Allison to Fuller 6 speed swap

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Starting the swap today to replace the Allison AT545 with a Fuller 6 speed. Completely removed the Allison, Bellhousing adapter ring, converter & flexplate. Now it is time to take the Fuller out of the donor truck with a
DT466E and see what pieces I will need to have to complete the swap. So far I know I need a Flywheel and driveshaft for the T444E.

Picture is Allison AT545 Flexplate, Converter Adapter and Pilot, Flexplate Bolts with support ring.

 

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Started the removal of the Fuller 6 speed from the donor truck. Does anyone know the procedure to remove the shifter from the top of the transmission?

Here is the Flywheel off the DT466E.

 

[towcat]

i've seen my rebuilder remove the top plate so he can install the hoist adapter onto it. this is on IH4700's 92-2003 years with the 6+1.

 

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Any suggestions on clutch selection. Single or double disc? Type of clutch material? Brand?

 

[towcat]

i ran whatever was stock OEM.
it was good for three years.
whatever you choose, do not float gears on these trans.
the heat treating on the gears are very thin. if you float gears, you will blow though the heat treating in no time flat and will need replacement inside a year.

 

[spg]

whatever you choose, do not float gears on these trans.
the heat treating on the gears are very thin. if you float gears, you will blow though the heat treating in no time flat and will need replacement inside a year.

Please explain the terminology "float".

 

[towcat]

Please explain the terminology "float".

not using the clutch when you're shifting.

 

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I thought that was one of the reasons I wanted to take the automatic out was to use the clutch for shifting the transmission.

 

[towcat]

I thought that was one of the reasons I wanted to take the automatic out was to use the clutch for shifting the transmission.

there's a school of thought by "big rig" drivers and ih4700's look and smell like a big truck, so their attitude is the clutch is for getting going and the rest of the gears do not need the clutch. With this trans, don't do it. It's not a big rig trans.

 

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Picked up the Flywheel, Flexplate and spacer to put the AT545 Allison behind the DT466E today.

Still need to find the Flywheel for the T444E.

 

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Installed the clutch pedal and clutch linkage. Everything transfered directly from donor truck to mine. All the cabs must be built the same. The wiring and plug connector for the clutch pedal switch was tucked into the wiring harness.

Here are the Clutch pedal and linkage install photos

 

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The Fuller 6 speed is out of the donor truck. Working on cleaning up all the clutch linkage parts so they will be ready to bolt onto the T444E.

The T444E Flywheel is ordered as well as a boot for the clutch linkage where it goes through the firewall.

The Allison is bolted in the DT466E donor truck. The shifter is installed. The driveshaft is getting modified for the smaller Allison U-joint, and all the wiring is hooked up. Looks like it will be drivable very soon.

New Longer Driveshaft for behind the Allison.

 

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The T444E Flywheel arrived and is now installed. Looks like tomorrow will be a good day to install the New Clutch and bellhousing.

 

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Installed the Clutch disc, Pressure plate and Bellhousing. Now I have to shorten up the clutch linkage rod since the T444E is shorter than the DT466E. The Transmission is cleaned and ready to install. Then it is time to cut the transmission cover plate for the shifter and boot. Measure for the driveshaft and have it made to length.

Here are the Pressure Plate, Clutch Disc and Pilot Bearing.

 

[towcat]

no pics?