Allison Transmission 1000, 2000 Troubleshooting Manual

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Allison 4

Generation Controls

Troubleshooting Manual

1000 and 2000 Product Families

TS3977EN

Troubleshooting Manual

TS3977EN 200707

1000 AND 2000 PRODUCT FAMILIES ALLISON 4

GENERATION CONTROLS

2007 FEBRUARY

Troubleshooting

REV. 1 2007 JULY

Manual

TS3977EN

Allison Transmission

ALLISON 4

1000 and 2000 Product Families

GENERATION CONTROLS

Allison Transmission, Inc.

P.O. Box 894 Indianapolis, Indiana 46206-0894

www.allisontransmission.com

Printed in USA

1000 AND 2000 PRODUCT FAMILIES TROUBLESHOOTING MANUAL—ALLISON 4

GENERATION CONTROLS

FOREWORD — How to Use This Manual

This manual provides troubleshooting information for Allison Transmission 1000 and 2000 Product Families transmissions. Service Manual SM4006EN, Mechanics Tips MT4007EN, and Parts Catalog PC3062EN may be used in conjunction with this manual.

This manual includes:

•

Description of the electronic control system.

•

Description of the electronic control system components.

•

Description of diagnostic codes, system responses to faults, and troubleshooting.

•

Wire, terminal, and connector repair information.

Speciﬁc instructions for using many of the available or required service tools and equipment are not included in this manual. The service tool manufacturer will furnish instructions for using the tools or equipment.

Additional information may be published from time to time in Service Information Letters (SIL) and will be included in future revisions of this and other manuals. Please use these SILs to obtain up-to-date information concerning Allison Transmission products.

This publication is revised periodically to include improvements, new models, special tools, and procedures. A revision is indicated by a new date on the title page and rear cover. Check with your Allison Transmission service outlet for the currently applicable publication. Additional copies of this publication may be purchased from authorized Allison Transmission service outlets. Look in your telephone directory under the heading of Transmissions—Truck, Tractor, etc.

Take time to review the Table of Contents and the manual. Reviewing the Table of Contents will aid you in quickly locating information.

NOTE: Allison Transmission is providing service of wiring harnesses and wiring harness components as

follows:

•

Repair parts for the internal wiring harness will be available through the Allison Transmission Parts Distribution Center (PDC). Use the P/N from your appropriate parts catalog or from Appendix E in this manual. Allison Transmission is responsible for warranty on these parts.

•

Repair parts for the external harnesses and external harness components must be obtained from the vehicle OEM or the OEM is responsible for warranty on these parts.

1000 AND 2000 PRODUCT FAMILIES TROUBLESHOOTING MANUAL—ALLISON 4

GENERATION CONTROLS

IMPORTANT SAFETY NOTICE

IT IS YOUR RESPONSIBILITY to be completely familiar with the warnings and cautions used in this manual. These warnings and cautions advise against using speciﬁc service procedures that can result in personal injury, equipment damage, or cause the equipment to become unsafe. These warnings and cautions are not exhaustive. Allison Transmission could not possibly know, evaluate, or advise the service trade of all conceivable procedures by which service might be performed or of the possible hazardous consequences of each procedure. Consequently, Allison Transmission has not undertaken any such broad evaluation. Accordingly, ANYONE WHO USES A SERVICE PROCEDURE OR TOOL WHICH IS NOT RECOMMENDED BY ALLISON TRANSMISSION MUST ﬁrst be thoroughly satisﬁed that neither personal safety nor equipment safety will be jeopardized by the service procedures used.

Also, be sure to review and observe WARNINGS, CAUTIONS, and NOTES provided by the vehicle manufacturer and/or body builder before servicing the Allison transmission in that vehicle.

Proper service and repair is important to the safe and reliable operation of the equipment. The service procedures recommended by Allison Transmission and described in this manual are effective methods for performing troubleshooting operations. Some procedures require using specially designed tools. Use special tools when and in the manner recommended.

The WARNINGS, CAUTIONS, and NOTES in this manual apply only to the Allison transmission and not to other vehicle systems which may interact with the transmission. Be sure to review and observe any vehicle system information provided by the vehicle manufacturer and/or body builder at all times the Allison transmission is being serviced.

WARNINGS, CAUTIONS, AND NOTES

Three types of headings are used in this manual to attract your attention:

WARNING!

CAUTION:

Is used when an operating procedure, practice, etc., which, if not correctly followed, could result in injury or loss of life.

Is used when an operating procedure, practice, etc., which, if not strictly observed, could result in damage to or destruction of equipment.

NOTE: Is used when an operating procedure, practice, etc., is essential to highlight.

1000 AND 2000 PRODUCT FAMILIES TROUBLESHOOTING MANUAL—ALLISON 4

GENERATION CONTROLS

TRADEMARKS USED IN THIS MANUAL

The following trademarks are the property of the companies indicated:

•

Adobe

Acrobat

Allison DOC™ For PC—Service Tool is a trademark of General Motors Corporation.

LPS

Cleaner is a registered trademark of LPS Laboratories.

Loctite

Teﬂon

Windows

is a registered trademark of the Loctite Corporation.

is a registered trademark of the DuPont Corporation.

Reader

95, Windows

are registered trademarks of Adobe Systems Incorporated.

98, Windows

XP, and Windows NT

are trademarks of Microsoft Corporation.

SERVICE LITERATURE

This service literature provides fully illustrated instructions for operation, maintenance, service, overhaul, and parts support for your transmission. For maximum performance and service life from you unit, you may order publications from:

SGI, Inc. Attn: Allison Literature Fulﬁllment Desk 8350 Allison Avenue Indianapolis, IN 46268 TOLL FREE: 888-666-5799 INTERNATIONAL: 317-471-4995

1000 and 2000 Product Families Service Literature

Publication Name Publication No.

