IS

INSTRUCTION SHEET
FS
Copyright 2011 Allison Transmission, Inc. All Rights Reserved.
Revisions to this IS are noted INSTRUCTION SHEET NO. 327
by a stripe in the left-hand margin. Rev A
P/N 29545238
February, 2011
Page 1 of 7
SUBJECT: S9800/S9810 Upgrade to S9820
This instruction sheet is included with the S9820 Basic Upgrade Kit 29547623 and the S9820 Special Overhaul
Kit 29547624.
The following components have been upgraded or replaced in the S9820 transmission. These kits contain the
internal components necessary to convert a qualified S9800 or S9810 (with the updates listed above) into a
S9820 transmission. Also required to complete this upgrade is Seal and Gasket Kit 29544266. For assembly
and disassembly instructions not covered in this document refer to Service Manual SM1833EN.
All parts mentioned in this instruction sheet are included in both kits unless otherwise noted.
Splitter Planetary Bearing
Prior to the release of the S9820 an improvement was released for the splitter planetary carrier to im-
prove durability. Planetary assembly 29543957 with carrier 29543958, featuring a full fillet root spline,
replaced planetary assembly 29541576 with carrier 29541575. It is required for units prior to S/N
4320002539 that carrier 29541575 be replaced by 29543958 in conjunction with this upgrade.
For the S9820, splitter planetary bearing 23012848 is replaced by bearing 29545371. The new splitter
planetary assembly is identified as 29545370. The new planetary bearings are provided in the Basic Up-
grade Kit. The complete planetary assembly is included in the Special Overhaul Kit.
NOTE: Prior to beginning this upgrade, it is required that the transmission be up to date per SIL
12-TR-01 and SIL 27-TR-02. Failure to update to SIL 12-TR-01 and SIL 27-TR-02 will adversely
affect lube oil distribution throughout the transmission and will lead to reduced product life.
INSTRUCTION SHEET NO. 327
Rev A
P/N 29545238
February, 2011
Page 2 of 7
Copyright 2011 Allison Transmission, Inc. All Rights Reserved.
Coupling and Splitter Input Shaft
Coupling 29544015 replaces rotor hub 23012004. The S9820 coupling features a full fillet radius spline.
In order to maintain proper lube flow through this spline a new splitter input shaft 29546741 is required.
The new shaft features an identification groove on the OD of the spline as shown in Figure 1.

Figure 1. Identification Groove on Splitter Input Shaft
CAUTION: This new shaft must be used with the new coupling only and should not be used with
the old rotor hub. The new coupling also requires the use of sealring 23016656 (in service kit
23019731) in place of 23016679 (in service kit 23019650). Bearing 29502065 and bearing
23048011 are provided with both kits for assembly purposes.
V11002.00.00
SPLITTER INPUT SHAFT
FORMER
(P/N 29541583)
CURRENT
(P/N 29546741)
IDENTIFICATION GROOVE
INSTRUCTION SHEET NO. 327
Rev A
P/N 29545238
February, 2011
Page 3 of 7
Copyright 2011 Allison Transmission, Inc. All Rights Reserved.
Input Bearing Retainer
To accommodate the new coupling the current input bearing retainer 29530093 must be reworked into
the S9820 input bearing retainer 29544016 by machining the ID per the instructions shown in Figure 2.

Figure 2. Rework of Input Bearing Retainer
Splitter Ring Gear Hub
Splitter ring gear hub 23013782 is replaced by 29545541. The new hub requires the use of backing
ring 29545661, O-ring 29507437, bearing 29547613, retainer 29545540, and center hub 29545539 as
shown in Figure 3.
30
100
0.1200.160 in.
(3.0484.064 mm)
0.060 in. (1.524 mm)
RAD. MAX.
1.297 in.
(32.944 mm)
V11004.00.00
NOTE: Rework 29530093 as shown to create 29544016.
Tolerance on machined dimensions is +/- 0.010 in. unless otherwise specified.
Must be clean and free from burrs after rework.
60120
4.6254.628 in.
(117.475117.551 mm)
A .005
0.060 in. (1.524 mm)
x 45 CHAMFER
A
INSTRUCTION SHEET NO. 327
Rev A
P/N 29545238
February, 2011
Page 4 of 7
Copyright 2011 Allison Transmission, Inc. All Rights Reserved.
