Allison, we have a love-hate relationship with you. We love that you have smooth shifts, learn quickly and are strong and reliable enough to keep us on the road for a long time, but we do hate some things about you. We hate that once we really start making good power, you like to go into Fail Safe mode. We don't like that once your C-3 clutch pack assembly gets glazed, you lose around 20 percent of your holding power. We also don't like that you only receive around 86 psi worth of oil pressure to the clutch packs when you're in fifth gear. If this relationship is going to work, there will need to be some compromises. These issues with Allison most recently came to light with Project Ronix Rig. After installing a K&N intake, 5-inch Bully Dog Rapid Flow and Triple Dog Power Pup programmer, the LBZ Duramax was putting 352.7 hp and 548.49 lb-ft of torque to the rear wheels. Taking into account the parasitic loss, we were definitely on the borderline of a stock Allison's limits and wanted to solve it before it became a problem. After considering several options, we ultimately decided to install a Co-Pilot from ATS Diesel Performance. The Co-Pilot is much different than mechanical kits on the market. Included in the box is a computer, two wiring harnesses, a solenoid and a small bag with installation parts. (It also comes with one of the best installation manuals we have seen yet.) What it does is piggybacks onto the factory computer, taking input from the MAP sensor, throttle position sensor and TCM, and adjusts lockup as well as line pressure and shifts based on engine torque. For example, in stock format the line pressure in the clutch packs while in fifth gear is only 86 psi and with the Co-Pilot transmission system, that pressure jumps to 230 psi. ATS says a Co-Pilot-equipped transmission can handle approximately 85 more horsepower and 120 more lb-ft of torque over where the stock tranny would enter Fail Safe mode and add 280 lb-ft of overall torque capacity. Since line pressure is only increased during high engine torque output, worries like excessive pressure on parts like delivery rings, drums and shafts during normal operation that can cut down a transmission's life expectancy are eliminated. Likewise, because the Co-Pilot is electronically controlled it can anticipate the shift and adjust pressure accordingly, resulting in less slipping which causes heat and the glazing of clutch packs. Not to mention the Co-Pilot controller can adjust shift firmness from soft towing to all-out, snap-your-neck racing. Interested to see if a solenoid, black plastic box and wiring harness could live up to all the hype, we headed to Corona, Calif., where we put Project Ronix Rig and the Co-Pilot in the hands of Redline Diesel Performance for the install. We also brought ATS' aluminum transmission pan to the party where its increased capacity and heat-dissipating fins can extend oil life, scheduled services and lower transmission heat by up to 30?. Plus it's a good looking piece with a built-in 1-inch magnetic drain plug to help ease servicing down the road. When Redline finished the install, we took the truck for a test drive and were ho-hum at first. The shifts were noticeably improved, but the impact we were expecting wasn't there. That was until we switched from soft driving to really putting our foot down to the firewall. As it grabbed second gear, the 35-inch tall Cooper tires broke loose. Hitting third yielded the same result. The mild-mannered, part-throttle Allison turned into a beast the harder we hit the throttle-and the Co-Pilot wasn't even turned up to its firmest setting. It's been a week and we're still smiling from the first time the Allison clicked its way through the gears under a heavy load. Expectation exceeded and the love-hate relationship with Allison got a whole lot sweeter.

Using a 14mm socket, remove the plug and drain the transmission fluid. Remove the bolts holding the pan to the transmission case with a 13mm socket. With bolts removed and fluid drained, drop the pan and remove filter. You don't have to, but for photo purposes Redline Diesel Performance removed the valve body. Mark 1 1/4 inches down from the bend of the stainless tube on the valve body. From the first mark, measure down 7/8 inch and place another mark.

