ALLISON AT540, 543, 545

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1 Transtar Industries, Inc. No part of this work, including but not limited to the Part Numbers, may be reproduced or transmitted in any form or by any means, electronic or mechanical, including photocopying and recording, or by any information storage or retrieval system without the prior written approval of Transtar Industries. Transtar Industries acknowledges that many of the illustrations in this catalog were inspired by photographs originally published by Slauson Transmission Parts and that Slauson is the owner of the copyright in those photographs. This catalog is the proprietary property of Transtar Industries, Inc.

2 NOTE: Early AT540/545 parts up to serial number Late AT545 parts from serial number Allison Transmissions B Rear Wheel Drive MASTER OVERHAUL KITS (WITH STEELS) N.I. Exc AT543 European (w/ Armstrong Gasket) Up A K1100 N.I. AT543 European Up B K1100A LESS STEEL KITS AT540 N.I. Exc AT543 European (w/ Armstrong Gasket) Up A K1100-LS N.I. AT543 European Up B K1100A-LS OVERHAUL KITS (W/ RINGS & SEALS) N.I. Exc AT543 European (w/ Cork Gasket) Up K11900 N.I. Exc AT543 European (w/ Armstrong Gasket) Up A K11900W N.I. AT543 European Up B K11900A FILTER KITS 40F Filter Kit (Metal Screen) Cork Up B FK F Filter Kit (Treated Paper) Cork Up D FK11800A 40F Filter Kit (Treated Paper) Armstrong Up E FK11800AW 40F Filter Kit (Metal Screen) Armstrong Up C FK11800W 40F Filter Kit (Brass Screen) Late AT Deep Pan Up FK34661SW FILTERS 45F Filter (Metal Screen) Up B F Filter (Treated Paper) Up D 11800A 45F Filter (545 Update) (Use with B Tube) Up F Filter (Brass Screen) Up 34010B 34661S N.I. External Spin on Cartridge (One Quart) Up PF-897 N.I. Governor Tube Screen Up BUSHINGS N.I. Bushing Kit (7 Bushings) AT540/Early Up K11902 N.I. Bushing Kit (7 Bushings) Late Up A K11902A 60A Pump Body (Bronze) Up B A Pump Body - Babbitt - Updated Version Up A Stator (Front) OD Up D Sun Gear (Front & Rear) OD (up to S# ) Up D Sun Gear (Front & Rear) OD (S# & Up) Up C Center Support (1.540 OD) Up C Center Support (1.600 O.D) Up A 11000A 72D Front Planet Up E Output Shaft.775 OD (up to S# ) Up E Output Shaft.815 OD (S# & Up) Up A 11002A METAL CLAD SEALS 52A Front Pump (Silicone) Up 44070B 38151A 52A Front Pump (Vamac Material) Up V 58F Selector Shaft Up N.I. Extension Housing Up

3 156 FRICTION PLATES 23B 4th Range Up B Forward Up C 2nd Range Up C 3rd Range Up E 1st Range Up STEEL PLATES 28C 2nd Range Up C 3rd Range Up B 4th Range Up 34126A 34305C 142 4th Range (Backing Plate) Up B Forward Up 34126A 34305C N.I. Forward (Waved) Up E 1st Range Up MODULATORS 50F Modulator (Large Can) Up A F Modulator (Small Can) Up A SEALING RINGS N.I. Ring Kit Up K A Turbine Shaft Up A Pump Up C Center Support Up THRUST WASHERS & BEARINGS N.I. Washer, Drain Plug (Metal) Up N.I. Washer, Drain Plug (Coated) Up A 11423B N.I. Bearing / Race Kit Up K 11500BK 87A Roller Bearing, Ground Sleeve Up A Washer, Front Pump (.056"-.060") # 0... AR 70-Up A A Washer, Front Cover (.089"-.093") # 2... AR 70-Up C 11407B 87A Washer, Front Cover (.105"-.109") # 3... AR 70-Up D 11407C 87A Washer, Front Cover (.121"-.125") # 4... AR 70-Up E 11407D 87A Washer, Front Cover (.138"-.142") # 5... AR 70-Up F 11407E N.I. Spacer, Turbine,.015" Gold (AT543)... AR 70-Up N.I. Spacer, Turbine,.030" Silver (AT543)... AR 70-Up A 11403A N.I. Spacer, Turbine,.042" Plain (AT543)... AR 70-Up B 11403B N.I. Spacer, Turbine,.060" Black (AT543)... AR 70-Up C 11403C N.I. Spacer, Turbine,.075" Copper (AT543)... AR 70-Up D 11403D 115B Bearing Package, Forward Hub, Front (3 Piece) Up K 11503BK 89B Washer, Fourth Clutch Driving Hub Up N.I. Washer, Front Planetary, Rear Carrier Up D Washer, Front Sun Gear, Front (up to S# ) Up D Washer, Front Sun Gear, Front (S# & Up) Up A 11411A 93D Washer, Front Sun Gear, Rear, ", Color Code Red... AR 70-Up D Washer, Center Planetary, Rear Carrier (up to S# ) Up C D Washer, Center Planetary, Rear Carrier (S# & Up) Up A 100D Washer, Center Planetary, Bronze Pinion Up A D Washer, Center Planetary, Steel Pinion Up B D Washer, Rear Planetary, Bronze Pinion Up A D Washer, Rear Planetary, Steel Pinion Up B N.I. Bearing, Rear Output to Case Up N/A N.I. Bearing, Output (up to S# ) Up N.I. Bearing, Output (S# & Up) Up A 11925A N.I. Roller Bearing, Converter Stator, Up A 11404