Splitter Output Shaft
The main feature of the S9820 transmission is the larger splitter output shaft assembly 29543459. This
shaft requires a different method of assembly than with the previous splitter output shaft. This method
is illustrated in Figure 3. First the intermediate clutch hub assembly 6884846 and bearing 23049160
should be installed onto the shaft. Then the high clutch drum assembly 29547622 with piston assembly
23045566, spring 6756042, sealrings 23016679, and snapring 6756041 must be installed onto the
shaft. The center hub 29545539, bearing 29547613, retainer 29545540, and splitter ring gear hub
29545541 must be installed into the main housing. The shaft must then be inserted from the rear of the
main housing through the splitter ring gear hub. From the front of the main housing, backing ring
29545661, O-ring 29507437, and snapring 6750259 are then installed to retain the splitter output shaft.
Backing plate 6770848 and snapring 6755100 are included in both kits to complete the assembly of high
clutch. Complete details are available in the current SM1833E
Figure 3. Installation of Splitter Output Shaft
DRUM ASSY (P/N 29547622)
PISTON ASSY (P/N 23045566)
SEALRING (P/N 6832481)
SPRING (P/N 6756042)
HUB ASSY (P/N 6884846)
SHAFT ASSEMBLY
(P/N 29543459)
SEALRING (P/N 23016679)
SEALRING (P/N 6770623)
BEARING (P/N 23049160)
RING (P/N 8892840)
RING (P/N 6756041)
SEALRING
(P/N 23016679)
SNAPRING
(P/N 6750259)
6-BOLT (P/N 9414052)
(TORQUE TO 96 - 115 LB - FT)
6 - WASHER (P/N 115551)
SPLITTER RING
GEAR HUB
(P/N 29545541)
BACKING RING
(P/N 29545661)
O-RING
(P/N 29507437)
INTO CENTER HUB AND
SPLITTER RING GEAR HUB
INSERT SHAFT WITH
COMPONENTS SHOWN
INSTALL O-RING,
BACKING RING, AND
SNAPRING AFTER
INSTALLATION
OF SHAFT
CENTER HUB (P/N 29545539)
BEARING (P/N 29547613)
HOUSING ASSY (P/N 29537807)
RETAINER (P/N 29545540)
V11013.00.01
INSTRUCTION SHEET NO. 327
Rev A
P/N 29545238
February, 2011
Page 5 of 7
Copyright 2011 Allison Transmission, Inc. All Rights Reserved.
Intermediate Carrier
The S9820 intermediate planetary carrier has been modified to accommodate the larger splitter output
shaft. Carrier 29543464 replaces 6884432 creating intermediate planetary assembly 29543465. Roller
bearing 29543466 replaces 29503975 and is retained by snapring 6774184. Carrier 29543464 is includ-
ed in the Basic Upgrade Kit. The complete planetary assembly 29543465 is included in the Special
Overhaul Kit.
Low Sun Gear
Low sun gear 29543467 replaces 23018429 for use with the larger splitter output shaft. Thrust
washer 23018430 is replaced by 29543468.
Speed Sensors
The production built S9820 is equipped with three CEC2 style speed sensors as a provision for future
Allison electronic controls operation. The only sensor currently required for transmission operation is the
output speed sensor. It is not required to update the sensor for normal transmission operation. This kit
does not provide a means to update to the CEC2 style sensor. The transmission will operate normally
with the existing speed sensor installed in your transmission.
Control Valve Assembly
Solenoid/Harness
The B solenoid is eliminated on the S9820. This is possible due to the elimination of the Lock feature.
The solenoid is replaced by solenoid blocking plate 29544178 as shown in Figure 4. Secure the plate
using the two included bolts 454813 and two flat washers 103339 (not included in kits). When re-install-
ing the solenoid harness, do not connect the B connector to any solenoid.
Lock Valves
Lock valve 6779837 is replaced by 29544153. The lock valve spring 6832304 is eliminated as shown in
Figure 4.
High-Intermediate Trim Valve
High-intermediate trim valve 6882222 is replaced by valve 29544149 as shown on Figure 4.
