I've also been considering switching to an Allison. My BTS is great, but- it's just "missing" a gear that it should have. Consequently, it spends a lot of time hunting when it should be working. It's not a problem until I tow, then it's a major annoyance for me.
The think that scares me senseless is the prices of Allisons. Yikes! Those things are spendy even as cores, and the cores aren't exactly stacked up in piles waiting to be dragged off. They are hard to find. From what I've seen so far, they have to be built up to withstand the abuses that Danny dishes out for sure. With the rate I break things, it's a foregone conclusion for me too. I've seen website pricing on "bullet proof" allisons for SIX GRAND. That's a ton of money for me.
One possible advantage I MIGHT have is that my cummins came with a SAE #2 housing on the back of it which is a fairly universal housing that MANY trannys bolt to (but not a 4R100 as far as I know). It also has a flex plate on it already, so I may save myself around $1,500 in my conversion by switching to an 840 pound allison garbage truck or dump truck tranny, but then I would have to run a divorced transfer case. An allison can be made to "talk" to a Cummins, but not to a 7.3 computer without an interface of some sort.
Decisions, decisions....
Danny is right, no matter how you cut it, it costs
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