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Old 04-24-2016, 08:16 PM   #1581
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Just wanted to confirm that I did NOT get a single thing done on my bus today. I did, however, manage to fabricate a lift/centerstand for a friends fully restored and fully kickass, 1973 CZ 400 MX bike so it was not a total loss. Those were some seriously competitive bikes in their day and remain thoroughly scary today...in a really good way.
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Old 04-24-2016, 09:58 PM   #1582
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All work and no play makes Jack a dull boy. Sorry Jack.
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Old 04-25-2016, 11:09 AM   #1583
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But it sure does keep me out of the bars! Jack
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Old 04-25-2016, 11:20 AM   #1584
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But it sure does keep me out of the bars! Jack

I have that same problem Jack. Gotta' figure out a way to work at my neighborhood tavern.
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Old 04-28-2016, 12:18 PM   #1585
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Yep...still on hold for some critical parts being machined.

Meanwhile, I am pulling together the info necessary to mount and install the shifter & TCM on my Allison 6 speed. In the process of researching that data, I came across some more broadly relevant info for anyone with a 4th Generation Allison that touches on a topic I think we briefly discussed elsewhere on the site...

How to protect the trannies computer(s) from electrical damage due to welding or painting (yes..painting, if electrostatic).


The following was taken directly from Allisons directives to installers and should be read by anyone who owns a vehicle with any of these transmissions as the units can be damaged/destroyed if the proper precautions are not taken. And since so many folks here routinely use welding as part of their conversion process, I consider this information critical. Below is the data taken from the Allison bulletin...

Allison Section C:
Controls Component Installation Bulletin


3.2 Welding on the Vehicle

Take the following steps whenever welding on the vehicle:
• Always disconnect the harnesses from the TCM.
• Always disconnect the TCM power and ground circuits from the battery.
• Do not connect welding cables to controls components.
• Do not weld on controls components.
• Always protect controls components from sparks and heat.


3.3.1 Electrostatic Painting

If the vehicle chassis or body is painted using an electrostatic painting process, electrical voltage must not be discharged through the TCM. To prevent this possibility, Allison recommends installing the TCM after the electrostatic paint process is complete. If the TCM is installed prior to electrostatic painting, the vehicle

Builder must insure the following:

• that the TCM is not painted
• that the elements being painted are properly and continuously grounded to earth during the entire painting process. Allison Transmission is not responsible for TCM damage which results from improper grounding during

Electrostatic painting of the vehicle.

During electrostatic painting, the paint droplets receive an electrostatic charge which attracts them to earth-grounded surfaces. Voltages at the spray gun can exceed several thousand volts. The charge which builds up on an improperly chassis or body can be discharged through the TCM, resulting in damage to the TCM.


Given that Allisons are so prevalent in Skoolies, this seemed important enough to me that I thought everyone here should be made aware of these considerations. I know that I was misinformed. I previously understood that simply disconnecting the battery was adequate but that turns out to be a dangerous misconception based on this "official" data. Fortunately, I have yet to install my TCM. Glad I found this first.
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Old 04-28-2016, 12:32 PM   #1586
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Originally Posted by Tango View Post
Yep...still on hold for some critical parts being machined.

Meanwhile, I am pulling together the info necessary to mount and install the shifter & TCM on my Allison 6 speed. In the process of researching that data, I came across some more broadly relevant info for anyone with a 4th Generation Allison that touches on a topic I think we briefly discussed elsewhere on the site...

How to protect the trannies computer(s) from electrical damage due to welding or painting (yes..painting, if electrostatic).


The following was taken directly from Allisons directives to installers and should be read by anyone who owns a vehicle with any of these transmissions as the units can be damaged/destroyed if the proper precautions are not taken. And since so many folks here routinely use welding as part of their conversion process, I consider this information critical. Below is the data taken from the Allison bulletin...

Allison Section C:
Controls Component Installation Bulletin


3.2 Welding on the Vehicle

Take the following steps whenever welding on the vehicle:
Always disconnect the harnesses from the TCM.
Always disconnect the TCM power and ground circuits from the battery.
Do not connect welding cables to controls components.
Do not weld on controls components.
Always protect controls components from sparks and heat.


3.3.1 Electrostatic Painting

If the vehicle chassis or body is painted using an electrostatic painting process, electrical voltage must not be discharged through the TCM. To prevent this possibility, Allison recommends installing the TCM after the electrostatic paint process is complete. If the TCM is installed prior to electrostatic painting, the vehicle

Builder must insure the following:

that the TCM is not painted
that the elements being painted are properly and continuously grounded to earth during the entire painting process. Allison Transmission is not responsible for TCM damage which results from improper grounding during

Electrostatic painting of the vehicle.

During electrostatic painting, the paint droplets receive an electrostatic charge which attracts them to earth-grounded surfaces. Voltages at the spray gun can exceed several thousand volts. The charge which builds up on an improperly chassis or body can be discharged through the TCM, resulting in damage to the TCM.


Given that Allisons are so prevalent in Skoolies, this seemed important enough to me that I thought everyone here should be made aware of these considerations. I know that I was misinformed. I previously understood that simply disconnecting the battery was adequate but that turns out to be a dangerous misconception based on this "official" data. Fortunately, I have yet to install my TCM. Glad I found this first.

good info!

so even on the 4th gen they use a separate TCM box? so it can be easily unplugged during work on the bus?

the more I think about it..the more I like the idea of swapping my 545 out for a 4th gen 6 speed...

-Christopher
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Old 04-28-2016, 01:38 PM   #1587
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Wonder if you could put some sort of protection inline? Like a GFI or a fuse, some sort of safety device, but in technical terms that I know not of.
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Old 04-28-2016, 01:43 PM   #1588
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Hey Cadillac --- Look around and see if you can locate a used 5th gen...they don't require any modding, hacking or non-existent harnesses to work. You can set it up with just a TPS and bypass any tricky coding or connectivity issues. And 6th gear is there, it doesn't need to be unlocked like nearly all 4th gen units. They have been out since about 2010 as I recall and are on plenty of newer medium duty trucks of different makes.
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Old 04-28-2016, 01:51 PM   #1589
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Hey Opus --- since my electrical savvy is just about zilch squared, I would personally not attempt to work around the requirements issued by Allison. Me...I'll just unplug that sucker before doing any welding.

The electrostatic painting thing will probably not be an issue with my rattle-cans unless I get hit by lightning while doing it, in which case the TCM will be the least of my worries.
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Old 04-28-2016, 02:25 PM   #1590
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Quote:
Originally Posted by Tango View Post
Hey Cadillac --- Look around and see if you can locate a used 5th gen...they don't require any modding, hacking or non-existent harnesses to work. You can set it up with just a TPS and bypass any tricky coding or connectivity issues. And 6th gear is there, it doesn't need to be unlocked like nearly all 4th gen units. They have been out since about 2010 as I recall and are on plenty of newer medium duty trucks of different makes.
5th gen thats right.. I was thinking it was 4th.. what did you do? get a reman unit?

to me it looks like the mounts and driveshaft are an inch or less from the AT545.. and of course its allison they will have the correct SAE to mate to a DT engine.. (or should)....

not like I havent moved a rear crossmember or fabbed an "adapter plate" to "move the hole" before.. and driveshafts are easy.. just get it cut down..

with only 3/4" in length I probably technically wouldnt have ot mess with the pinion angle
-Christopher
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