ALLISON

AT540, 543, 545

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

138
 ALLISON
AT540, 543, 545
NOTE: Early AT540/545 parts up to serial number 3210775436.
Late AT545 parts from serial number 3210775437.

Allison Transmissions
AT540, 543, 545

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

AT540
Rebuilder Kits - Exc. 543
- w/Armstrong® 1 - K1100 K1100-LS K11900W
Overhaul Kit - Exc. 543
- w/Cork & Neoprene 1 - K11900
Rebuilder Kits - 543 European 1 - K1100A K11900A
Front Pump Re-Seal Kit - All (1) 1 - K11900-2
(1) Contains front pump gasket, rubber lathe-cut seal, o-ring and pump bolt washers.

ILL. DESCRIPTION QTY. YEAR PART NO. REFERENCE NO.

MISCELLANEOUS GASKETS & SEALS/PAN GASKETS
1F Gasket - Oil Pan - Cork - Neoprene ........................................................ (23016682) 1 - 13540X 29501160
1F Gasket - Oil Pan - Update - Armstrong® ................................................ (23016682) 1 - 13540W 29501160
N.I. Gasket - Converter Pump Hub - 543 - Bolt On Hub ................................ (29524795) 1 - 13150W 29536726
N.I. Seal - Lathe Cut - Converter Pump - 543 .................................................................. 1 - 13151 23016564
2A Seal - Lathe Cut - Front Pump Body ......................................................................... 1 - 3877L 23016559
3A Seal - Washer - Front Pump Body Bolt ...................................................................... 9 - 13268A 8626281
4A Seal - Lathe Cut - Front Pump Support ..................................................................... 1 - 13152 23016600
6A Gasket - Front Pump To Case ................................................................................... 1 - 13153 23015883
7A Lip Seal - Forward Clutch - Inner ............................................................. (8623102) 1 - 3956L 29520291
8A Lip Seal - Forward Clutch - Outer ............................................................. (8623101) 1 - 3643L 29520292
9B Lip Seal - Fourth Clutch - Inner ................................................................................ 1 - 3284L 23015880
10B Lip Seal - Fourth Clutch - Outer ................................................................................ 1 - 3643L 8623101
11C Lip Seal - Third Clutch - Inner .................................................................................. 1 - 13154 23011475
12C Lip Seal - Third Clutch - Outer .................................................................................. 1 - 13155 23011456
13C Lip Seal - Second Clutch - Outer .............................................................................. 1 - 13155 23011456
14C Lip Seal - Second Clutch - Inner .............................................................................. 1 - 13154 23011475
15E Lip Seal - First Clutch - Outer ................................................................. (23011474) 1 - 13156 29509198
16E Lip Seal - First Clutch - Inner ................................................................. (23011457) 1 - 13157 29509983
17F Gasket - Power Takeoff Cover - Update - Armstrong® .............................................. 1 - 13158W 29501161
18F O-Ring - Modulator ............................................................................... (23017367) 1 - 3410L 8658110
19F Gasket - Governor Cover - Fibre ................................................................................ 1 - 3914D 23011670
20F O-Ring - Oil Filter ...................................................................................................... 1 - 3547L 1363951
N.I. Washer - Drain Plug (Metal) ...................................................................................... 1 - 11423 29507909
N.I. Washer - Drain Plug (Coated) ................................................................................... 1 - 11423B 29507909
N.I. Check Ball - 1/4" ...................................................................................................... 1 - 13924 23045388
N.I. Check Ball - 5/16" .................................................................................................... 1 - 13924A 23045386

CLUTCH PLATES
21B Friction - Forward Clutch (2) .................................................................................... 5 - R11103 23042197
21B Friction - Forward Clutch (3) .................................................................................... 5 - W11103 23042197
23B Friction - Fourth Clutch (2) ...................................................................................... 5 - R11103 23042197
23B Friction - Fourth Clutch (3) ...................................................................................... 5 - W11103 23042197
25C Friction - Third Clutch (2) ..................................................................... (29529492) 3 - R11104 29537887
25C Friction - Third Clutch (3) ........................................................................................ 3 - W11104 29537887
(2) Raybestos brand plate. OEM approved heat-treated paper.
(3) S.K. Wellman plate. OEM approved graphitic.

