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Old 03-20-2015, 08:49 PM   #1
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at545 to mt643 swap on dt466

has anyone done this swap and what do you have to change if you have?

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Old 03-21-2015, 08:40 AM   #2
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has anyone done this swap and what do you have to change if you have?
I'm going to have to swap my At545 out.

But I'm going to swap it for a Cummins 8.3 and md 3060 combo.

I will find a 8.3 with a 3060 already behind it.

Nat
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Old 03-21-2015, 10:55 AM   #3
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I think you're a bit ahead of me in this swap, but from what I've found, you're likely going to need to swap/remove/add an adapter between engine and trans as the two trans have different bolt patterns. And, I believe you have to adjust drive shaft length/connection as well as trans mount.
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Old 03-21-2015, 06:46 PM   #4
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if you accidentally roll your MT643 on it's side while trying to get it off the trailer, it will spill an incredible amount of tranny fluid on your driveway LOL
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Old 03-21-2015, 11:54 PM   #5
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Ha ha, woops.
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Old 03-22-2015, 12:44 AM   #6
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Only about 4 1/2 gallons.
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Old 03-22-2015, 01:56 PM   #7
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You'll have to look at your current flywheel housing to see what you'll need. On my bus, it has an sae2 flywheel housing necked down to an sae3 adapter that mates to the transmission. You'll also have to see if your current flexplate will work with the new converter. I bet it would but you might need spacers changed to get it to sit at the right depth. After that, the transmission should bolt right up. As said previously, you'll have to check driveshaft length.
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Old 03-22-2015, 06:33 PM   #8
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I think I have bought the sae 3 to sae 2 adapter and it is being shipped, if not I just wasted 60 dollars
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Old 03-22-2015, 07:54 PM   #9
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I think I have bought the sae 3 to sae 2 adapter and it is being shipped, if not I just wasted 60 dollars
You just wasted $60. What you probably bought is what you already have. The DT466 has a #2 with a #3 bolted to it if you have an AT545. I wouldn't proceed any further without going to a Allison transmission shop and finding out exactly what you need. While there is nothing wrong with asking for advice on a or this forum, it is worth what you paid for it. Zero. I think very few on here have actually done this swap. I want to be one of those few but not enough $$$ or time.
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Old 03-22-2015, 07:58 PM   #10
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You'll have to look at your current flywheel housing to see what you'll need. On my bus, it has an sae2 flywheel housing necked down to an sae3 adapter that mates to the transmission. You'll also have to see if your current flexplate will work with the new converter. I bet it would but you might need spacers changed to get it to sit at the right depth. After that, the transmission should bolt right up. As said previously, you'll have to check driveshaft length.

The MT643 needs a #2 and the AT545 needs a #3. Usually a DT466 has both, one bolted onto the other for the AT545.
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Old 03-23-2015, 11:01 AM   #11
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The MT643 needs a #2 and the AT545 needs a #3. Usually a DT466 has both, one bolted onto the other for the AT545.
Yes, I forgot to mention that I'm currently using an at545 which has the neck down for the sae3 housing. He will likely have the same neck down which will need to be removed. That elimination of the neck down might require elimination/creation of spacers behind the flywheel to set up the correct converter distance/depth into the trans. Your driveshaft will also for sure have to be shortened because IIRC the mt643 is something like 4" longer then the at545 that you're removing.
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Old 03-23-2015, 11:57 AM   #12
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For what its worth, this makes me think about a cooler install if he doesn't have one now. 4" is a lot. Could the motor be mounted back farther with fabricated brackets so the drive shaft is long enough and then have enough room to place a cooler in front of the radiator? It would make room to move the radiator back which eliminates that problem. I suppose it depends on the room he has behind the motor. Just creative thinking here.
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Old 03-23-2015, 06:10 PM   #13
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For what its worth, this makes me think about a cooler install if he doesn't have one now. 4" is a lot. Could the motor be mounted back farther with fabricated brackets so the drive shaft is long enough and then have enough room to place a cooler in front of the radiator? It would make room to move the radiator back which eliminates that problem. I suppose it depends on the room he has behind the motor. Just creative thinking here.
Your better off modifying the drive shaft.

Moving a engine is way way more work. Many many connections to a ton of different things.

Nat
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Old 03-23-2015, 06:18 PM   #14
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with the MT643 there should be no tranny heating issues because of the lock up torque converter, the build in cooler will be sufficient
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Old 03-24-2015, 12:28 PM   #15
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The converter in the MT643 only locks in 3rd and 4th gears. So, if you're climbing steep hills, it's probably still a good idea to add a transmission cooler.

I have one on my bus, because we are driving through the mountains of Colorado with an AT542. It was required. We mounted it in the front bumper, only had to add one short section of hose from the radiator intercooler over to the oil cooler, and reused the old return line. Doing this while swapping the transmission would probably only add 10% more work.
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