Cloning the software from a TCM is actually pretty easy..
you'll need a laptop with the internet DIsabled..
a copy of the Allison DOC software with reprogramming enabled.. it is "available online"..
a Nexiq USB link2 or chinese Clone RP1210 to USB hardware device.
running the DOC software you can read a TCM's complete data into your laptop and save it as a file.
you can then run the programmer routine and write a file to a TCM..
so simply cloning one was i read both TCM's into the computer.. and then I wrote the 6 speed one to the TCM of the 5 speed bus..
I cleared the ADAPTs which essentially clears out the meager auto-learning functions of the TCM.. Auto learn .. this may not have really done anything as the earlier versions of code didnt support it.. but since these busses are newer than 99 when it was introduced i did it..
take the bus out and floor it shifting up to at least 4th gear each time for several times to set the adapts..
adaptive learn is a shift-quality learning process.. Allisons dont have Bands.. they are clutch-only transmissions.. in this configuration Flare shifts and Binding can become a problem if the calibration is off.. the TCM protects itself from damaging the transmission by taking generally "looser" shifts.. in later revisions adaptive learning was created to "tighten" up the shifts without creating binds..
Flare shift - clutch 1 disengages and there is a lag before clutch 2 engages.. you'll notice a lag and surge feel to your shift and your tach may jump up a couple hundred RPM before dropping down into next gear.
Bind - clutch 2 engages before clutch 1 disengages enough to allow good slippage.. you'll notice a sharp quick snap back and forth (not a forward surge or push like a solid shift but a back N forth once quick snap).. this is dangerous because you are tryingto slip a clutch that is engaged and also slip a clutch that wants to spin faster as it engages.. causes fast wear of clutches and extra heat..
not all shifts in an allison require release of 1 clutch and then grab of another.. some shifts are simply a grab of another clutch (some gears actually use 2 clutches at once purposely).. that is why different shifts in allisons feel different from each other apart from the ratio changes..
-Christopher