Allison DOC™ For PC–Service Tool User Guide GN3433EN Automatic Transmission Fluid Technician’s Guide GN2055EN *Mechanic’s Tips MT4007EN *In-Chassis Maintenance GN4008EN *Emergency Vehicle Series Operator’s Manual OM3761EN *Highway Series Operator’s Manual OM3757EN *Rugged Duty Series Operator’s Manual OM3759EN *Motorhome Series Operator’s Manual OM3364EN *Pupil Transport/Shuttle Series Operator’s Manual OM3758EN *Bus Series Operator’s Manual OM3765EN *1000, 2000, 2400 Operator’s Manual OM3063EN *Owner’s Manual (2000MH) OM3364EN *Parts Catalog PC3062EN Parts Catalog On CD-ROM CD3062EN Principles Of Operation PO4009EN Service Manual SM4006EN

Troubleshooting Manual—Allison 4

Also Available On The Internet At www.allisontransmission.com

Generation Controls TS3977EN

1000 AND 2000 PRODUCT FAMILIES TROUBLESHOOTING MANUAL—ALLISON 4

GENERATION CONTROLS

TABLE OF CONTENTS

Foreword . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .ii

SAFETY INFORMATION

Important Safety Notice . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . iii

Warnings, Cautions, and Notes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . iii

Trademarks Used in This Manual . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . iv

Service Literature. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . iv

SECTION 1. GENERAL DESCRIPTION

1–1. TRANSMISSION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1–1

1–2. TRANSMISSION CONTROL MODULE (TCM) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1–3

1–3. SHIFT SELECTOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1–3

A. Shift Selector Range Positions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1–3

B. Manual Selector Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1–4

C. Internal Mode Switch (IMS). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1–5

1–4. THROTTLE POSITION SENSOR (TPS) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1–5

1–5. SPEED SENSORS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1–6

A. Input (Engine) Speed Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1–6

B. Turbine Speed Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1–6

C. Output Speed Sensor. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1–7

1–6. CONTROL VALVE ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1–7

A. Main Modulation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1–8

1–7. WIRING HARNESSES. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1–8

A. External Wiring Harness. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1–8

B. Internal Wiring Harness . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1–10

1–8. SPECIAL ELECTRONIC/ELECTRICAL TOOLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1–11

Page

SECTION 2. DEFINITIONS AND ABBREVIATIONS

2–1. CHECK TRANS LIGHT. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2–1

2–2. RANGE INHIBIT RESPONSES. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2–1

2–3. ALLISON DOC™ FOR PC–SERVICE TOOL INHIBITS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2–1

2–4. ALLISON DOC™ FOR PC–SERVICE TOOL. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2–4

2–5. ABBREVIATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2–5

SECTION 3. BASIC KNOWLEDGE

3–1. BASIC KNOWLEDGE REQUIRED . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3–1

3–2. USING THE TROUBLESHOOTING MANUAL. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3–1

3–3. SYSTEM OVERVIEW . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3–1

3–4. IMPORTANT INFORMATION IN THE TROUBLESHOOTING PROCESS. . . . . . . . . . . . . . . . .3–2

3–5. BASIC TROUBLESHOOTING INFORMATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3–3

3–6. TCM DIAGNOSTIC PROCEDURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3–9

3–7. RESETTING OF TCM PARAMETERS TO SUPPORT ENGINE UPDATE. . . . . . . . . . . . . . . . . .3–9

3–8. RESETTING TCM SEM AUTOSELECT. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3–10

1000 AND 2000 PRODUCT FAMILIES TROUBLESHOOTING MANUAL—ALLISON 4

TABLE OF CONTENTS

(cont’d)

GENERATION CONTROLS

SECTION 4. WIRE CHECK PROCEDURES

4–1. CHECKING OPENS, SHORTS BETWEEN WIRES, AND SHORTS-TO-GROUND . . . . . . . . . 4–1

4–2. CHECKING AT TRANSMISSION CONNECTOR AND THE INTERNAL HARNESS

FOR OPENS, SHORTS BETWEEN WIRES, AND SHORTS-TO-GROUND. . . . . . . . . . . . . . . . 4–2

SECTION 5. DIAGNOSTIC TROUBLE CODES (DTC)

5–1. DTC MEMORY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5–1

5–2. FAILURE RECORDS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5–1

5–3. DTC READING AND DTC CLEARING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5–3

A. Clearing DTCs. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5–3

B. Clearing Active Indicators. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5–3

5–4. BEGINNING THE TROUBLESHOOTING PROCESS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5–3

A. Starting Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5–3

B. Solenoid Locations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5–4

C. Wire/Terminal Numbering Scheme. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5–4

D. Available Diagnostic Adapters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5–4

5–5. DIAGNOSTIC TROUBLE CODES (DTCs—Includes Index) . . . . . . . . . . . . . . . . . . . . . . . . . . . 5–10

Page

SECTION 6. INPUT AND OUTPUT FUNCTIONS

6–1. SPECIAL INPUT AND OUTPUT FUNCTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6–1

A. Input Functions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6–1

B. Output Functions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6–1

SECTION 7. GENERAL TROUBLESHOOTING OF PERFORMANCE COMPLAINTS . . . . . . . . . . 7–1

APPENDICES

A. DIAGNOSING INTERMITTENT DTCs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A–1

B. MAIN PRESSURE CHECK PROCEDURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B–1

C. SOLENOID AND CLUTCH TABLE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C–1

D. WIRE/CONNECTOR TABLES. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D–1

E. CONNECTOR REPAIR INFORMATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . E–1

F. THROTTLE POSITION SENSOR ADJUSTMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F–1

G. WELDING ON VEHICLE/VEHICLE INTERFACE MODULE . . . . . . . . . . . . . . . . . . . . . . . . . . G–1

H. HYDRAULIC SCHEMATICS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . H–1

J. WIRING SCHEMATIC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .J–1

K. RESISTANCE vs. TEMPERATURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . K–1

L. ELECTRONIC INTERFERENCE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . L–1

M. Allison DOC™ FOR PC–SERVICE TOOL. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .M–1

N. INPUT/OUTPUT FUNCTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . N–1

P. J1939 AND J2284 HARDWARE AND TCM CONNECTIONS. . . . . . . . . . . . . . . . . . . . . . . . . . . P–1

R. FLUID CHECK PROCEDURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . R–1

1000 AND 2000 PRODUCT FAMILIES TROUBLESHOOTING MANUAL—ALLISON 4

ECTION

1—GENERAL DESCRIPTION

GENERATION CONTROLS

1–1. TRANSMISSION

The 1000 and 2000 Product Families Allison 4 provide superior shift quality over a wide range of operating conditions. The 1000 and 2000 Product Families conﬁgurations can be programmed to provide up to six forward speeds, neutral, and reverse. The ﬁfth and sixth ranges are overdrive gear ratios. The 1000 and 2000 Product Families incorporates a variety of standard and optional design features.

Figure 1–1 is a block diagram of the basic system inputs and outputs.

PRESSURE SWITCH MANIFOLD

SPEED SENSORS

THROTTLE POSITION SENSOR

VEHICLE/ENGINE

COMMUNICATION LINKS

Generation Controls system features closed-loop clutch control to

INTERNAL MODE SWITCH

SOLENOIDS

(VBS, ON/OFF)

TCM

TEMPERATURE SENSOR

(SUMP/ENGINE)

INPUTS

OUTPUTS

Figure 1–1. Transmission Control Module Block Diagram

Figure 1–2 shows the electronic control components.