4 GASKETS & O-RINGS 1F Gasket, Bottom Pan (Armstrong ) Up A 13540W 1F Gasket, Bottom Pan (Cork) Up X 19F Gasket, Governor Cover Up D 19F Gasket, Governor Cover (Armstrong ) Up LW 3A Seal / Washer, Front Pump Body Bolt Up A 6A Gasket, Pump to Case Up A Lathe Cut O-Ring, Pump Body Up A Lathe Cut O-Ring, Pump Body (GM 350 Style) Up L 4A Lathe Cut Seal, Front Pump Support Up F Gasket, Power Take Off Cover (Update) Armstrong Up W 17F Gasket, Power Take Off Cover Up W N.I. Gasket, Converter Pump Hub (AT543 w/ Bolt On Hub) Up W 20F O-Ring, Oil Filter Up 12368A 3547L N.I. Front Pump Re-Seal Kit (pump gasket, lathe-cut seal, O-ring and bolt washers) Up K TECHNICAL MANUALS AT540 N.I. Service Manual Up M N/A N.I. Parts Catalog Up P N/A ELECTRICAL COMPONENTS N.I. Switch, Reverse Signal / Backup Light (AS36-033) Up N.I. Tube & Dip Stick Assembly (Universal) Up U 11999U 195F Tube, Oil Filter (AT545 Update, use w/ Filter) Up B 21225A HARD PARTS Prefix Key: D = OEM, A = Aftermarket New, R = Remanufactured PUMPS 210A Pump Body & Gears (Universal) Up A CN 210A Pump Body & Gears (AT540) Body Cast # Up C 210A Pump Body & Gears (AT545) Body Cast # Up A 34200D 225A Support, Front Pump (6 Bolt) (AT540) Body Cast # Up A Support, Front Pump (7 Bolt) (AT545) Body Cast # Up A 11921B 120A Gear Kit, Front Pump.727 Thick Up K A Gear Kit, Front Pump (Oversized) Up OS K11201B DRUMS & CLUTCH HUBS 216B Housing, 4th Clutch (up to serial # ) Up B Housing, 4th Clutch (from serial # ) Up A 11769A 222A Housing, Forward Clutch (w/o Turbine Shaft) (up to serial # ) Up A Housing, Forward Clutch (w/ Turbine Shaft) (serial # & Up) Up A 11298B 214B Hub, Forward Clutch (up to serial # ) Up B Hub, Forward Clutch (from serial # ) Up A 11634A 212B Hub, 4th Clutch (up to serial # ) Up B Hub, 4th Clutch (from serial # ) Up A 11732A PLANETS 201D Center Planet Up D Front Planet Up E Rear Planet Up D Kit - Center Planetary Repair Up K K D Kit - Front Planetary Repair Up K E Kit - Rear Planetary Repair Up K K D Needle Roller - Center Planetary Up D Needle Roller - Front Planetary Up

