ALLISON AT540, 543, 545. To Get The Correct Parts, You Must Provide The Assembly Number Found On The Transmisson Name Plate.

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2 NOTE: Early AT540/545 parts up to serial number Late AT545 parts from serial number Allison Transmissions 21 Bolt Pan Rear Wheel Drive REBUILDER KITS DELUXE MASTER LESS STEELS OVERHAUL GASKET & DESCRIPTION QTY. YEAR KIT O/H KIT KIT KIT SEAL KIT Rebuilder Kits - Exc w/armstrong 1 - K1100 K1100-LS K11900W Overhaul Kit - Exc w/cork & Neoprene 1 - K11900 Rebuilder Kits European 1 - K1100A K11900A Front Pump Re-Seal Kit - All (1) 1 - K (1) Contains front pump gasket, rubber lathe-cut seal, o-ring and pump bolt washers. AT540 ILL. DESCRIPTION QTY. YEAR PART NO. REFERENCE NO. MISCELLANEOUS GASKETS & SEALS/PAN GASKETS 1F Gasket - Oil Pan - Cork - Neoprene... ( ) X F Gasket - Oil Pan - Update - Armstrong... ( ) W N.I. Gasket - Converter Pump Hub Bolt On Hub... ( ) W N.I. Seal - Lathe Cut - Converter Pump A Seal - Lathe Cut - Front Pump Body L A Seal - Washer - Front Pump Body Bolt A A Seal - Lathe Cut - Front Pump Support A Gasket - Front Pump To Case A Lip Seal - Forward Clutch - Inner... ( ) L A Lip Seal - Forward Clutch - Outer... ( ) L B Lip Seal - Fourth Clutch - Inner L B Lip Seal - Fourth Clutch - Outer L C Lip Seal - Third Clutch - Inner C Lip Seal - Third Clutch - Outer C Lip Seal - Second Clutch - Outer C Lip Seal - Second Clutch - Inner E Lip Seal - First Clutch - Outer... ( ) E Lip Seal - First Clutch - Inner... ( ) F Gasket - Power Takeoff Cover - Update - Armstrong W F O-Ring - Modulator... ( ) L F Gasket - Governor Cover - Fibre D F O-Ring - Oil Filter L N.I. Washer - Drain Plug (Metal) N.I. Washer - Drain Plug (Coated) B N.I. Check Ball - 1/4" N.I. Check Ball - 5/16" A CLUTCH PLATES 21B Friction - Forward Clutch (2) R B Friction - Forward Clutch (3) W B Friction - Fourth Clutch (2) R B Friction - Fourth Clutch (3) W C Friction - Third Clutch (2)... ( ) 3 - R C Friction - Third Clutch (3) W (2) Raybestos brand plate. OEM approved heat-treated paper. (3) S.K. Wellman plate. OEM approved graphitic. 139

3 ILL. DESCRIPTION QTY. YEAR PART NO. REFERENCE NO. CLUTCH PLATES (Cont.) 27C Friction - Second Clutch (2)... ( ) 3 - R C Friction - Second Clutch (3) W E Friction - First Clutch (2) R E Friction - First Clutch (3) W B Steel - Forward Clutch... ( ) C B Steel - Fourth Clutch... ( ) C C Steel - Third Clutch... ( ) C Steel - Second Clutch... ( ) E Steel - First Clutch B Plate - Backing - 4th Clutch N.I. Plate - Waved - Forward Clutch (2) Raybestos brand plate. OEM approved heat-treated paper. (3) S.K. Wellman plate. OEM approved graphitic. FILTERS/FILTER KITS 40F Filter Kit - Screen - with Cork - Neoprene... 1 FK F Filter Kit - Screen - Armstrong FK11800W F Filter Kit - Treated Paper - with Cork - Neoprene FK11800A PF F Filter Kit - Treated Paper - Armstrong FK11800AW F Filter Kit - Screen - Late AT Deep Pan... ( ) 1 - FK34661SW N.I. Filter Kit - Deep Pan Design (contains tube, bracket) UDK F Filter - External Spin on Cartridge - One Quart... (PH35109) 1 - PF F Filter - Metal Screen... ( ) F Filter - Brass Screen S F Filter - Treated Paper A N.L. 45F Filter Update N.I. Screen - Governor Tube VACUUM MODULATORS 50F Modulator - w/ O-Ring - Lg Can Modulator - w/ O-Ring - Sm Can A METAL CLAD SEALS 52A Front Pump - Vamac Material V F Extension Housing F Selector Shaft BUSHINGS N.I. Bushing Kit - 7 Bushings - AT540/ Early K11902 N.L. Bushing Kit - 7 Bushings - Late K11902A N.L. 60A Front Pump Body - Babbitt - Update Version... ( ) A Stator Shaft - Front - Bronze Lined... ( ) C Center Support O.D Center Support O.D A D Sun Gear Shaft - Front - 1st Design O.D.... ( ) Sun Gear Shaft - Front - 2nd Design O.D D Sun Gear Shaft - Rear... ( ) D Front Planetary Carrier E Output Shaft O.D Output Shaft O.D A SEALING RINGS/RING KITS N.I. Sealing Ring Kit - Complete - 5 Rings K11901 N.L. 80A Front Pump A Turbine Shaft C Center Support

