M35A3 Transmission Swap 1545 to 545 questions

[Neversatisfied]

Well the dreaded has happened, the 1545 has failed and is pouring fluid. I found a great condition 545 for cheap. The question is will it just go straight up in there? We have it pulled apart and the first thing I noticed that may be an issue is the adapter plate for the fly wheel?

will the 1545 flywheel adapter plate work on the 545? It doesn’t look like it will have enough “reach” it looks like I need an adapter plate similar to this in the photo I’m going to post.

Has anyone done this swap on here and could they chime in on any tricks/potential issues/or needed parts that i will need such as a different adapter plate?

Thank you steel soldier family !

 

[HDN]

The general support TMs have instructions for doing a 1545 to 545 swap. I believe an adapter plate is the only new part required for the swap - can't remember for sure.

It seems the Army was anticipating the lack of 1545 transmissions and made the instructions as a result. If it were me, I'd keep it and try to rebuild it. They're unique for having the locking torque converter. The skoolie crowd bought up all the surplus ones for that reason.

 

[Neversatisfied]

The general support TMs have instructions for doing a 1545 to 545 swap. I believe an adapter plate is the only new part required for the swap - can't remember for sure.

It seems the Army was anticipating the lack of 1545 transmissions and made the instructions as a result. If it were me, I'd keep it and try to rebuild it. They're unique for having the locking torque converter. The skoolie crowd bought up all the surplus ones for that reason.

Do you know where I could find those instructions? I am going to rebuild it, but the parts are going to be hard to source in good used condition. So I got this 545, I don’t drive ever in 3-4 so I won’t ever use the locking feature hardly at all. It only engages in 3-4.

 

[HDN]

Do you know where I could find those instructions? I am going to rebuild it, but the parts are going to be hard to source in good used condition. So I got this 545, I don’t drive ever in 3-4 so I won’t ever use the locking feature hardly at all. It only engages in 3-4.

I hope these help:

M35A3 Trucks, Allison AT545/1545 Service Manual

I didn't realize this forum existed until now. Do these eventually get uploaded to the TM section up top? Anyway here's a service manual I found for the AT545 and AT1545, which are used in the M35A3.

www.steelsoldiers.com

TM's for the Deuce

Listed below are a number of the TM's for the M35 trucks. To save them to your computer, right click, select "save as". GTA-9-1-1851-8.pdf M35 complete diagram of with descriptions of all components. LO9-2320-209-12-1.pdf LO9-2320-209-12-1 Lubrication Order for the M35 series...

www.steelsoldiers.com

For the second link you're looking for manuals for the M35A3 and/or Extended Service Program trucks. Ctrl+F will help with that

 

[glcaines]

If your 1545 transmission is leaking fluid, that sounds like only a seal has failed. I would recommend checking out the possibility that you can replace the seal and still be in business with the 1545 transmission. Seals normally have a part number on them as well as checking the TM for a part number and then you can check the availability from your local NAPA or online. It is likely it is a standard seal. This would also be a good time to switch to Dextron 3. The transmission shifts much smoother with Dextron 3 instead of motor oil, especially downshifting. Dextron 3 isn't compatible with motor oil, so you would need to do multiple flushes to get rid of the motor oil. Transmission fluids with a higher number than Dextron 3 are not compatible with your transmission and will destroy seals, so only use Dextron 3 if you switch. I used NAPA Dextron 3 compatible which is made by Valvoline, but much cheaper.

 

[Neversatisfied]

If your 1545 transmission is leaking fluid, that sounds like only a seal has failed. I would recommend checking out the possibility that you can replace the seal and still be in business with the 1545 transmission. Seals normally have a part number on them as well as checking the TM for a part number and then you can check the availability from your local NAPA or online. It is likely it is a standard seal. This would also be a good time to switch to Dextron 3. The transmission shifts much smoother with Dextron 3 instead of motor oil, especially downshifting. Dextron 3 isn't compatible with motor oil, so you would need to do multiple flushes to get rid of the motor oil. Transmission fluids with a higher number than Dextron 3 are not compatible with your transmission and will destroy seals, so only use Dextron 3 if you switch. I used NAPA Dextron 3 compatible which is made by Valvoline, but much cheaper.

Unfortunately we found a good amount of metal debris in the pan and a good amount of metal In the filter. The fluid was very burnt too and smelled terrible. I will probably take a look at it eventually but I think it’s toasted.