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ALLISON
AT540, 543, 545
To Get The Correct Parts, You Must Provide The Assembly Number Found On The Transmisson Name Plate.
ILL. DESCRIPTION QTY. YEAR PART NO. REFERENCE NO.

CLUTCH PLATES (Cont.)

27C Friction - Second Clutch (2) ................................................................. (29529492) 3 - R11104 29537887
27C Friction - Second Clutch (3) .................................................................................... 3 - W11104 29537887
29E Friction - First Clutch (2) .......................................................................................... 7 - R11106 23042198
29E Friction - First Clutch (3) .......................................................................................... 7 - W11106 23042198
22B Steel - Forward Clutch ............................................................................. (6836518) 5 - 34305C 29530330
24B Steel - Fourth Clutch ............................................................................... (6836518) 5 - 34305C 29530330
26C Steel - Third Clutch ............................................................................... (23045554) 3 - 11105 29515399
28C Steel - Second Clutch ........................................................................... (23045554) 3 - 11105 29515399
30E Steel - First Clutch .................................................................................................... 7 - 11107 6831705
35B Plate - Backing - 4th Clutch ..................................................................................... 1 - 11763 23017763
N.I. Plate - Waved - Forward Clutch ................................................................................ 1 - 11875 29505875
(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 FK11800 6884270
40F Filter Kit - Screen - Armstrong® ............................................................................... 1 - FK11800W 29502295
40F Filter Kit - Treated Paper - with Cork - Neoprene ......................................................... 1 - FK11800A PF-168
40F Filter Kit - Treated Paper - Armstrong® ..................................................................... 1 - FK11800AW 29506392
40F Filter Kit - Screen - Late AT Deep Pan ..................................................... (29513271) 1 - FK34661SW 29540976
N.I. Filter Kit - Deep Pan Design (contains tube, bracket) ................................................. 1 - UDK-545-1 29538490
45F Filter - External Spin on Cartridge - One Quart .......................................... (PH35109) 1 - PF897 25611122
45F Filter - Metal Screen ................................................................................. (6884270) 1 - 11800 29502295
45F Filter - Brass Screen .................................................................................................. 1 - 34661S 29500365
45F Filter - Treated Paper ................................................................................................. 1 - 11800A N.L.
45F Filter - 545 Update ................................................................................................... 1 - 21800 6883044
N.I. Screen - Governor Tube ........................................................................................... 1 - 11712 23045247

VACUUM MODULATORS
50F Modulator - w/ O-Ring - Lg Can ............................................................................... 1 - 11820 3039092
Modulator - w/ O-Ring - Sm Can .............................................................................. 1 - 11820A 29501199

METAL CLAD SEALS

52A Front Pump - Vamac Material ................................................................................... 1 - 38151V 8641300
55F Extension Housing ................................................................................................... 1 - 11850 6778050
58F Selector Shaft .......................................................................................................... 1 - 38511 23010610

BUSHINGS
N.I. Bushing Kit - 7 Bushings - AT540/ Early 545 ............................................................ 1 - K11902 N.L.
Bushing Kit - 7 Bushings - Late 545 ......................................................................... 1 - K11902A N.L.
60A Front Pump Body - Babbitt - Update Version .......................................... (23018806) 1 - 8005 29511860
63A Stator Shaft - Front - Bronze Lined ........................................................... (6836272) 1 - 34002 23015807
65C Center Support - 1.540 O.D. .................................................................................... 1 - 11000 23012990
Center Support - 1.600 O.D. .................................................................................... 1 - 11000A 29506468
68D Sun Gear Shaft - Front - 1st Design - 1.125 O.D. ..................................... (6836272) 1 - 34002 23015807
Sun Gear Shaft - Front - 2nd Design - 1.190 O.D. ..................................................... 1 - 11007 29522949
70D Sun Gear Shaft - Rear .............................................................................. (6836272) 1 - 34002 23015807
72D Front Planetary Carrier ............................................................................................... 1 - 11001 23045072
75E Output Shaft - .775 O.D. .......................................................................................... 1 - 11002 8622947
Output Shaft - .815 O.D. .......................................................................................... 1 - 11002A 29502231

SEALING RINGS/RING KITS

N.I. Sealing Ring Kit - Complete - 5 Rings ....................................................................... 1 - K11901 N.L.
80A Front Pump ............................................................................................................. 2 - 11302 23046598
82A Turbine Shaft ........................................................................................................... 1 - 11301 8616052
85C Center Support ........................................................................................................ 2 - 11302 23046598

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 ALLISON
AT540, 543, 545
To Get The Correct Parts, You Must Provide The Assembly Number Found On The Transmisson Name Plate.
ILL. DESCRIPTION QTY. YEAR PART NO. REFERENCE NO.