4 ILL. DESCRIPTION QTY. YEAR PART NO. REFERENCE NO. THRUST WASHERS/NEEDLE BEARINGS N.I. Spacer - Turbine: -.015" - Gold AR " - Silver AR A " - Plain AR B " - Black AR C " - Copper AR D A Washer - Front Cover: -.056"-.060" No AR "-.076" No AR A "-.093" No AR B "-.109" No AR C "-.125" No AR D "-.142" No AR E B Washer - Fourth Clutch Driving Hub Washer - Front Sun Gear: 91D - Front (up to serial number ) Front (from serial number ) A D - Rear " - Color Code Red... AR Washer - Front Planetary: 95D - Bronze - Pinion Gear D - Steel - Pinion D - Rear - Carrier Washer - Center Planetary: 100D - Bronze - Pinion D - Steel - Pinion D - Rear - Carrier (up to serial number ) Rear - Carrier (from serial number ) A Washer - Rear Planetary: 106E - Bronze - Pinion E - Steel - Pinion E Washer - Rear Planet Carrier - Front & Rear F Washer - Output Flange Bolt N.I. Washer - Center Support Bolt N.I. Washer - Drain Plug (Metal) N.I. Washer - Drain Plug (Coated) B BEARINGS 115B Bearing Package - Forward Hub - Front - (3 Piece) BK N.I. Bearing/Race Kit BK N.L. N.I. Roller Bearing - Converter Stator HARD PARTS Hard Parts may only require the base number for OEM/Aftermarket New or a "-R" suffix for remaufactured. Exceptions are listed individually. NOTE: A separate column is provided to indicate a primary or specific brand/type. AT540 ILL. DESCRIPTION BRAND QTY. YEAR PART NO. REF NO. 120A Kit - Front Pump Gear - Oversized K11201B N.L. 120A Kit - Front Pump Gear.727 Thick K11201 N.L. 123A Roller Bearing - Ground Sleeve A Ground Sleeve (Finished I.D. - Bearing Inst.) D Pin - Front Planetary D Needle Roller - Front Planetary D Kit - Front Planetary Repair K11215 N.L. 141D Needle Roller - Center Planetary D Pin - Center Planetary D Kit - Center Planetary Repair K11216 N.L. 141

5 ILL. DESCRIPTION BRAND QTY. YEAR PART NO. REF NO. HARD PARTS (Cont.) 148C Center Support - Early (7) C Center Support - Late - Large Hole (8) A E Needle Roller - Rear Planetary E Pin - Rear Planetary E Kit - Rear Planetary Repair K11216 N.L. 160A Turbine Shaft - Early - All A Turbine Shaft - Late - All B D Shaft - Sun Gear - Early (7) D Shaft - Sun Gear - Late (8) A D Shaft - Main - 1" Journal - Early (7) D Shaft - Main - Reinforced Journal - Late (8) B D Sun Gear - Front - Early (7) D Sun Gear - Front - Late (8) A D Sun Gear - Center - Early D Sun Gear - Center - Late B D Sun Gear - Rear - (Low) - Early (7) D Sun Gear - Rear - (Low) - Late (8) A F Bolt - Output Flange... ( ) F Governor Assembly I.D. No F Governor Assembly I.D. No A F Governor Assembly I.D. No B F Oil Pan - Deep - Offset Threaded Inlets F Oil Pan - Deep - Even Threaded Inlets A F Kit - Manual Selector Shaft K C Piston - Center Support D Front Planet Assembly... ( ) R D Center Planet Assembly... R E Rear Planet Assembly... R A Pump Body & Gears - AT540 Only (9)... R C A Pump Body & Gears - AT R D B Hub - 4th Clutch - Early (7) Hub - 4th Clutch - Late (8) A B Hub - Forward Clutch - Early (7) Hub - Forward Clutch - Late (8) A F Tube & Dip Stick Assembly - Universal U N.L. 216B Housing - 4th Clutch - Early (7) B Housing - 4th Clutch - Late (8) A A P.T.O. Gear... R A Housing - w/o Turbine Shaft - Forward Clutch - Early (7)... ( ) R A Housing - w/ Turbine Shaft - Forward Clutch - Late (8) B A Support - Front Pump - AT540 - Body Cast # R A Support - Front Pump - AT545 - Body Cast # R B F Bearing - Output - Early F Bearing - Output - Late A N.I. Bolt - Torque Converter N.I. Center Support Repair Sleeve - Early DF636B N.L. N.I. Conversion Kit - (Deep Pan) AT540 To AT UDK N.I. Drain Plug - Oil Pan DP-789 N.L. N.I. Housing & Flex Plate Package CK-545 N.L. N.I. Housing & Flex Plate package - w/tower CK-545A N.L. (7) Early AT540/545 parts up to serial number (8) Late AT545 parts from serial number (9) Reference No old style support will work in late 545 applications when mated with charging pump with casting #895. Casting #919 pump only mates to late style support reference no

6 ILL. DESCRIPTION BRAND QTY. YEAR PART NO. REF NO. HARD PARTS (Cont.) N.I. Kit - Governor Gear K34411A N.I. Lock Nut - Second Clutch Spring Retainer (Push On) N.I. Lock Nut - Third Clutch Spring Retainer (Push On) N.I. Nut - Flex Disc N.I. P.T.O. Cover N.I. Reverse Signal Switch - Backup Light... (AS36-033) N.I. Strip Lock - Converter Pump Hub MISCELLANEOUS PRODUCTS N.I. Bolt - Pan A N.I. Bolt - Torque Converter... ( ) N.I. Governor Bore Tool (w/2 Sleeves) T-9119 N.L. N.I. Governor Sleeve Only - Aluminum (Aluminum Case) T-119A N.L. N.I. Governor Sleeve Only - Bronze (Cast Iron Case) T-119B N.L. N.I. Torque Converter - Gas - (270) DC N.I. Torque Converter - Diesel - (290) DC AT540 NOTES GOVERNOR APPLICATION CHART TRANSMISSION CODE ON GOVERNOR USE 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 143

ALLISON AT540, 543, 545

ALLISON AT540, 543, 545 111 154 2008 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

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