Revisions to this document are notedby a stripe in the left-hand margin

SUBJECT:#2001, Rev. B
August 16, 2019
Product Code(s): 66 and 65
Page 1 of 2

Filter Cover Bolt Hole Repair Kit

MODELS AFFECTED:All 3000 and 4000 Series Product Families Transmission Models

Introduction:
To facilitate the repair of the filter cover bolt threads in the main case a Filter Cover Bolt Hole Repair Kit, J-42385-AT
has been released. The kit can be used for thread repair with any 3000 and 4000 Product Families model. The kit
allows the threads to be repaired in or out of chassis. The kit utilizes a solid, thin-walled, self-locking steel bushinginsert to repair the filter cover bolt threads in the main housing of the transmission. The thread inserts repair thefilter cover bolt threads to their original thread specification of an M10 x 1.5.
The Filter Cover Bolt Hole Repair Kit contains:• Template J-42385-230 (Main Filter)• Insert Driver J-42385-233• Template J-42385-234 (Lube Filter)• Tap Wrench 510260• Two (2) Alignment Pins J-42385-308• Six (6) M10 Retaining Bolts 206158• M10 Step Drill J-42385-231• Driver Oil J-42385-110• Tap J-42385-232• 60 Inserts J-42385-514, the kit contains six (6) packets of ten (10) M10 x 1.5 x 24.5

The kit contains 60 inserts and 1 bottle of oil. Additional inserts and oil can be purchased through Bosch
Automotive Service Solutions LLC.
Bosch Automotive Service Solutions LLC
28635 Mound Road
Warren, MI 48092-3499
US and CANADA: 1-866-621-2128
INTERNATIONAL: 1-507-455-7223
FAX: 1-800-578-7375
https://allison.service-solutions.com
3000 and 4000 series transmissions have been manufactured with two versions of filter cover bolt patterns. It
is important to first determine which version is being repaired before proceeding. Transmissions manufactured
prior to 2002 have M10 x 1.50 tapped holes in the main housing that accept the filter cover bolts directly. Aroundlate 2002 the main housing configuration was changed with the addition of factory installed helicoil inserts in thefilter cover bolt patterns.

MC / SL5350EN

4650277

Copyright © 2019 Allison Transmission, Inc. All Rights Reserved.

#2001, Rev. B
August 16, 2019
Product Code(s): 66 and 65
Page 2 of 2
It is necessary to first inspect the housing being repaired to determine if factory installed helicoil inserts arepresent. The instruction sheet included in the Filter Cover Bolt Hole Repair Kit, J-42385-AT has been modified toinclude two separate repair processes, one for housings without helicoil inserts and a second for housings withhelicoil inserts. Use the applicable process for the housing being repaired.
WARNING: For housings without factory installed helicoil inserts, prior to beginning the repair, the filter
cover bolt holes must be inspected to assure the M10 Step Drill (J-42385-231) can properly prepare thehole for thread cutting with the Tap J-42385-232. If any of the filter cover bolt holes are found oversized
the transmission main housing must be replaced.

WARNING: For housings with factory installed helicoil inserts, it is important to remove the helicoil insertsfrom all holes before cutting the needed countersink with the M10 Step Drill J-42385-231. The countersink
is needed for proper installation of the Thread Repair Kit inserts. The Allison factory installed helicoilinserts use the same hole and thread size as the Thread Repair Kit inserts – so the kit’s J-42385-232
Tap should not be run afterward. When cutting the countersink with the step drill, take care to avoid
damaging the existing threads with the drill.
Field Repair Procedures:
The two attached Instruction Sheets (with & without factory installed helicoils) must be used to facilitate the repairof the filter cover bolt threads in the main housing.

Copyright © 2019 Allison Transmission, Inc. All Rights Reserved.

Automotive Service Solutions
J-42385-AT Filter Cover Bolt Hole Repair Kit (Without Helicoils)
Allison Transmission
Step 1

Step 8Remove control modulefrom the transmission.
Refer to appropriate
service manual for correct
removal procedure.

Step 2

Step 3

Align the fixture using twoalignment pins. Secure
the plate with threeattachment bolts.

Step 4

Step 4

LUBE

MAIN

MAIN

Step 9J-42385-308

Step 10Inspect the insert forcorrect installation. It must
be flush or below the basesurface.

J-42385-232

Step 5

Remove fixture. Verify
holes are free of chips ordebris.

Step 7

Step 7

Kit Contains

Part NumberQty.

Driver OilDrill Fixture- Main
Step Drill Bit
TapDriver
Drill Fixture- Lube
Alignment Pin
Thread Inserts (bag of 10)
Tap Wrench
Attachment Bolts

J-42385-110
J-42385-230
J-42385-231
J-42385-232
J-42385-233
J-42385-234
J-42385-308
J-42385-514
510260206158

1 bottle
11
1
1
1
2
6
16.
.
IMPORTANT.
• Cutting fluid, such as WD40 or equivalent, is recommended for all drilling and tapping operations.
• Driver oil J-42385-110 must be used on the insert driver• After each cutting operation, clean out metal ships using compressed air• Do not allow metal chips to enter the transmission. Cover and clean components as necessary

J-42385-514
TIME-SERT®
Inserts

J-42385-230 (Main)
J-42385-234 (Lube)

206158J-42385-231

J-42385-233

Step 6

Lubricate the threads of thedriver tool with J-42385-110
driver oil.

