Allison Rebuild help with Banks Stinger Kit

[BurnettFarms]

I installed the banks stinger system (with dial switch not PDA) on my 2005 CC D/A with 90,000 miles on it. i tow our 5'r about 3,000 miles a year, drive solo the rest to work, etc. I just fried the C3 pack and have the tranny torn apart at the dealership for extended warranty work (fingers crossed and damn glad i'm covered until 100,000).
What upgrades can i look at to enhance the performance and longevity of the Allison? I'm not wanting to break bank but figure there could be something to help a little. Just for a budget i don't want to exceed $1,500 extra (Vegas is calling)
The dealer is great and will bring the tranny to factory specs, i'm just looking for anything a little extra along the way.
Also, any recommendations on settings for the Banks Economind while towing vs. daily driving? The rep i called wasnt very helpful, just said leave it at 6 and forget about it. He told me the Allison tested well with their tuners under all conditions and is virtually bullet-proof . . . i told him i shoot silver bullets
Thanks

[DmaxMaverick]

Welcome aboard!

Have a look at www.suncoastconverters.com.

They have lots of options.

[Jake99Z71]

I would also add a C3 oiler kit to help cool the C3 clutch. This will make it last longer as it is used for 3rd and 5th gear.

[More Power]

Also, any recommendations on settings for the Banks Economind while towing vs. daily driving? The rep i called wasnt very helpful, just said leave it at 6 and forget about it.

I've been communicating with a snowbird member who is currently in FL with his 2005 3500 and fifth-wheel travel trailer, and is in the process of having his Allison rebuilt. He also has the full Banks system with PDA, larger intercooler, air intake, exhaust and many other items. He'd been towing on level 3, and experienced a P0735 a number of times. In his particular case, his Allison first set this code once while completely stock when the truck was nearly new, so the Banks system may have just brought out the problem sooner. He's a retired trucker, so he knows how to take care of his equipment.

A typical 2001-2005 Allison can usually handle 50-75 additional horsepower while towing without a problem. The newer Allisons (with the higher stock HP Duramax) don't seen to have quite the cushion because the engine is already more powerful than the earlier engines.

I've towed quite a lot with my 2001 and an additional 50 hp, and not had a problem. So, I'd recommend not exceeding that, and be a little more careful while towing.

Jim

[BurnettFarms]

All- Thanks for the suggestions

Jim- You were right on the money, the code i had was the same, PO735. I'll try to lighten my foot, otherwise the wallet will be lighter on any work next time. i think the PDA might allow tighter monitoring but i didn't want to risk having long term issues with the PDA (kids, dust, handling, etc). I'm running naked on boost and egt, do you think monitoring guages would help?

[Mark Rinker]

Gauges are always a good idea if towing and running extra fuel/boost, but I don't believe gauges would have indicated your problem. Did you ever experience a 'limp' while towing, or please explain how the transmission failed. Any overheating or burnt, stinky fluid?

We just roasted a 115K mile 2006 Allison that had the snot towed out of it, about 80K miles in 18 months all towing moderately heavy stuff, random drivers, and a 70hp tune thrown on top of 360hp LBZ...Call it asking for trouble. $3000 later, I am cured of turning up the later model trucks. I'll be leaving my new(er) 2006 K3500 stock for the time being.

It hauls butt just fine - straight and bone stock from the factory.