THRUST WASHERS/NEEDLE BEARINGS

N.I. Spacer - Turbine:
- .015" - Gold - 543 ................................................................................................. AR - 11403 6837429
- .030" - Silver - 543 ................................................................................................ AR - 11403A 6837430
- .042" - Plain - 543 ................................................................................................. AR - 11403B 6837431
- .060" - Black - 543 ................................................................................................ AR - 11403C 6837432
- .075" - Copper - 543 ............................................................................................. AR - 11403D 6837433
87A Washer - Front Cover:
- .056"-.060" No. “0” .............................................................................................. AR - 11407 6831620
- .072"-.076" No. “1” .............................................................................................. AR - 11407A 6831621

AT540
- .089"-.093" No. “2” .............................................................................................. AR - 11407B 6831622
- .105"-.109" No. “3” .............................................................................................. AR - 11407C 6831623
- .121"-.125" No. “4” .............................................................................................. AR - 11407D 6831624
- .138"-.142" No. “5” .............................................................................................. AR - 11407E 6831625
89B Washer - Fourth Clutch Driving Hub ......................................................................... 1 - 34301 23013454
Washer - Front Sun Gear:
91D - Front (up to serial number 3210775436). ...................................................................... 1 - 11411 6831658
- Front (from serial number 3210775437) ................................................................ 1 - 11411A 29506146
93D - Rear .064 -.068" - Color Code Red ........................................................................ AR - 11412 23013451
Washer - Front Planetary:
95D - Bronze - Pinion Gear .............................................................................................. 8 - 11413 6839514
97D - Steel - Pinion ......................................................................................................... 8 - 11414 6833991
98D - Rear - Carrier ......................................................................................................... 1 11415 6831673
Washer - Center Planetary:
100D - Bronze - Pinion ...................................................................................................... 8 - 11416 6839376
102D - Steel - Pinion ......................................................................................................... 8 - 11417 6831680
104D - Rear - Carrier (up to serial number 3210775436) .................................................... 1 - 11418 6831692
- Rear - Carrier (from serial number 3210775437) ..................................................... 1 - 11418A 29506147
Washer - Rear Planetary:
106E - Bronze - Pinion ...................................................................................................... 8 - 11416 6839376
108E - Steel - Pinion ......................................................................................................... 8 - 11417 6831680
110E Washer - Rear Planet Carrier - Front & Rear ................................................................ 2 - 11419 6831697
112F Washer - Output Flange Bolt ..................................................................................... 1 - 11421 29500739
N.I. Washer - Center Support Bolt ................................................................................... 1 - 11422 23014094
N.I. Washer - Drain Plug (Metal) ...................................................................................... 1 - 11423 29507909
N.I. Washer - Drain Plug (Coated) ................................................................................... 1 - 11423B 29507909
BEARINGS
115B Bearing Package - Forward Hub - Front - (3 Piece) .................................................... 1 - 11503BK 9414211
N.I. Bearing/Race Kit ...................................................................................................... 1 - 11500BK N.L.
N.I. Roller Bearing - Converter Stator - 543 ...................................................................... 1 - 11404 23016866

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.

ILL. DESCRIPTION BRAND QTY. YEAR PART NO. REF NO.

120A Kit - Front Pump Gear - Oversized ........................................................................ 1 - K11201B N.L.

120A Kit - Front Pump Gear .727 Thick ........................................................................ 1 - K11201 N.L.
123A Roller Bearing - Ground Sleeve ............................................................................. 1 - 11221 148415
126A Ground Sleeve (Finished I.D. - Bearing Inst.) ........................................................ 1 - 11202 23014304
130D Pin - Front Planetary ............................................................................................ 4 - 11215 6834309
135D Needle Roller - Front Planetary ............................................................................. 80 - 11919 9426919
137D Kit - Front Planetary Repair .................................................................................. 1 - K11215 N.L.
141D Needle Roller - Center Planetary ............................................................. 9426920 76 - 11920 29501499
143D Pin - Center Planetary .......................................................................................... 4 - 11216 6831679
147D Kit - Center Planetary Repair ................................................................................ 4 - K11216 N.L.

