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This SIL replaces 18-TR-99. 21-TR-02
June, 2002
Product Code(s): All
Page 1 of 5

SUBJECT: AT 500 Series Transmissions, Addressing Shift Quality Concerns with Mechanical Modulators
or Reduced Modulation Modification

EQUIPMENT AFFECTED: AT 500 Equipped with Electric Step Modulators and Above S/N 3210302450

AFFECTED SERIAL NUMBERS: In Production: Various

RETRAN: Various

Introduction:
The electric step modulator used with AT Series Transmissions invokes either closed throttle or full throttle transmission
shifts. These two modulator pressure schedules may not satisfy all shift expectations of vocations utilizing the AT Series
Transmissions.
Installing the Reduced Modulation Modification (SIL 18-TR-99), was introduced to reduce shift quality concerns and
increase durability of AT 500 Series Transmissions equipped with electric modulators. This modification reduces the
effect of modulator pressure during the 2 to 3, and 3 to 4 range shifts, but doesn’t effect the 1 to 2 shift.
Residual shift concerns may be corrected by the installation of a mechanical modulator assembly, allowing variable
modulator pressure.

NOTE: Mechanical modulator assemblies may not be available for all vehicle configurations uti-
lizing the AT Series Transmission. Consult with vendors of mechanical modulators, to
determine if a mechanical modulator assembly is available for your application.
Tech-One, Inc. Trans-Machine, Inc.
PO Box 329 PO Box 489
Cobalt, CT 06414 Miller Place, NY 11764
(631) 209-0955 (860) 267 - 9568 or (888) 505-4455
 21-TR-02
June, 2002
Product Code(s): All
Page 2 of 5
NOTE: Since the introduction of the Reduced Modulation Modification, Allison AT 500 Series
ReTran transmissions have been equipped with a yellow warning tag, advising installa-
tion of the reduced modulation kit. Allison AT 500 Series ReTran transmissions starting
with and including S/N 9108144251, now contain the reduced modulation configuration
where required, Therefore it is no longer necessary to install the Reduced Modulation
Kit before AT ReTran installation.
NOTE: Shift concerns should always be initially investigated by verifying proper dipstick cali-
bration, fluid level, and shift linkage adjustment.

Diagnostic Procedures:
Before installing a Mechanical Modulator Assembly or Reduced Modulation Modification, verify the condition of
possible shift complaint contributors:
WARNING: When performing tests, be sure the transmission is in N (Neutral) or P (Park), parking
brake and/or the emergency brakes are set and properly engaged, and the wheels
blocked.
1. Perform dipstick calibration test (see Mechanic’s Tips, MT1321EN, Dipstick Markings Illustration).
2. Check transmission fluid level at operating temperature (180–220ºF) and adjust if necessary.
3. Check for proper adjustment of shift linkage (see Mechanic’s Tips, MT1321EN, Connecting Shift Selector Control).
If continuing to utilize the electric step modulator, voltage to the modulator must be verified as follows:
a. Verify voltage with ignition key on and accelerator at WOT (wide-open throttle). A minimum of 10 volts must be
present at the electric modulator connector when the throttle is depressed to 80 percent. This voltage signal should
discontinue when releasing the throttle and below 65 percent. After September 1999, the modulator voltage should
be present at 60 percent accelerating, and 45 percent deccelerating, reference Watch # 231. If voltage reading is
less than 10 volts, you may have to “T” into the circuit or check integrity of the circuit (see Figure 1).

CAUTION: Be sure the wires are properly installed (+/-). The modulator is marked for proper
polarity, and will be damaged by reverse polarity.
VEHICLE HARNESS
ELECTRIC MODULATOR
CONNECTOR

DVOM
TO ECM
EXTENSION
HARNESS

FABRICATED "T"
HARNESS
PLUGS

PLUG
RECEPTACLES TO
ELECTRIC
MODULATOR

12v TEST LIGHT

V07539.00.01

Figure 1.
 21-TR-02
June, 2002
Product Code(s): All
Page 3 of 5

b. Voltage on vehicles with the electronically controlled Cummins Engines must be checked with the electric mod-
ulator connector plugged into the electric modulator. Voltage less than 12 volts (usually 5 to 7 volts) will be mea-
sured from the engine ECM unless the electric modulator connector is connected to the electric modulator. This
can be accomplished by fabricating a test harness that will connect into the OEM modulator wire connector and
the electric modulator with two test leads that will plug into a voltmeter. See Figure 1.
c. Vehicles with electronically controlled CAT engines built before January 2000 do not supply voltage to the elec-
tric modulator until the vehicle reaches 15 MPH. CAT can reprogram some ECMs to allow a signal to the electric
modulator before 15 MPH. Engines built after January 2000 are programmed to allow the voltage signal to the
electric modulator at 60 percent throttle regardless of vehicle speed.
4. Verify electric modulator is actuating. Electric step modulator coil resistance should be 5.0 – 7.0 Ω.
5. Proceed with the valve body modifications described in Instruction Sheet No. 298, if installing a Mechanical Modu-
lator Assembly. Follow Instruction Sheet No. 292, Rev. B, if installing Reduced Modulation and using an electric
modulator.