Electronic Controls consist of the following elements:

•

Remote 12V or 24V Transmission Control Module (TCM)

•

Throttle Position Sensor (TPS), electronic engine throttle data, or PWM signal

•

Speed Sensors—Input (Engine), Turbine, and Output

•

Control Valve Assembly (Electro-Hydraulic Valve Body)

•

Internal Mode Switch (IMS)

•

Pressure Switch Manifold (PSM)

•

Wiring Harnesses

NOTE: All external harnesses are OEM-supplied.

V05726.00.01

1000 AND 2000 PRODUCT FAMILIES TROUBLESHOOTING MANUAL—ALLISON 4

GENERAL DESCRIPTION

TRANSMISSION

CONTROL

MODULE

(TCM)

TRANSMISSION

HARNESS

80-WAY CONNECTOR

J1939 CONNECTOR

OEM SUPPLIED

INTERFACE HARNESS

GENERATION CONTROLS

ENGINE

SPEED SENSOR

CONNECTOR

TURBINE

SPEED SENSOR

CONNECTOR

THROTTLE POSITION

SENSOR (TPS)

CONNECTOR

(OPTIONAL)

THROTTLE

POSITION

SENSOR (TPS)

NOTE: Illustration is not to scale. Actual harness configuration may differ from this illustration.

OUTPUT SPEED SENSOR CONNECTOR

24-WAY MAIN

TRANSMISSION

CONNECTOR

20-WAY CONNECTOR (OPTIONAL)

Figure 1–2. Electronic Control Components

V06475.03.00

1000 AND 2000 PRODUCT FAMILIES TROUBLESHOOTING MANUAL—ALLISON 4

GENERATION CONTROLS

GENERAL DESCRIPTION

1–2. TRANSMISSION CONTROL MODULE (TCM)

The electronic control of the transmission is performed by a microcomputer. The microcomputer is an independent controller and is referred to as a Transmission Control Module (TCM). TCMs are available in both 12V and 24V conﬁgurations to match the conﬁguration of the vehicle electrical system.

The TCM (refer to Figure 1–3) receives and processes signals from various switches and sensors. The TCM determines shift sequences, shift timing, and clutch apply and release pressures. The TCM uses the information to control transmission solenoids and valves, supply system status, and provide diagnostic information.

V09005.00.00

Figure 1–3. Transmission Control Module (TCM)

1–3. SHIFT SELECTOR

The vehicle is equipped with a lever-type shift selector (refer to Figure 1–4). In addition to the lever assembly provided for the operator, other components associated with the shift selector are the manual selector valve in the main control valve body and an Internal Mode Switch (IMS) mounted on the selector shaft inside the transmission oil pan. Shift selector components (with the exception of the transmission selector shaft) are customer-supplied.

A. Shift Selector Range Positions

The operator chooses the transmission range by moving the selector lever to the appropriate gate position (refer to Figure 1–4). When properly adjusted, the shifter gates prevent inadvertent shifting between ranges and correspond to the internal transmission detent positions. A positive detent is provided in the transmission to maintain the selector shaft in the selected position.

D , 2 , 1

1000 AND 2000 PRODUCT FAMILIES TROUBLESHOOTING MANUAL—ALLISON 4

GENERAL DESCRIPTION

SHIFT SELECTOR

Figure 1–4. Typical Lever-Type Shift Selector

GENERATION CONTROLS

P R N

2 1

TOP VIEW

V06476.01.00

The TCM shift calibration determines the available forward ranges for each selector position. Although speciﬁc installations vary, typical selector positions for the 1000 and 2000 Product Families are:

—Park. Parking pawl or parking brake is engaged, if available. This position is not available on all

shift selectors.

—Reverse.

—Neutral. May be used when starting the engine and for stationary operations.

—Overdrive. The highest forward range used for normal driving. The transmission shifts to ﬁrst

range for starting, then automatically upshifts through the ranges (as operating conditions permit) until the highest range is attained.

—Forward Range. The transmission shifts to ﬁrst range for starting. The range selected on the

shift selector is the highest range which will be attained during automatic shifting (on GM truck applications, a position

is used for Tap Up/Tap Down functionality).

B. Manual Selector Valve

The manual shift selector shaft is attached to the manual selector valve within the transmission main control valve body. The selector valve has three positions: reverse, neutral, and forward.

NOTE: For transmissions equipped with a P (Park) position, the selector valve remains in

the neutral position when the selector is moved to P (Park).

The neutral and reverse selector valve positions (refer to Appendix H—Hydraulic Schematics) exhaust the C1 and C2 rotating clutches. By exhausting C1 and C2 clutches, forward range is inhibited. This provides the capability for the operator to override the electronically commanded ranges if neutral is required.

1000 AND 2000 PRODUCT FAMILIES TROUBLESHOOTING MANUAL—ALLISON 4

GENERAL DESCRIPTION

C. Internal Mode Switch (IMS)

An internally-mounted switch, commonly called an Internal Mode Switch or IMS (refer to Figure 1–5), mounts inside the transmission oil pan at the shift selector shaft. The IMS detects the angular position of the shift selector shaft. This position is communicated to the TCM so that certain vehicle control functions can be coordinated with the position of the shift controls. The neutral signal output of the IMS is typically used as conﬁrmation that the transmission is in neutral before the engine starter is engaged.

GENERATION CONTROLS

V09076.00.00

Figure 1–5. Internal Mode Sensor (IMS)

1–4. THROTTLE POSITION SENSOR (TPS)

The Throttle Position Sensor (TPS) can be mounted to the engine, chassis, or transmission. The TPS (refer to Figure 1–6) contains a pull actuation cable and a potentiometer. One end of the cable is attached to the engine fuel lever and the other, inside a protective housing, to the TPS potentiometer. Output voltage from the TPS is directed to the TCM through the external harness. The voltage signal indicates the throttle position and, in combination with other input data, determines shift timing.

THROTTLE POSITION SENSOR (TPS)

V00628.01

Figure 1–6. Throttle Position Sensor (TPS)

1000 AND 2000 PRODUCT FAMILIES TROUBLESHOOTING MANUAL—ALLISON 4

GENERATION CONTROLS

GENERAL DESCRIPTION

1–5. SPEED SENSORS

There are three speed sensors available for use with 1000 and 2000 Product Families transmissions: the input (engine) speed sensor, the turbine speed sensor, and the output speed sensor (refer to Figure 1–7). The speed sensors provide rpm information to the TCM. The speed ratios between the various sensors allow the TCM to determine the transmission operating range. Speed sensor information is also used to control the timing of clutch apply pressures, resulting in the best possible shift quality.