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ALLISON
AT540, 543, 545
To Get The Correct Parts, You Must Provide The Assembly Number Found On The Transmisson Name Plate.
ILL. DESCRIPTION BRAND QTY. YEAR PART NO. REF NO.

HARD PARTS (Cont.)

148C Center Support - Early (7) ................................................................................... 1 - 11229 23013015
148C Center Support - Late - Large Hole (8) ................................................................ 1 - 11229A 29525518
153E Needle Roller - Rear Planetary .............................................................................. 76 - 11920 9426920
155E Pin - Rear Planetary ............................................................................................. 4 - 11216 6831679
157E Kit - Rear Planetary Repair ................................................................................... 1 - K11216 N.L.
160A Turbine Shaft - Early - All ..................................................................................... 1 - 11939 6835939
160A Turbine Shaft - Late - All ...................................................................................... 1 - 11939B 29525516
162D Shaft - Sun Gear - Early (7) ................................................................................. 1 - 11225 6835937
162D Shaft - Sun Gear - Late (8) .................................................................................. 1 - 11225A 29506158
164D Shaft - Main - 1" Journal - Early (7) ..................................................................... 1 - 11226 23013474
164D Shaft - Main - Reinforced - 1.060 Journal - Late (8) ............................................ 1 - 11226B 29524363
165D Sun Gear - Front - Early (7) ................................................................................. 1 - 11232 6835732
165D Sun Gear - Front - Late (8) .................................................................................. 1 - 11232A 29506151
166D Sun Gear - Center - Early ..................................................................................... 1 - 11227 6835936
166D Sun Gear - Center - Late ...................................................................................... 1 - 11227B 29506150
168D Sun Gear - Rear - (Low) - Early (7) ...................................................................... 1 - 11228 6884902
168D Sun Gear - Rear - (Low) - Late (8) ...................................................................... 1 - 11228A 29506149
170F Bolt - Output Flange ......................................................................... (23014159) 1 - 11222 29510838
172F Governor Assembly I.D. No. 460 ......................................................................... 1 - 11410 6881466
172F Governor Assembly I.D. No. 461 ......................................................................... 1 - 11410A 6885570
172F Governor Assembly I.D. No. 462 ......................................................................... 1 - 11410B 6885571
180F Oil Pan - Deep - Offset Threaded Inlets ................................................................. 1 - 11545 23045906
180F Oil Pan - Deep - Even Threaded Inlets .................................................................. 1 - 11545A 29501358
190F Kit - Manual Selector Shaft .................................................................................. 1 - K11235 23017610
192C Piston - Center Support ...................................................................................... 2 - 11817 6834817
200D Front Planet Assembly ........................................................................ (6835768) R 1 - 11768 23046074
201D Center Planet Assembly ....................................................................................... R 1 - 11676 6831676
207E Rear Planet Assembly .......................................................................................... R 1 - 11719 6837719
210A Pump Body & Gears - AT540 Only (9) ................................................................. R 1 - 34200C 23018811
210A Pump Body & Gears - AT545 .............................................................................. R 1 - 34200D 29537354
212B Hub - 4th Clutch - Early (7) ................................................................................ 1 - 11732 23015732
Hub - 4th Clutch - Late (8) ................................................................................. 1 - 11732A 29509661
214B Hub - Forward Clutch - Early (7) ........................................................................ 1 - 11634 6831634
Hub - Forward Clutch - Late (8) ......................................................................... 1 - 11634A 29506145
215F Tube & Dip Stick Assembly - Universal ................................................................. 1 - 11999U N.L.
216B Housing - 4th Clutch - Early (7) ......................................................................... 1 - 11769 29510769
216B Housing - 4th Clutch - Late (8) .......................................................................... 1 - 11769A 29506156
220A P.T.O. Gear .......................................................................................................... R 1 - 11915 6885145
222A Housing - w/o Turbine Shaft - Forward Clutch - Early (7) .................... (6838298) R 1 - 11298 29509660
222A Housing - w/ Turbine Shaft - Forward Clutch - Late (8) ........................................ 1 - 11298B 29506185
225A Support - Front Pump - AT540 - Body Cast #895 ............................................... R 1 - 11920 23014020
225A Support - Front Pump - AT545 - Body Cast #919 ............................................... R 1 - 11920B 29509636
228F Bearing - Output - Early ....................................................................................... 1 - 11925 23047959
228F Bearing - Output - Late ........................................................................................ 1 - 11925A 23047970
N.I. Bolt - Torque Converter ....................................................................................... 1 - 96-178 23014542
N.I. Center Support Repair Sleeve - Early .................................................................... 1 - DF636B N.L.
N.I. Conversion Kit - (Deep Pan) AT540 To AT545 ..................................................... 1 - UDK-545 23012575
N.I. Drain Plug - Oil Pan ............................................................................................. 1 - DP-789 N.L.
N.I. Housing & Flex Plate Package - 545 .................................................................... 1 - CK-545 N.L.
N.I. Housing & Flex Plate package - w/Tower - 545 .................................................... 1 - CK-545A N.L.