To prevent any debris from getting into the valve body, Redline chose to remove the tube to cut it. Doing this required first taking out a cover by removing the six bolts holding it.	Remove the two bolts holding the stainless tube to the valve body. A gentle pry with a screwdriver should be enough to get it out.	Using a tube cutter, cut at the two previously marked spots.
Redline examined the freshly cut tube for burrs and when they were removed, brake cleaner was sprayed to get rid of any remaining small particles.	Install the solenoid block between the two tube sections and bolt it back into the valve body. Make sure the pinhole on the solenoid is pointed to what would be the front of the truck and the plug is positioned to what would be the rear.	The secondary harness (smaller of the two provided harnesses) goes into the port next to the PTO. From the factory there is a block-off plug there that must first be removed, then put the brown plug into the port.
Plug the harness into the solenoid and using wire ties, secure the wires out of the way.	The ATS Deep Pan uses a different filter than stock. Keep this in mind when it comes time to service the transmission and order the correct filter beforehand. (Allison Part #29537966)	The stock gasket should be reused when installing the ATS tranny pan. Redline also gave the pan a quick onceover with the brake parts cleaner to remove any possible debris that might have collecting during shipping.
Using the bolts supplied with the ATS pan, install and torque them to 18 lb-ft. Refill the transmission and recheck it when the install has been completed and the truck has been driven for a short distance.	Unplug the 20-pin connector from the back of the transmission and install the harness supplied with the Co-Pilot. Plug the factory connector into the ATS harness as well. The plugs will click when they are fully in place.	Route the other end of the harness into the engine bay. While routing, be careful to avoid any moving objects or piping that might get hot and damage the harness.
The brown wire with green tracer on the Co-Pilot harness needs to be tapped into the MAP sensor. ATS recommends grabbing it off the map sensor itself (light green wire on in the middle of the plug), but Redline went to the main harness on the driver's side of the engine and got the wire there as opposed to running it across the engine compartment.	The yellow wire with black tracer on the ATS harness goes to the TCM module on the driver's side by the fan shroud. To make unplugging it easier, Redline unbolted the TCM.	Locate the yellow wire in the harness and splice the ATS yellow/black wire into it. (Notice that Redline solders all of the connections. This along with heat shrink tubing help provide a solid, durable connection.)
Pull the remaining section of the wire harness through the firewall and into the driver's compartment. On the plug near the throttle, tap into the throttle position sensor's blue wire, soldering the Co-Pilot's brown wire with blue tracer to it.	Find a good place to ground the black wire to metal. The use of a star washer helps make a good ground connection as well as scuffing the surface slightly with a screwdriver or file.	Plug the Co-Pilot controller in and mount using the supplied Velcro and you're ready to hit the road.

When it came time to refilling the transmission with fluid, we chose to go with Amsoil's Torque-Drive Synthetic Automatic transmission fluid. Torque-Drive synthetic transmission fluid from Amsoil is a direct replacement for TranSynd Synthetic ATF in heavy duty, on and off highway automatic transmissions manufactured by Allison, General Motors, Ford, Voith and ZF or wherever the standards TES-295, C-4, Dexron III, Mercon, Voith G-1363 or TE-ML 14C are specified.

Owners can enjoy benefits from a synthetic trans fluid engineered to eliminate the deficiencies common to all conventional, petroleum ATFs while providing protection against thermal and oxidative degradation, sludge and varnish formation, viscosity shear down, cold temperature oil thickening, poor friction stability, high component wear and shortened oil life.

According to Amsoil, delivering the ultimate in oxidation resistance, wear control and friction performance, Torque-Drive extends lubricant life up to six times and provides protection beyond that possible from conventional ATFs. Vehicles stay on the road longer, unnecessary labor and maintenance costs are reduced, and the return on costly transmission investments is maximized.

Amsoil
715-392-7101
www.amsoil.com

ATS Diesel Performance
866-230-4089
www.atsdiesel.com
Products: Co-Pilot Transmission Controller, Deep Aluminum Transmission Pan

Redline Diesel Performance
1787 Pomona Road. Unit F
Corona, CA 92880
Services: Co-Pilot Install

Amsoil
715-392-7101
www.amsoil.com
Products: Torque-Drive Synthetic Automatic Transmission Fluid

Previous Project Ronix Rig Sources:
K&N Engineering
800-858-3333
www.knfilters.com
Products: FIPK AirCharger Intake
 
Bully Dog Technologies
888-367-9922
www.bullydog.com
Products: Rapid Flow 5-Inch Exhaust, Triple Dog Power Pup Downloader
 
Cognito Motorsports
866-426-4648
www.cognitomotorsports.com
Products: GM Eight-Lug 7-9 Inch Lift, Tubular Upper Control Arms, Dual Shock Hoop Kit
 
King Off-Road Racing Shocks
714-530-8701
www.kingshocks.com
Products: Pre-Runner Billet Piggyback Reservoir 2.5 Shocks
 
American Racing Equipment
310-635-7806
www.americanracing.com
Products: Chamber Chrome 18x9.5 Wheels
 
Cooper Tire & Rubber Co.
419-423-1321
www.coopertire.com
Products: Discoverer STT 35x12.5x18 Tires
 
SnugTop
562-432-5454
www.snugtop.com
Products: XTRA Vision Cap
 
Bushwacker Inc.
800-234-8920
www.bushwacker.com
Products: Pocket-Style Fender Flares
 
Shocker Motorsports
661-588-7702
www.shocker-inc.com
Products: Quick-Release Clear Mudflaps, Lift Kit Installation