V04736

Figure 1–7. Typical Speed Sensor

The speed sensors are variable reluctance devices which convert mechanical motion to an AC voltage. Each sensor consists of a wire coil wrapped around a pole piece that is adjacent to a permanent magnet. These elements are contained in a housing which is mounted adjacent to a rotating ferrous member (such as a gear tooth). Two signal wires extend from one end of the housing and an exposed end of the pole piece is at the opposite end of the housing. The permanent magnet produces lines of ﬂux around the pole piece. As a ferrous object (such as a gear tooth) approaches and passes through the gap at the end of the pole piece, an AC voltage pulse is induced in the wire coil. The TCM calculates the frequency of these AC pulses and converts it to a speed value. The AC voltage generated varies from 150mV at low speed to 15V at high speed. The signal wires from the sensor are formed as twisted pairs to cancel magnetically induced ﬁelds. The cable is also shielded to protect from voltage-related ﬁelds. Noise from other sources is eliminated by using two-wire differential inputs at the TCM.

NOTE: Do not rotate the speed sensor in the retaining bracket. Orientation is ﬁxed, and if changed, may cause

improper operation.

A. Input (Engine) Speed Sensor

The input speed sensor is externally mounted in the torque converter housing directed at the ribs protruding from the torque converter. The input speed sensor connector should be positioned at approximately four o’clock, as viewed from the left side of the transmission (refer to Figure 1–8).

B. Turbine Speed Sensor

The turbine speed sensor is externally mounted in the main housing directed at the tone wheel or PTO drive gear attached to the rotating clutch module. The turbine speed sensor connector should be positioned at approximately three o’clock, as viewed from the left side of the transmission (refer to Figure 1–8).

1000 AND 2000 PRODUCT FAMILIES TROUBLESHOOTING MANUAL—ALLISON 4th GENERATION CONTROLS

GENERAL DESCRIPTION

C. Output Speed Sensor

The output speed sensor is externally mounted in the rear cover and directed at the teeth of a tone wheel splined to and rotating with the output shaft. The output speed sensor connector should be positioned at approximately ﬁve o’clock, as viewed from the left side of the transmission (refer to Figure 1–8).

ENGINE SPEED

SENSOR CONNECTOR

ORIENTATION = 4 o'clock

TURBINE SPEED

SENSOR CONNECTOR

ORIENTATION = 3 o'clock

OUTPUT SPEED

SENSOR CONNECTOR

ORIENTATION = 5 o'clock

V06457.01.00

Figure 1–8. Speed Sensor Connector Orientation

1–6. CONTROL VALVE ASSEMBLY

The hydraulic control valve assembly (Figure 1–9) governs ﬂuid ﬂow to the clutches (including the torque converter clutch). Solenoids, actuated by the TCM, control valve movement.

The control valve assembly consists of two components, the main valve body and the control valve body. The main valve body contains the pressure control valves (PCV), the TCC valve, the exhaust backﬁll valve, and the control main relief valve. The shift valve body contains the shift valves, the control main pressure valve, and the manual selector valve. The control valve assembly attaches to the bottom of the gearbox module and is enclosed by the oil pan. An internal wiring harness connects the solenoids and Pressure Switch Manifold (PSM) to the main transmission connector and external wiring harness.

1000 AND 2000 PRODUCT FAMILIES TROUBLESHOOTING MANUAL—ALLISON 4th GENERATION CONTROLS

GENERAL DESCRIPTION

A. Main Modulation

Main pressure is reduced by utilizing an on/off Main Mod solenoid that is located in the control valve body assembly. The Main Mod solenoid body is bolted to the main valve body. Main pressure will be reduced under various conditions such as low throttle, low torque, low engine speeds, and low output speeds. The primary beneﬁt of modulating main pressure is to increase cooler ﬂow at low engine speeds.

SS1

PCS1

PCS2

SS3

MAIN MOD

TCC

SS2

V07476.02.01

Figure 1–9. Control Valve Assembly

1–7. WIRING HARNESS

A. External Wiring Harness

The external wiring harness (refer to Figure 1–10) requirements are typically met through the use of a single harness with one branch connecting the TCM to the transmission, throttle position sensor, IMS, and speed sensors; another branch connecting the TCM to Allison DOC™ For PC–Service Tool and other vehicle interfaces. All wiring harnesses and mating connectors are OEM-supplied.

NOTE: Repair parts for the external harness and external harness components must be obtained through the

vehicle OEM. The OEM is responsible for warranty on these parts.

1000 AND 2000 PRODUCT FAMILIES TROUBLESHOOTING MANUAL—ALLISON 4th GENERATION CONTROLS

GENERAL DESCRIPTION

TRANSMISSION

CONTROL

MODULE

(TCM)

TRANSMISSION

HARNESS

80-WAY CONNECTOR

J1939 CONNECTOR

OEM SUPPLIED

INTERFACE HARNESS

ENGINE

SPEED SENSOR

CONNECTOR

TURBINE

SPEED SENSOR

CONNECTOR

THROTTLE POSITION

SENSOR (TPS)

CONNECTOR

(OPTIONAL)

THROTTLE

POSITION

SENSOR (TPS)

NOTE: Illustration is not to scale. Actual harness configuration may differ from this illustration.

OUTPUT SPEED SENSOR CONNECTOR

24-WAY MAIN

TRANSMISSION

CONNECTOR

20-WAY CONNECTOR (OPTIONAL)

V06475.03.00

Figure 1–10. Typical External Wiring Harnesses

1000 AND 2000 PRODUCT FAMILIES TROUBLESHOOTING MANUAL—ALLISON 4th GENERATION CONTROLS

GENERAL DESCRIPTION

B. Internal Wiring Harness

An internal wiring harness (refer to Figure 1–11 and Figure 1–12) connects the shift solenoids (SS1, SS2, SS3), pressure control solenoids (PCS1, PCS2), torque converter clutch solenoid (TCC), internal mode switch (IMS), pressure switch manifold (PSM), and temperature sensor to the external harness leading to the TCM.

MAIN

MOD

GRAY

IMS

INTERNAL

MODE

SWITCH

A B C D E F

MAIN

MOD

GRAY

SS1

GRAY

PSM

A B C D E F

PCS1

PCS2

SS3

LOCKARM

TCC

SS2

GRAY

Figure 1–11. Typical Internal Wiring Harness (24-Way Connector)

SS1

GRAY

PSM

A B C D E F

PCS1

MAIN TRANSMISSION CONNECTOR

LOCKARM

V08975.00.00

MAIN TRANSMISSION CONNECTOR

LOCKARM

IMS

INTERNAL

MODE

SWITCH

A B C D E F

LOCKARM

TCC

SS2

GRAY

Figure 1–12. Typical Internal Wiring Harness (20-Way Connector for GM Applications Only)

SS3

GRAY

PCS2

LOCKARM

V08974.00.00

1000 AND 2000 PRODUCT FAMILIES TROUBLESHOOTING MANUAL—ALLISON 4th GENERATION CONTROLS

J 47275

J 47276

J 47277

J 47278

GENERAL DESCRIPTION

1–8. SPECIAL ELECTRONIC/ELECTRICAL TOOLS

All tools listed are essential for overhaul, maintenance, and/or recalibration of the 1000 and 2000 Product Families electronic and electrical systems. The tools listed below are available for purchase from SPX/Kent-Moore.