(7) Early AT540/545 parts up to serial number 3210775436.

(8) Late AT545 parts from serial number 3210775437.
(9) Reference No. 23014020 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. 29509636.

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 ALLISON
AT540, 543, 545
To Get The Correct Parts, You Must Provide The Assembly Number Found On The Transmisson Name Plate.
ILL. DESCRIPTION BRAND QTY. YEAR PART NO. REF NO.

HARD PARTS (Cont.)

N.I. Kit - Governor Gear ............................................................................................. 1 - K34411A 23045382
N.I. Lock Nut - Second Clutch Spring Retainer (Push On) .......................................... 4 - 11213 3909063
N.I. Lock Nut - Third Clutch Spring Retainer (Push On) .............................................. 4 - 11213 3909063
N.I. Nut - Flex Disc - 543 ........................................................................................... 6 - 21214 23014462
N.I. P.T.O. Cover ........................................................................................................ 1 - 11147 6774322
N.I. Reverse Signal Switch - Backup Light ................................................ (AS36-033) 1 - 11610 29503665
N.I. Strip Lock - Converter Pump Hub - 543 .............................................................. 4 - 11212 6769631

AT540
MISCELLANEOUS PRODUCTS
N.I. Bolt - Pan ................................................................................................................ 21 - 96-175A 29500738
N.I. Bolt - Torque Converter ........................................................................... (1261968) 1 - 96-178 23014542
N.I. Governor Bore Tool (w/2 Sleeves) ............................................................................. 1 - T-9119 N.L.
N.I. Governor Sleeve Only - Aluminum (Aluminum Case) ................................................. 1 - T-119A N.L.
N.I. Governor Sleeve Only - Bronze (Cast Iron Case) ........................................................ 1 - T-119B N.L.
N.I. Torque Converter - Gas - (270) ................................................................................ 1 - DC-540 29514487
N.I. Torque Converter - Diesel - (290) ............................................................................ 1 - DC-545 29514486

NOTES
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GOVERNOR APPLICATION CHART

CODE ON USE
TRANSMISSION GOVERNOR GOVERNOR NO.

AT 500 SERIES
Up to and including - 2800 RPM Range ........................................................................ 461 11410A
3000 - 3400 RPM Range .............................................................................................. 462 11410B
Gas Engine - 3600 - 3800 RPM Range ......................................................................... 460 11410

AT643
2200 - 2600 RPM Range .............................................................................................. 461 11410A
3000 - 3400 RPM Range .............................................................................................. 463 21410

MT653
2400 - 2600 RPM Range .............................................................................................. 462 11410B
2800 RPM Range ......................................................................................................... 463 21410
3000 RPM Range ......................................................................................................... 465 21410A
3200 - 3800 RPM Range - Bronze Gear ........................................................................ 738 21410B
3600 - 3800 RPM Range - Bronze Gear ........................................................................ 739 21410C
Caterpillar Engine w/Blower - 2600 RPM Range ............................................................. - 21410B
Caterpillar Engine w/o Blower - 2800 RPM Range .......................................................... - 21410C

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