Modifying an AT 500 Series Transmission to use a Mechanical Modulator:

See Instruction Sheet No. 298
Procedure:
NOTE: Prior to installing a Mechanical Modulator Assembly, determine if the subject AT Series
Transmission is equipped with the Reduced Modulation Modification (SIL 18-TR-99).
This can be determined by identifying the valve body engineering group number
(16-XXXX), see Table A ‘Current Number Column’. Field installations are identified by
“RMC” stamped in the nameplate, as shown in Instruction Sheet No. 292, Rev. B, Figure
4. If so equipped, remove the Reduced Modulation Modification components, to receive
full benefits of variable modulation.

Table “A”
Current Number Engineering groups included Reduced Modulation during production assembly
Current Number Former Number
16-1752 16-980
16-1753 16-982
16-1754 16-983
16-1755 16-984
16-1756 16-985
16-1757 16-986
16-1758 16-1374
16-1759 16-1390
16-1760 16-1462
16-1761 16-1471
16-1762 16-1523
16-1763 16-1553
16-1764 16-1564
16-1765 16-1565
16-1766 16-1573
16-1767 16-1584
16-1768 16-1607
16-1769 16-1704
16-1771 16-1729
 21-TR-02
June, 2002
Product Code(s): All
Page 4 of 5
The reduced modification can be reversed and the transmission restored to full modulation configuration by:
1. Observing and recording the 2 to 3 and 3 to 4 shift adjusting ring positions.
2. Remove the 2 to 3 and 3 to 4 shift modulator valves and sleeves.
3. Install original manufacture design 2 to 3 and 3 to 4 range modulator valves (2 to 3 valve — P/N 6835924, 3 to 4
valve — P/N6883149). Set adjusting rings to same position as recorded in step 1.
4. Install valve body.
5. Install the mechanical modulator, utilizing the modulator manufacturer’s instructions and road test. You should now
have part throttle and closed throttle shifts.

CAUTION: The reduced modulation modification should not be removed if continuing to use an
electric step modulator.

Spare Parts Information:

All transmission parts listed are released in the Service Parts System.
Identification:
Identify modified transmissions by stamping MMOD on the nameplate, as shown in Instruction Sheet No. 298, Figure 3,
for future reference.

Warranty Information:
If it is necessary to file an AFA, use Activity Indicator MMOD and Complaint Code SL. Fill in the Primary Failed P/N
as 29508036 and Failure Code OXX.

Calibration Information:
When valve body modifications are complete, if the adjustment was not recorded before rework, you must calibrate the
valve body on an approved valve body test stand. Calibrate the valve body to the appropriate shift points located in the
AT 500 Service Manual SM1241EN, Section 3, Tables 3–7 and 3–8.

Reduced Modulation Modification used with Electric Modulator:

See Instruction Sheet No. 292, Rev. B
If continuing to use the Electric Modulator, and require the installation of Reduced Modulation Modification:
Parts required to install the Reduced Modulation Modification in AT 500 Transmissions:

Kit Description

Qty Part Part Number

1 Service Kit 29537879
1 * 2 to 3, valve 29537727
1 * 2 to 3, sleeve 29537731
1 * 3 to 4, valve 29537729
1 * 3 to 4, sleeve 29537732
1 * Instruction Sheet 292, Rev. B. 29537880
* Denotes parts included in Service Kit
 21-TR-02
June, 2002
Product Code(s): All
Page 5 of 5

NOTE: The 2–3 shift spring and oil pan gasket are not included in the service kit. You must obtain
one P/N 29501160 oil pan gasket and the proper 2–3 shift spring in Table “B” (if needed)
to complete this modification. SPRING DIAMETER INFORMATION: If the spring you
have has the outside diameter (both ends) of 0.640 inch or less, you can reuse this spring.
If it is greater than 0.640 inch (on either end), you must order a new spring from Table
“B.” The spring you choose depends on the valve body group you have.