LUBE

Install the insert into the holeuntil it is seated in thecounterbore. Continue torotate the driver through theinsert. The driver will tighten
up before screwing
completely through theinsert. This is normal
because the bottom threadsof the insert are being
formed and mechanicallylocked into the hole. Lightly
bottom the driver in the hole
to ensure complete
threading and insert lock-in.
Remove the driver, and therepair is complete.

Step 10

Step 5

Use Tap J-42385-232 andTap Wrench 510260 tothread new hole. Tap mustbottom to ensure thread
depth. Clean out ALL
chips or foreign material.
Retap if necessary.

3000 MH/MD 3060

J-42385-110

Use the step drill bit
J-42385-231 with anelectric drill to drill out thedamaged thread. Collar ondrill must contact theguide. Clean out ALL chips
or foreign material.

4000 MH/HD 4060
FILTERCOVER

Step 9

Step 2

Determine correct drill
fixture for hole pattern tobe repaired (i.e. “MainJ-42385-230” or “LubeJ-42385-234”). Locate
FRONT of fixture to frontof transmission.

Step 8Install the insert onto theDriver Tool J-42385-233.
Do not allow oil or foreignmaterial to contact theoutside of the insert.

510260WARNING: Always wear safety glasses when performing this task.
WARNING: The Allison factory installed steel inserts use the same holeand thread size as the Thread Repair Kit inserts; however, the M10 Step
Drill J-42385-231 must be used to countersink the existing holes before theThread Repair inserts are installed. Take care to avoid damaging theexisting threads with the step drill when machining the countersinks.

Form No. 507330 Rev B
Litho in USA 201905

Automotive Service Solutions
J-42385-AT Filter Cover Bolt Hole Repair Kit (With Helicoils)
Allison Transmission
Step 1

Step 8Remove control modulefrom the transmission.
Refer to appropriate
service manual for correct
removal procedure.

Step 1a

Step 2

Determine correct drill
fixture for hole pattern tobe repaired (i.e. “MainJ-42385-230” or “LubeJ-42385-234”). Locate
FRONT of fixture to frontof transmission.
Align the fixture using twoalignment pins. Secure
the plate with threeattachment bolts.

Step 4

MAIN

Step 9J-42385-308

Step 10Inspect the insert forcorrect installation. It must
be flush or below the basesurface.

J-42385-232
J-42385-233

Step 5

Step 5

Clean out ALL chips orforeign material.
Retap if necessary .

Step 6Remove fixture. Verify
holes are free of chips ordebris.

Step 7LUBE

MAIN

Step 10

Step 4

Use the step drill bit
J-42385-231 with anelectric drill to drill out thedamaged thread. Collar on
drill must contact theguide. Clean out ALL chips
or foreign material.

LUBE

Install the insert into the holeuntil it is seated in thecounterbore. Continue torotate the driver through theinsert. The driver will tighten
up before screwing
completely through theinsert. This is normal
because the bottom threadsof the insert are being
formed and mechanicallylocked into the hole. Lightly
bottom the driver in the hole
to ensure complete
threading and insert lock-in.
Remove the driver, and therepair is complete.

Step 7

Kit Contains

Part NumberQty.

Driver Oil
Drill Fixture- Main
Step Drill Bit
TapDriver
Drill Fixture- Lube
Alignment Pin
Thread Inserts (bag of 10)
Tap Wrench
Attachment Bolts

J-42385-110
J-42385-230
J-42385-231
J-42385-232
J-42385-233
J-42385-234
J-42385-308
J-42385-514
510260206158

1 bottle
111
1
12
6
1
6

Lubricate the threads of thedriver tool with J-42385-110
driver oil.
IMPORTANT• Cutting fluid, such as WD40 or equivalent, is recommended for all drilling and tapping operations.
• Driver oil J-42385-110 must be used on the insert driver.
• After each cutting operation, clean out metal ships using compressed air.
• Do not allow metal chips to enter the transmission. Cover and clean components as necessary.

J-42385-514
TIME-SERT®
Inserts

J-42385-230 (Main)
J-42385-234 (Lube)

206158J-42385-231

Step 33000 MH/MD 3060
FILTER
COVER

Step 9Step 2

4000 MH/HD 4060

J-42385-110

Remove helicoils with pliersand dispose – taking carewhen doing so not todamage the tapped holes
in the housing.

Step 8Install the insert onto theDriver Tool J-42385-233.
Do not allow oil or foreignmaterial to contact theoutside of the insert.

510260WARNING: Always wear safety glasses when performing this task.
WARNING: The Allison factory installed steel inserts use the same holeand thread size as the Thread Repair Kit inserts; however, the M10 Step
Drill J-42385-231 must be used to countersink the existing holes before theThread Repair inserts are installed. Take care to avoid damaging theexisting threads with the step drill when machining the countersinks.

Form No. 507330 Rev C
Litho in USA 201905