Table 1–1. Essential Tools

3 4 of 9 D I G I T A L M U L T I M E T E R

100

500

200

300

900

400

600

200

500

300

600

400

500

700

600

COM

abcde

xyz ab

10 A

abcde

xyz ab

m ultim

eter

J 34520-A

Digital

Volt/Ohmmeter

J 47275

TCM Breakout

Harness Adapter

J 39700

J 42455-A

J 39700

Univeral Breakout Box

J 42455-A

Load Box

J 44950

Allison DOC™ For

PC–Service Tool

J 47276

“T” Breakout and TCM

Reﬂashing Harness

J 47277

Terminal Probe

NOTE: J 47277 is now included in the J 39197-A Kit.

J 47278

1000 and 2000 Product

Families Breakout Harness

J 44950

1000 AND 2000 PRODUCT FAMILIES TROUBLESHOOTING MANUAL—ALLISON 4th GENERATION CONTROLS

J 47949

J 47139

GENERAL DESCRIPTION

Table 1–1. Essential Tools (cont’d)

J 47943

J 47944

J 47943

DPA4 USB

Translator Device

J 47944

1000 and 2000 Product

Families Main

Transmission Connector

Removal Tool

Table 1–2. Available Tools

J 38125-12A

Terminal Remover

(80-way connector)

GM P/N: 12094429

J 47949

GMLAN Cable

J 44722-3 Overlay

J 44722-3 Cable

NOTE: J-44722-3 overlay is for pick-up truck use only.

J 38125-12A

J 39197-A

Jumper Kit

J 39197-A

J 47139

Crimper

1000 AND 2000 PRODUCT FAMILIES TROUBLESHOOTING MANUAL—ALLISON 4th GENERATION CONTROLS

SECTION 2—DEFINITIONS AND ABBREVIATIONS

2–1. CHECK TRANS LIGHT

The electronic control system is programmed to inform the operator of a problem with the transmission system and automatically take action to protect the operator, vehicle, and transmission. To do this, the TCM turns on the CHECK TRANS light on the instrument panel, which notiﬁes the operator that a Diagnostic Trouble Code (DTC) has been stored.

Each time the engine is started, the TCM will illuminate the CHECK TRANS light, then turn it off after a few seconds. This is a circuit check to verify that the lamp and wiring are in proper working order. Illumination of the CHECK TRANS light at any time after start-up indicates that the TCM has set a DTC. Allison DOC™ For PC– Service Tool is used to verify that the TCM has set a DTC (refer to Section 2–2). While the CHECK TRANS light is on, upshifts and downshifts may be restricted and direction changes (D–R, R–D) may not occur. The torque converter clutch is inhibited when transmission shifting is restricted or during any critical transmission malfunction.

The 1000 and 2000 Product Families transmissions DTCs are latching DTCs. When a failure condition is detected, the DTC set by the TCM remains active for the entire time the ignition is on. When the ignition is turned off and then on again, the transmission DTCs will reset and the TCM will recheck for the failure condition. If the failure condition is not present, the previously set DTC will remain in history; the CHECK TRANS light will turn off after the circuit check, and the transmission will function normally unless another failure occurs. This feature allows the vehicle to be driven to a service outlet.

2–2. RANGE INHIBIT RESPONSES

The range inhibit feature is a function of the TCM logic. The TCM senses when certain input variables are exceeded and takes action to prevent transmission damage. The TCM inhibits neutral-to-range shifts and illuminates a light on the dash when the inhibit is active.

Listed below are three variables that, when exceeded, cause inhibited shifts (with thresholds listed).

• Engine speed above 1000 rpm

• Throttle setting above 40 percent

• Output speed above 225 rpm

There are two levels of the special logic inhibits.

• Self-clearing inhibit—This inhibit clears itself if one of the above conditions is not present after a

calibrated time. This is three seconds in the case of medium-duty vehicles. If the shift inhibit is active, but not latched, the bulb will stay lit until self-cleared.

• Latching inhibit — This inhibit latches when one of the conditions listed above is still present after a

calibrated time. This is above three seconds for medium duty vehicles. To clear a latching inhibit, move the selector into any other position than the one originally selected.

2–3. ALLISON DOC™ FOR PC–SERVICE TOOL INHIBITS

If an inhibit has occurred since the last DTC was cleared, the inhibit state will indicate ON and will stay ON until the next manual DTC clear with Allison DOC™ For PC–Service Tool. These latched inhibits do not turn OFF after a speciﬁed number ignition cycles.

1000 AND 2000 PRODUCT FAMILIES TROUBLESHOOTING MANUAL—ALLISON 4th GENERATION CONTROLS

DEFINITIONS AND ABBREVIATIONS

The range inhibit light will illuminate and/or an inhibited state will be shown on Allison DOC™ For PC–Service Tool when the transmission is inhibited to Neutral for the following reasons:

• Low Main Pressure

If the transmission pressure switches do not indicate transmission pressurized at start-up, shifts-to-range may be inhibited and the range inhibit light will illuminate. Allison DOC™ For PC–Service Tool will indicate an active inhibit.

Common causes are transmission low on ﬂuid, transmission ﬁlter has just been changed, or pan has been removed and ﬂuid recently drained.

May produce DTC P0701.

• Transfer Case Neutral

If the transfer case is shifted into neutral while the transmission is in drive or reverse at a speed above idle, the transmission will continue to command range until the output speed is reduced to a point where neutral range is commanded. The range inhibit light will illuminate and Allison DOC™ For PC–Service Tool will indicate an active inhibit.

• Diagnostic Active

This indicates that an active diagnostic code was set and the driver attempted a range selection that was inhibited. In some failure modes, reverse cannot and will not be commanded. If reverse is selected during these failure modes a range inhibit light will illuminate in reverse.

During diagnostic responses, Neutral-to-Range Inhibits and Direction Change Inhibits continue to operate, but they may latch under certain conditions. In these cases, shutting down ignition and waiting for at least 5 seconds before restarting will clear the inhibit condition. Allison DOC™ For PC–Service Tool will indicate an active inhibit.

• Auto Neutral for PTO

Neutral-to-Drive and Neutral-to-Reverse shifts will be inhibited to neutral and Allison DOC™ For PC–Service Tool will show an inhibited state when TCM detects that auto neutral function input is active.