Table “B”

Qty Add Parts Delete Qty

1 29537794 2–3 shift spring 6880991 1
1 29537899 2–3 shift spring 23017028 1
1 29537900 2–3 shift spring 23013271 1
1 29537901 2–3 shift spring 23012950 1
1 29537902 2–3 shift spring 6880992 1
1 29537903 2–3 shift spring 23013267 1
1 29537904 2–3 shift spring 23045295 1
1 29537905 2–3 shift spring 23013269 1
1 29537906 2–3 shift spring 6883665 1

Procedure:
Order a Service Kit, pan gasket, and the proper 2–3 shift spring (see Table “A”). This procedure will involve valve body
removal and all modifications must be performed as described in Instruction Sheet No. 292, Rev. B (attached), and
included with the Service Kit.

Interchangeability:

CAUTION: This modification should not be removed if continuing to use an electric step
modulator.

Spare Parts Information:

All transmission parts listed are released in the Service Parts System.

Identification:
Identify modified transmissions by stamping RMC on the nameplate, as shown in Instruction Sheet No. 292, Rev. B,
Figure 4, for future reference.

Warranty Information:
If it is necessary to file an AFA, use Activity Indicator RMC and Complaint Code SL. Fill in the Primary Failed P/N as
29508036 and Failure Code OXX.

Calibration Information:
When valve body modifications are complete, if the adjustment was not recorded before rework, you must run the valve
body on an approved valve body test stand. Calibrate the valve body to the appropriate shift points located in the AT 500
Service Manual SM1241EN, Section 3, Tables 3–7 and 3–8.
 P/N 29537880
Page 1 of 5
June, 2002

INSTRUCTION SHEET NO. 292, Rev. B

AT 500 2 to 3 and 3 to 4 Range, Reduced Modulation Modification for AT Model Transmissions
Using Electric Modulator Controls on 3400 rpm and Below Only
and Above S/N 3210302450
(Reduced Modulation Kit P/N 29537879)

Introduction:
This valve body modification will reduce the 2 to 3 and 3 to 4 modulation without altering the trimmer regulator
circuit. This modification is released to reduce shift quality concerns and increase durability of AT 500 transmissions
equipped with the electric modulator. This is accomplished by replacing the 2 to 3 and 3 to 4 modulator shift valves
with new shift modulator valves, sleeves, and 2–3 shift spring. The 1 to 2 shift does not change.

NOTE: This modification can only be performed on 3400 rpm and below and above S/N 3210302450.

Parts Required for Modification of AT 500 Transmissions:

Kit Description

Qty Part Part Number

1 Service Kit 29537879
1 * 2 to 3, valve 29537727
1 * 2 to 3, sleeve 29537731
1 * 3 to 4, valve 29537729
1 * 3 to 4, sleeve 29537732
1 * Instruction Sheet 292, Rev. B 29537880
* Denotes parts included in Service Kit

NOTE: The 2–3 shift spring and oil pan gasket are not included in the service kit. You must obtain
one P/N 29501160 oil pan gasket and the proper 2–3 shift spring in Chart “A” (if needed) to
complete this modification. SPRING DIAMETER INFORMATION: If the spring you have has
the outside diameter (both ends) of 0.640 inch or less, you can reuse this spring. If it is greater
than 0.640 inch (on either end), you must order a new spring from Chart “A.” The spring you
choose depends on the valve body group you have.

Chart “A”
Qty. Add Parts Delete Qty
1 29537794 2–3 shift spring 6880991 1
1 29537899 2–3 shift spring 23017028 1
1 29537900 2–3 shift spring 23013271 1
1 29537901 2–3 shift spring 23012950 1
1 29537902 2–3 shift spring 6880992 1
1 29537903 2–3 shift spring 23013267 1
1 29537904 2–3 shift spring 23045295 1
1 29537905 2–3 shift spring 23013269 1
1 29537906 2–3 shift spring 6883665 1
 P/N 29537880
Page 2 of 5
June, 2002

Identification:
Identify modified transmissions by stamping RMC on the nameplate, as shown in Instruction Sheet No. 292, Rev. B,
Figure 4, for future reference.

READ THE FOLLOWING INSTRUCTIONS CAREFULLY. REMEMBER, CLEANLINESS IS IMPORTANT!

1. Remove the valve body from the transmission and place it on a work bench.

NOTE: Locate the 2 to 3 and 3 to 4 shift valve adjusting ring and record the settings so when you install the new
valve and sleeve you can place it back to the original setting.

2. Remove the modulator valve body by removing 3 bolts. Then remove the separator plate, priority valve, spring,
and stop.

3. Locate the 2 to 3 shift valve as shown in Figure 1 and remove the retaining pin, adjusting ring, spring, stop, and
shift modulator valve.

