Extended SAE No. 2
Housing)
AS04-318-D - Perkins Phaser (Extended SAE No. 2 Housing)
AS04-321-F - Detroit V92, S50, S60 Series (SAE No. 2 Housing)
SIL 60-TR-81, Rev. J
August 13, 2020
Page 11 of 18
Copyright © 2020 Allison Transmission, Inc. All Rights Reserved.
29503524
AS04-291-K - Cummins B & C Series (B, ISB, BG, BLPG, C, ISC, ISL,
CG, LG, & ILPG) 8/10 Pitch Ring Gear : 12 flexplate bolts, with starter
spacer....NOTE: AS04-459 and AS04-474 reflect recommended designs
for new vehicle builds.
Table 1. Flexplate Adapter Offsets (cont'd)
B
Flex
Adapter
P/N
Flex
Adapter
Offset
TC
Cover
to Conv
Hsg.
Flange
29507742
32.20
49.87
C
Adapter Ring
P/N
23049392
Adapter Ring
Offset
Nominal
Flywheel
Hsg. Face
to Flexplate
Face mm (in)
0.00
82.45 (3.246)
AS04-326-J - Caterpillar 3176, C9, C10, C11, C12, C13 (SAE No.1
Hsg. / No.1 Ring Gear Position)
80.45 (3.167)
AS04-328-F - Cummins B Series (B, ISB, BG, BLPG) 10/12 Pitch Ring
Gear : 12 flexplate bolts....NOTE: AS04-459 and AS04-474 reflect
recommended designs for new vehicle builds.
Description
29503524
30.20
49.87
None
29509445
37.45
49.87
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