• Reverse Enable

Neutral-to-Reverse shifts will be inhibited to neutral and Allison DOC™ For PC–Service Tool will show an inhibited state when no input is detected from dash or ﬂoor mounted reverse enable switch when selecting reverse range. Allison DOC™ For PC–Service Tool will indicate an active inhibit.

This function is only used in European transit and tour buses applications.

• Refuse Packer Step Switch

Transmission operation is limited to only 1st range. Neutral-to-reverse shifts will be inhibited to neutral and Allison DOC™ For PC–Service Tool will show an inhibited state when input is detected from a step switch indicating that personnel is present on rear step platform.

• Auxiliary Function Range Inhibit

Neutral-to-Drive and Neutral-to-Reverse shifts will be inhibited to neutral and Allison DOC™ For PC–Service Tool will show an inhibited state when input is detected from an auxiliary switch or device. This inhibit will remain active until the auxiliary switch input is shut off and range is reselected.

1000 AND 2000 PRODUCT FAMILIES TROUBLESHOOTING MANUAL—ALLISON 4th GENERATION CONTROLS

DEFINITIONS AND ABBREVIATIONS

• PTO Neutral Lockup

Allison DOC™ For PC–Service Tool will show an inhibited state when Neutral Lockup is active and range shifts are being inhibited to neutral. When the selector is moved, lockup is released and the inhibit clears.

• Engine Speed

Neutral-to-Drive and Neutral-to-Reverse shifts will be inhibited to neutral and the range inhibit light will illuminate if the Engine Speed is greater than a calibrated value (1400 rpm for medium duty non-emergency vehicles). Allison DOC™ For PC–Service Tool will indicate an active inhibit.

• Output Speed

Reverse-to-Drive, Drive-to-Reverse, and Neutral-to-Reverse shifts initiated above 300 rpm of output speed will be inhibited to neutral and the range inhibit light will illuminate. Allison DOC™ For PC– Service Tool will indicate an active inhibit.

• Throttle

Reverse-to-Drive, Drive-to-Reverse, Neutral-to-Drive, and Neutral-to-Reverse shifts where throttle position is greater then 25 percent will be inhibited to neutral and the range inhibit light will illuminate. Allison DOC™ For PC–Service Tool will indicate an active inhibit.

• IMS Function or Alignment

Reverse-to-Drive, Drive-to-Reverse, Neutral-to-Drive, and Neutral-to-Reverse shifts will be inhibited to neutral and the range inhibit light will illuminate when an IMS failure or misalignment is detected. A common cause would be an error in the four-bit IMS input signal that is sent to the TCM. Allison DOC™ For PC–Service Tool will indicate an active inhibit.

• IMS PS4 Disagree

Reverse-to-Drive, Drive-to-Reverse, Neutral-to-Drive, and Neutral-to-Reverse shifts will be inhibited to neutral and the range inhibit light will illuminate when the Pressure Switch 4 (PS4) status is in the incorrect state when compared to the IMS state. Allison DOC™ For PC–Service Tool will indicate an active inhibit. This inhibit may be caused by a defective IMS, PSM, or valve body concerns.

• MSV Mis-Alignment/Unable to detect ratio after shift to range

If the range veriﬁcation test fails to detect turbine speed pull-down or valid gear ratio when the Manual Selector Valve (MSV) shifts to either forward or reverse range from neutral, the transmission will shift back to a neutral condition and the range inhibit light will illuminate.

Conditions that may cause this include: Attempts to shift the transmission from Neutral-to-Drive or Neutral-to-Reverse with the transfer case in neutral; transmission low on ﬂuid; misadjustment in the IMS or Selector Linkage; turbine or output speed sensor failure that may prevent the pull down test/ratio test from passing; solenoid A or B hydraulically failures; and possibly failed range clutch (C1 or C5 for 1st, C3 or C5 for Reverse).

Allison DOC™ For PC–Service Tool will indicate an active inhibit response.

• Wheel Spin or Lock

When the TCM detects that wheel lock or spin is occurring, the TCC is disengaged and a lock-to-range response is commanded for 6 seconds. Allison DOC™ For PC–Service Tool will indicate an active inhibit response.

1000 AND 2000 PRODUCT FAMILIES TROUBLESHOOTING MANUAL—ALLISON 4th GENERATION CONTROLS

DEFINITIONS AND ABBREVIATIONS

2–4. ALLISON DOC™ FOR PC–SERVICE TOOL

Allison DOC™ For PC–Service Tool v5.0.0 (or later) is available through Kent-Moore Heavy-Duty Division.

When installed on a Windows receives data to and from the TCM via the vehicle data communications link, processes the data, and displays appropriate information. Use Allison DOC™ For PC–Service Tool during installation checkout and troubleshooting.

For more details on Allison DOC™ For PC–Service Tool features, refer to the User Guide for Allison DOC™ For PC–Service Tool Version 5.0.0, GN3433EN.

PC, the Allison DOC™ For PC–Service Tool (refer to Figure 2–1) transmits and

V05490

Figure 2–1. Allison DOC™ For PC–Service Tool

1000 AND 2000 PRODUCT FAMILIES TROUBLESHOOTING MANUAL—ALLISON 4th GENERATION CONTROLS

DEFINITIONS AND ABBREVIATIONS

2–5. ABBREVIATIONS

A/N Assembly Number

ABS Anti-lock Brake System—OEM-provided means to detect and prevent wheel stoppage to

enhance vehicle handling. Retarder and engine brakes will not apply when ABS is active.

Amp Ampere—Unit of electrical current

CAN Controller Area Network—A network for all SAE J1939 communications in a vehicle

(engine, transmission, diagnostics, ABS, etc.)

CC Calibration Compatibility—First two digits of the CIN

CIN Calibration Identiﬁcation Number—Used to identify transmission controls software level

CMC Customer Modiﬁable Constants

CT Closed Throttle

DNA Does Not Adapt—Adaptive shift control is disabled.

DNS DO NOT SHIFT—Refers to the DO NOT SHIFT diagnostic response during which the

CHECK TRANS light is illuminated and the transmission will not shift and will not respond to the Shift Selector.

DTC Diagnostic Trouble Code

DVOM Digital volt/ohmmeter

ECM Engine Controller Module—Available on electronically-controlled engines—provides

some relevant data to TCM.

EMI ElectroMagnetic Interference

GPI General Purpose

condition.

GPO General Purpose Output—Output signal from the TCM to control vehicle components

(such as PTOs, backup lights, etc.) or allow a special operating mode or condition.

IMS Internal Mode Switch

IPC Instrument Panel Controller

J 1939 High-speed vehicle serial data communications standard.