4. Open your kit and locate the 2 to 3 new modulator valve sleeve P/N 29537731. Install it into the 2 to 3 shift valve
bore — either end will work. Locate the 2 to 3 new modulator valve P/N 29537727 and install it into the sleeve
with the round end first, as shown in Figure 2. Place the valve body on end with the 2 to 3 valve up and install the
new 2 to 3 shift spring you have selected from Chart “A.” Install the adjusting ring. With a pair of needle nose
pliers, hold the valve stop so the pin hole is open. Install the stop with the pliers against the adjusting ring. Push
in until you can install the retaining pin. Now with the pliers push down and rotate the adjusting ring to the
original setting you recorded in Step (1).

5. Locate the 3 to 4 shift valve as shown in Figure 1 and remove the retaining pin, adjusting ring, spring, stop and
shift modulator valve.

6. Locate the 3 to 4 shift modulator sleeve P/N 29537732 and install it into the 3 to 4 shift valve bore — either end
will work. Locate the 3 to 4 new modulator valve P/N 29537729 and install it into the sleeve with the round end
first, as shown in Figure 2. Place the valve body on end with 3 to 4 valve up and install the 3 to 4 shift spring.
Install the adjusting ring. With a pair of needle nose pliers hold the valve stop so the pin hole is open. Install the
stop with the pliers against the adjusting ring. Push in until you can install the retaining pin. With the pliers push
down and rotate the adjusting ring to the original setting you recorded in Step (1).

7. Place the valve body on the work bench with the separator plate side up. Install the priority valve spring, stop,
and the valve. Place the separator plate on the valve body, then place the modulator valve body on the plate and
start the 3 bolts. With a valve body mounting bolt placed through the separator plate and valve body in hole “A”
for bolt hole alignment shown in Figure 3. Hand tighten the 3 bolts and torque them to 120 inch lbs and remove
the mounting bolt from hole “A,” as shown in Figure 3.

8. The valve body is now ready to be installed onto the transmission per AT 500 Service Manual SM1241EN.
 P/N 29537880
Page 3 of 5
June, 2002

ORIGINAL CONFIGURATION

Figure 1.
 P/N 29537880
Page 4 of 5
June, 2002

REDUCED MODULATION CONFIGURATION

Figure 2.
 P/N 29537880
Page 5 of 5
June, 2002

SEPARATOR PLATE INSTALLATION

Figure 3.

DIVISION OF
GENERAL MOTORS D
AG
RICU
LTURAL
I MP
L
AN

EM

UAW
E, A E ROSPACE

ENT

CORPORATION
WORKERS

DIVISION OF Div. of General Motors Corp.

933
BIL

OF
MO

AM

Indianapolis, Indiana, USA

O

INDIANAPOLIS
UT ER
ICA
UNITED A
ICULTURA

GENERAL MOTORS AN
D
AGR L
IM
PL
E

01-XXX 10-XXX
EM

UAW 14-XXX
ILE AEROSPAC

INDIANA
CORPORATION
ENT
WORKERS

INDIANAPOLIS 933
OB
OM

OF

16-1326 21-XXX 22-XXX

UT AM
DA ER
UNITE ICA

INDIANA

24-XXX 34-XXX
SERIAL NO. PART NO.
37-XXX
XXXXX XXXXXXX
MODEL Model XX XXX XXXXXXXX
NO. XX XXXXX S/N XXXXXXXXXX 98XXX

Stamp RMC here

SAMPLE NAMEPLATES V06087

Figure 4.
 P/N 29541533
Page 1 of 4
June, 2002

INSTRUCTION SHEET NO. 298

Procedure to Remove the Reduced Modulation Modification (18-TR-99),

from AT 500 Series Transmissions Prior to installing a Mechanical Modulator Assembly

Introduction:
When removing the electric modulator and installing a mechanical modulator, the reduced modulation modification
should be removed from AT transmissions, if so equipped. One way to determine if Reduced Modulation was included
during production is to obtain the valve body engineering group number from the nameplate and observing Table A. If
the Engineering group number is contained in the ‘Current Number Column’, Reduced Modulation was installed during
production. If the nameplate has been field altered, as shown in Instruction Sheet No. 292, Rev. B, Figure 4, Reduced
Modulation Modification was field installed.