Lo-Lo channel plate
To improve diagnostics the lo-lo channel plate 6839870 is replaced by plate 29544173.
NOTE: Must be used together with 29544666 separator plate, and gaskets 29544151 and
29544152.
INSTRUCTION SHEET NO. 327
Rev A
P/N 29545238
February, 2011
Page 6 of 7
Copyright 2011 Allison Transmission, Inc. All Rights Reserved.
Separator Plate and Gaskets
Separator plate 23016161 is replaced by separator plate 29544666. Gasket 23016162 that fits between
the channel plate and separator plate is replaced by gasket 29544151. Gasket 23016163 that fits be-
tween the separator plate and valve body is replaced by gasket 29544152. These new gaskets are in-
cluded in the Seal and Gasket Kit 29545237.
Figure 4. Rework of Control Valve Assembly
NOTE: Separator plate 29544666 must be used together with 29544173 lo-lo channel plate.
V11001.00.00
REMOVE B SOLENOID
REPLACE WITH PLATE - P/N 29544178
2 - BOLTS - P/N 454813
REMOVE LOCK SHIFT VALVE AND SPRING
REPLACE WITH VALVE - P/N 29544153
WITHOUT SPRING
REMOVE HIGH-INTERMEDIATE TRIM VALVE
REPLACE WITH VALVE - P/N 29544149
INSTRUCTION SHEET NO. 327
Rev A
P/N 29545238
February, 2011
Page 7 of 7
Copyright 2011 Allison Transmission, Inc. All Rights Reserved.
Parts List for S9820 Kits
S9820 Basic Upgrade Kit
29547623
S9820 Special Overhaul Kit
29547624
P/N Qty Name P/N Qty Name
29544015 1 Coupling 29544015 1 Coupling
23019731 1 Sealring Kit 23019731 1 Sealring Kit
29545371 4 Bearing Splitter Planet 29545370 1 Planetary Assy - Splitter
29545541 1 Hub Splitter Ring Gear 29545541 1 Hub Splitter Ring Gear
29547613 1 Bearing Ball 29547613 1 Bearing - Ball
29502065 1 Bearing 29502065 1 Bearing
23048011 1 Bearing 23048011 1 Bearing
29545540 1 Retainer Bearing 29545540 1 Retainer Bearing
29545539 1 Hub Oil Transfer 29545539 1 Hub Oil Transfer
29546741 1 Shaft- Splitter Input 29546741 1 Shaft- Splitter Input
29545661 1 Ring Backing 29545661 1 Ring Backing
29507437 1 O-ring 29507437 1 O-ring
29547622 1 Drum Assy High Clutch 29547622 1 Drum Assy High Clutch
6770848 1 Backing Plate 6770848 1 Backing Plate
6755100 1 Snapring 6755100 1 Snapring
29543464 1 Carrier Int. Planetary 29543465 1 Planetary Assy Int.
29543459 1 Shaft Assy Spl. Output 29543459 1 Shaft Assy Spl. Output
29543466 1 Bearing 29543466 1 Bearing
6774184 1 Snapring 6774184 1 Snapring
29543467 1 Sun Gear Low 29543467 1 Sun Gear Low
29543468 1 Thrust Washer 29543468 1 Thrust Washer
29544666 1 Separator Plate 29544666 1 Separator Plate
29544178 1 Plate Solenoid Blocking 29544178 1 Plate Solenoid Blocking
454813 2 Bolt 454813 2 Bolt
29544149 1 Valve Trimmer 29544149 1 Valve Trimmer
29544153 1 Valve Lock 29544153 1 Valve Lock
29544173 1 Plate Low Low Channel 29544173 1 Plate Low Low Channel
29545238 1 Instruction Sheet 6884312 1 Gear Spl. Sun
29503894 1 Gear High-Int. Sun
29503895 1 Gear High-Int Ring
23041616 25 Plate Clutch Friction
6776610 24 Plate Clutch Reaction
23041615 11 Plate Clutch Friction
6777796 11 Plate Clutch Reaction
6832138 3 Plate Clutch Friction
6779887 2 Plate Clutch Reaction
29545238 1 Instruction Sheet