LED Light-Emitting Diode—Electronic device used for illumination.

LRTP Low-Range Torque Protection—A feature limiting engine torque in lower ranges and

reverse to protect the transmission from damage.

NVL Neutral Very Low—The TCM has sensed turbine speed below 150 rpm. This is usually

caused by a dragging C1 or C3 clutch or a failed turbine speed sensor. When attained, the C4 and C5 clutches are applied to lock the transmission output.

OBD II On Board Diagnostics Second generation. EPA mandated speciﬁcation for vehicle

diagnostics.

Input—Input signal to the TCM to request a special operating mode or

OEM Original Equipment Manufacturer—Maker of vehicle or equipment.

Ohm Unit of electrical resistance.

PC Personal Computer

PCCS Production Calibration Conﬁguration System

1000 AND 2000 PRODUCT FAMILIES TROUBLESHOOTING MANUAL—ALLISON 4th GENERATION CONTROLS

DEFINITIONS AND ABBREVIATIONS

2–5. ABBREVIATIONS (cont’d)

PCM Powertrain Controller Module—Electronic device used on some vehicles.

PCS Pressure Control Solenoid

PCV Pressure Control Valve

PDM Parallel Data Module

PPC Pressure Proportional to Current solenoid. Solenoid control of clutch pressure is

proportional to the current being supplied to the solenoid.

PROM Programmable Read Only Memory

PS Pressure Switch

PSM Pressure Switch Manifold—Part of transmission control system located inside the oil pan.

PTO Power Takeoff

PWM Pulse Width Modulation

RFI Radio Frequency Interference

RPR Return to Previous Range—Diagnostic response in which the transmission is commanded

to return to previously commanded range.

SEM Shift Energy Management—Allows the TCM to request torque reduction from the ECM

during upshifts for increased clutch life.

SOL OFF All SOLenoids OFF

SS Shift

SV Shift Valve

TBC Truck Body Controller

TCC Torque Converter Clutch

TCM Transmission Control Module (also commonly referred to as the “computer”)

TFT Transmission Fluid Temperature—Data provided by thermistor that is part of the PSM.

TPS Throttle Position Sensor—Potentiometer for signaling the position of the engine fuel

V Version—Abbreviation used in describing TCM software levels.

VBS Variable Bleed Solenoid—Another name for Pressure Proportional to Current (PPC)

VDC Volts Direct Current (DC)

VIW Vehicle Interface Wiring—Interfaces TCM programmed input and output functions with

Volt Unit of electrical force

Solenoid

control lever.

solenoid. Solenoid control of clutch pressure is proportional to the current being supplied to the solenoid.

the vehicle wiring.

VOM Volt/ohmmeter

WOT Wide Open Throttle

∞ Inﬁnity—Condition of a circuit with higher resistance than can be measured; effectively an

open circuit.

1000 AND 2000 PRODUCT FAMILIES TROUBLESHOOTING MANUAL—ALLISON 4th GENERATION CONTROLS

SECTION 3—BASIC KNOWLEDGE

3–1. BASIC KNOWLEDGE REQUIRED

To service 1000 and 2000 Product Families Allison 4th Generation Controls, the technician must understand basic electrical concepts. Technicians need to know how to use a digital volt/ohmmeter (DVOM) to make resistance and continuity checks. Most troubleshooting checks consist of checking resistance and continuity, and checking for shorts between wires and to ground. The technician should be able to use jumper wires and breakout harnesses and connectors. Technicians unsure of making the required checks should ask questions of experienced personnel or ﬁnd instruction.

The technician should also have the mechanical aptitude required to connect pressure gauges or transducers to identiﬁed pressure ports used in the troubleshooting process. Pressure tap locations and pressure values are shown in Appendix B—Main Pressure Check Procedure.

Input power, ground, neutral start circuitry, etc., can cause problems with electronic controls or vehicle functioning

and may not generate a DTC. A working knowledge of 1000 and 2000 Product Families Allison 4 Controls vehicle installation is necessary in troubleshooting installation-related problems.

Refer to Section 7 for information concerning performance complaints (non-DTC) troubleshooting. A complete wiring schematic is shown in Appendix J. Refer to the 1000 and 2000 Product Family Tech Data for information concerning electronic controls installation and the Installation Checklist. Reliable transmission operation and performance depend upon a correctly installed transmission. For proper installation, review the Installation Checklist in the 1000 and 2000 Product Family Tech Data, available on the extranet under Engineering at www.allisontransmission.com.

Generation

3–2. USING THE TROUBLESHOOTING MANUAL

Use this manual as an aid to troubleshooting the 1000 and 2000 Product Families Allison 4th Generation Controls. Every possible problem and its solution cannot be encompassed by any manual. However, this manual does provide a starting point from which most problems can be resolved.

Once a problem solution is discovered in the manual do not look further for other solutions. It is necessary to determine

why a problem occurred. The root cause of a problem as well as the symptom must be corrected to

ensure trouble free operation. For example, taping a wire that has been rubbing on a frame rail will not correct the problem unless the rubbing contact is eliminated.

3–3. SYSTEM OVERVIEW

1000 and 2000 Product Families Allison 4th Generation Control functions are controlled by the TCM. The TCM reads shift selector range selection, output speed, and throttle position to determine when to command a shift. When a shift occurs, the TCM monitors turbine speed, output speed, and throttle position to control the oncoming and off-going clutches during the shift.

When the TCM detects an electrical fault, it logs a DTC indicating the faulty circuit and may alter the transmission operation to prevent or reduce damage.

When the TCM detects a non-electrical problem while trying to make a shift, the TCM may try that shift a second or third time before setting a DTC. Once that shift has been retried, and a fault is still detected, the TCM sets a DTC and holds the transmission in a fail-to-range mode of operation.

1000 AND 2000 PRODUCT FAMILIES TROUBLESHOOTING MANUAL—ALLISON 4th GENERATION CONTROLS

BASIC KNOWLEDGE

The 1000 and 2000 Product Families transmission utilizes “clutch to clutch” shift control to achieve range changes. In every case (except shifts to or from neutral), one clutch is exhausted and another applied to make a range shift. The “handoff” between exhausting and applying clutches is very precisely controlled by use of two Variable-Bleed Solenoids (VBS), commonly known as Pressure Proportional to Current (PPC) solenoids. These solenoids are labelled PCS1 and PCS2 in the transmission, and are referred to as “pressure control” solenoids. For example, to make a 1–2 shift, PCS1 is used to trim pressure off C5 clutch, and PCS2 is used to trim pressure on C4 clutch.