5 ill. DESCRIPTION QTY. YEAR PART NO. REFerence NO. PLANETS (Cont.) 153E Needle Roller - Rear Planetary Up D Pin - Center Planetary Up D Pin - Front Planetary Up E Pin - Rear Planetary Up D Washer - Front Planetary - Bronze - Pinion Gear Up A D Washer - Front Planetary - Steel - Pinion Up B SUN GEARS, SHELLS & SUPPORTS 166D Sun Gear, Center (up to S# ) Up D Sun Gear, Center (S# & Up) Up B 11227B 165D Sun Gear, Front (Up to S# ) Up D Sun Gear, Front (S# & Up) Up A 11232A 168D Sun Gear, Rear (Up to S# ) Up D Sun Gear, Rear (S# & Up) Up A 11228A 148C Center Support (up to S# ) Up C Center Support (S# & Up) Up A 11229A SHAFTS 164D Shaft, Main 1.000" Journal (up to S# ) Up D Shaft, Main 1.060" Journal (up to S# ) Up C 11226A 164D Shaft, Main - Reinforced Journal - Late (S# & Up) Up A 11226B 160A Turbine Shaft (Up to S# ) Up A Turbine Shaft (From S# ) Up B 11939B 162D Shaft, Sun Gear (Up to S# ) Up D Shaft, Sun Gear (From S# ) Up A 11225A GOVERNORS 172F Governor (Code # 460) RPM Range Up F Governor (Code # 461) Up to 2800 RPM Range Up A 11410A 172F Governor (Code # 462) RPM Range Up B 11410B N.I. Gear, Governor Gear Kit Up 34684B K34411A MISCELLANEOUS COMPONENTS 170F Bolt, Output Flange ( ) Up N.I. Bolt, Pan Up A N.I. Bolt, Torque Converter ( ) Up M464GE N.I. Bolt, Use w/ Update Bracket (For Conversion Kit 540 to 545) Up N.I. Bracket, Updated (For Conversion Kit 540 To 545) Up B N.I. Check Ball (1/4") Up A76741A N.I. Check Ball (5/16") Up A N.I. Drain Plug (Oil Pan) Up DP-789 N.I. Gear, P.T.O Up F Kit, Manual Selector Shaft Up K11235 N.I. Lock Nut, Second Clutch Spring Retainer (Push On) Up N.I. Lock Nut, Third Clutch Spring Retainer (Push On) Up N.I. Nut, Flex Disc (AT543) Up C N.I. Strip Lock - Converter Pump Hub Up A F Oil Pan, Deep (Even Threaded Inlets) Up A 180F Oil Pan, Deep (Offset Threaded Inlets) Up A C Piston, Center Support Up N.I. Plug, Cooling Line Ports (Pkg of 100) Up M479-1 PL1 N.I. Plug, Speedo Bore (Pkg of 100) Up M479-2 PL2 N.I. Plug, Modulator Bore (Pkg of 100) Up M479-5 PL5 N.I. Sleeve, Center Support Repair (Early) Up A DF636B 158

6 MISCELLANEOUS COMPONENTS (Cont.) 126A Sleeve, Ground (Finished I.D. Bearing Inst.) Up AK N.I. Washer, Center Support Bolt Up W F Washer, Output Flange Bolt Up W N.I. Washer, Use w/ Update Bracket (For Conversion Kit 540 to 545) Up W Tool Governor Sleeve Only - Aluminum (Aluminum Case) Up T-119A T-119A Tool Governor Sleeve Only - Bronze (Cast Iron Case) Up T-119B T-119B Tool Governor Bore Tool (w/ 2 Sleeves) Up T-9119 T-9119 Tool Conversion Kit (Deep Pan) AT540 to AT Up UDK-545 UDK-545 AT540 GOVERNOR APPLICATION CHART CODE ON CODE ON USE TRANSMISSION GOVERNOR GOVERNOR NO. AT 500 SERIES Up to and including RPM Range A RPM Range B Gas Engine RPM Range AT RPM Range A RPM Range MT RPM Range B 2800 RPM Range RPM Range A RPM Range - Bronze Gear B RPM Range - Bronze Gear C Caterpillar Engine w/blower RPM Range B Caterpillar Engine w/o Blower RPM Range C NOTES 159

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