Table “A”
Engineering Groups That Included Reduced Modulation During Production Assembly
Current Number Former Number
16-1752 16-980
16-1753 16-982
16-1754 16-983
16-1755 16-984
16-1756 16-985
16-1757 16-986
16-1758 16-1374
16-1759 16-1390
16-1760 16-1462
16-1761 16-1471
16-1762 16-1523
16-1763 16-1553
16-1764 16-1564
16-1765 16-1565
16-1766 16-1573
16-1767 16-1584
16-1768 16-1607
16-1769 16-1704
16-1771 16-1729

This is accomplished by replacing the 2 to 3 and 3 to 4 shift modulator valves and sleeves with former design modulator
shift valves.
NOTE: This modification can only be performed on 3400 rpm and below and above S/N 3210302450.

CAUTION: This modification should not be removed if continuing to use an electric step
modulator.
 P/N 29541533
Page 2 of 4
June, 2002

Parts required when installing Mechanical Modulation on AT 500 Transmissions:

Qty Part Part Number

1 2 to 3, valve 6835924

1 3 to 4, valve 6883149

1 Oil Pan Gasket 29501160

Identification:
Identify modified transmissions by stamping MMOD on the nameplate, as shown in Instruction Sheet No. 298, Figure 3,
for future reference.

READ THE FOLLOWING INSTRUCTIONS CAREFULLY. REMEMBER, CLEANLINESS IS IMPORTANT!

1. Remove the valve body from the transmission and place it on a work bench.
NOTE: Locate the 2 to 3 and 3 to 4 shift valve adjusting ring, and record the settings so when you install the
new valves you can place it back to the original setting.

2. Remove the modulator valve body by removing 3 bolts. Then remove the separator plate, priority valve, spring, and
stop.
3. Locate the 2 to 3 shift valve, identified in Figure 1 and remove the retaining pin, adjusting ring, spring, stop, and shift
modulator valve and sleeve.
4. Locate the 2 to 3 modulator shift valve P/N 6835924 and install as shown in Figure 1. Place the valve body on end
with the 2 to 3 valve up and install the 2 to 3 shift spring. Install the adjusting ring. With a pair of needle nose pliers,
hold the valve stop so the pin hole is open. Install the stop with the pliers against the adjusting ring. Push in until you
can install the retaining pin. Now with the pliers push down and rotate the adjusting ring to the original setting you
recorded in Step (1).
5. Locate the 3 to 4 shift valve, identified in Figure 1 and remove the retaining pin, adjusting ring, spring, stop and shift
modulator valve and sleeve.
6. Locate the 3 to 4 shift modulator shift valve P/N 6883149 and install it into the 3 to 4 shift valve bore as shown in
Figure 1. Place the valve body on end with 3 to 4 valve up and install the 3 to 4 shift spring. Install the adjusting ring.
With a pair of needle nose pliers hold the valve stop so the pin hole is open. Install the stop with the pliers against
the adjusting ring. Push in until you can install the retaining pin. With the pliers push down and rotate the adjusting
ring to the original setting you recorded in Step (1).
7. Place the valve body on the work bench with the separator plate side up. Install the priority valve spring, stop, and
the valve. Place the separator plate on the valve body, then place the modulator valve body on the plate and start the
3 bolts. With a valve body mounting bolt placed it through the separator plate and valve body in hole “A” for bolt
hole alignment shown in Figure 2. Hand tighten the 3 bolts and torque them to 120 inch lbs and remove the mounting
bolt from hole “A,” as shown in Figure 2.
8. The valve body is now ready to be installed onto the transmission per AT 500 Service Manual SM1241EN.
 P/N 29541533
Page 3 of 4
June, 2002

P/N 6835924

P/N 6883149

B06295.00.01

Figure 1.
 P/N 29541533
Page 4 of 4
June, 2002

SEPARATOR PLATE INSTALLATION

Figure 2.

LTURAL
RICU I MP
AG L
D
AN

EM
E , A E ROSPACE

EN
T WORKERS O

DIVISION OF Div. of General Motors Corp.

BIL
MO

AM

Indianapolis, Indiana, USA

O ER
UT ICA
UNITED A
ICULTURA
AGR
GENERAL MOTORS AN
D
L
IM
PL
E

01-XXX 10-XXX
EM

14-XXX
ILE AEROSPAC

UAW
ENT

CORPORATION
WORKERS

INDIANAPOLIS 933
OB
OM

OF

16-1326 21-XXX 22-XXX

UT AM
DA ERI
UNITE CA

INDIANA

24-XXX 34-XXX
SERIAL NO. PART NO.
37-XXX
XXXXX XXXXXXX
MODEL Model XX XXX XXXXXXXX
NO. XX XXXXX S/N XXXXXXXXXX 98XXX

Stamp MMOD here

SAMPLE NAMEPLATES V06087.00.01

Figure 3.