The TCM (transmission control module) modulates the current to both PCS1 and PCS2, which translates to a proportional level of pressure to the clutch. In order to make a shift, the TCM uses software and calibration settings of several program parameters to determine the level of current sent to the respective pressure control solenoids. These parameters are referred to as “adaptive values.” With a new transmission and TCM calibration, the adaptive values are set to “base calibration” level. The transmission uses the base calibration to perform the ﬁrst of each type of shift. However, once it has performed a shift, the TCM evaluates the actual shift and compares it to an “ideal” shift in the TCM’s memory. Based on that comparison, the TCM changes the settings of the adaptive values to a level that it believes will result in a shift closer to the “ideal” shift the next time it makes that type of shift. This is referred to as “adaptive shifting.”

When the transmission/TCM calibration is new, the TCM is in “fast adaptive” mode. In other words, the TCM is allowed to make relatively large changes in the adaptive values after each shift. Once the TCM determines that a given shift is close to its ideal level it switches to “slow adaptive” mode. In slow adaptive the TCM still is evaluating shifts and changing adaptive values, but is only allowed to do so in smaller increments.

The TCM is programmed to try to switch from fast to slow adaptive mode within approximately ﬁve shifts. It is important to understand that there are many different distinct shifts recognized by the TCM, and each of these shifts has its own adaptive values. For example, there are upshift and downshifts to and from each range, as well as unique adaptive values for several different throttle regions for each upshift and downshift. The point is, it may take a signiﬁcant amount of time before most of the shifts converge from fast to slow adaptive, and thus it is not unusual to experience somewhat harsh or unpleasant shift quality until these shifts are adapted.

TCC engagement is accomplished by a separate PPC (pressure proportional to current) TCC solenoid. There are adaptive values for this as well, and thus it will also require some driving for TCC engagement to adapt.

3–4. IMPORTANT INFORMATION IN THE TROUBLESHOOTING PROCESS

Before beginning the troubleshooting process, read and understand the following:

• Allison recommended wire numbers (i.e. 112) are a combination of the ﬁrst digit indicating the TCM 80-way

connector number and the last two digits indicating the pin-out information (i.e. 12).

• Shut off the engine and ignition before any harness connectors are disconnected or connected.

• Remember to do the following when checking for shorts and opens:

— Minimize movement of wiring harnesses when looking for shorts. Shorts involve wire-to-wire or wire-to-

ground contacts and moving the harnesses may eliminate the problem.

— Wiggle connectors, harnesses, and splices when looking for opens. This simulates vehicle movements

which occur during actual operation.

• When disconnecting a harness connector, be sure that pulling force is applied to the connector itself and not

the wires extending from the connector.

• Resistance checks involving the wiring between the TCM connectors and other components adds about

one Ohm of resistance to the component resistance shown.

1000 AND 2000 PRODUCT FAMILIES TROUBLESHOOTING MANUAL—ALLISON 4th GENERATION CONTROLS

BASIC KNOWLEDGE

• Inspect all connector terminals for damage. Terminals may have bent or lost the necessary tension to maintain

ﬁrm contact.

• Clean dirty terminals or connectors with isopropyl alcohol and a cotton swab, or a good quality, non-residue,

non-lubricating, cleaning solvent such as LPS Electro Contact Cleaner® or LPS NoFlash Electro Contact Cleaner®.

The cleaning solvent must not be chlorine based, contain petroleum distillates, or conduct electricity. The cleaning solvent should evaporate quickly to prevent the

CAUTION:

possibility of condensation within the connectors. Always blow or shake any excess cleaner from the connector before assembling it to its mating connector or hardware. Cleaner trapped in the connector can affect the connector seal. (Refer to SIL 17-TR-94 for detailed information on the recommended cleaners.)

CAUTION:

• DTCs displayed after system power is turned on while a harness connector is disconnected can be ignored and

cleared from memory. Refer to Section 5, DTCs, for the DTC clearing procedure.

Care should be taken when welding on a vehicle equipped with electronic controls. Refer to Appendix G.

3–5. BASIC TROUBLESHOOTING INFORMATION

1. Begin troubleshooting by checking the transmission ﬂuid level and ignition voltage. Remember that some problems may be temperature related. Do troubleshooting, including the ﬂuid level and ignition voltage checks, at the temperature level where the problem occurs.

NOTE: Fluid level and igniton voltage MUST be checked before any troubleshooting is performed.

NOTE: If you are experiencing harsh shifts, it is important to use Allison DOC™ For PC–Service Tool to

verify whether that particular shift is adapted. If it is not, the TCM is still “learning” how to adapt that shift and simply needs to be driven further while performing more of that particular type of shift.

If a particular shift is in slow adapt but still objectionable, it’s good troubleshooting practice to reset the adaptive values for that shift back to “base cal” level. This will automatically reset the TCM to fast adaptive mode. The vehicle should then be driven to allow the TCM to “re-learn” the shift. Many times this will correct the problem. It is possible to reset individual shifts without affecting the other shifts.

CAUTION:

Whenever a transmission is overhauled, exchanged, or has undergone repairs, the Transmission Control Module (TCM) must be “RESET TO UNADAPTED SHIFTS.” This will cause the TCM to erase previous adaptive information and begin to adapt in Fast Adaptive Mode from the base calibration. Failure to follow this procedure may cause premature failure of the overhauled, repaired, or replaced transmission.

1000 AND 2000 PRODUCT FAMILIES TROUBLESHOOTING MANUAL—ALLISON 4th GENERATION CONTROLS

BASIC KNOWLEDGE

2. If a transmission has been overhauled, exchanged, or repaired, use Allison DOC™ For PC–Service Tool to “RESET ADAPTIVE SHIFT PARAMETERS.”

To reset Adaptive Shift Parameters:

• Select the Action Request drop-down menu.

• Click on the Reset Adaptive Shift Parameters menu item—the Reset Adaptive Parameters window

displays.

• The Reset Adaptive Shift Parameters window contains 10 tabs; one for each upshift and downshift

region, garage shifts and a reset tab for All regions.

— To reset all adaptive shift parameters, select the ALL tab.

— The adaptive shift parameters are reset when you click on the RESET ADAPTIVE SHIFT

PARAMETERS button—the Reset Adaptive Shift Parameters Successful window displays. Click the OK button.

3. For proper operation of Allison DOC™ For PC–Service Tool v5.0.0 or later, check the following:

• The desktop or laptop computer must meet the minimum system requirements (see Allison DOC™

For PC–Service Tool Version 5.0.0 User Guide, GN3433EN):

— Microsoft Windows® 2000 Professional (SP4 or later) or Windows® XP Professional

— 600 MB free hard drive space

— 20 GB hard drive (40 GB preferred)

— 128 MB of RAM (256 MB preferred)

— Intel® Pentium® III or IV processor

— Available USB 1.1 or 2.0 port

— 1024 x 768 screen resolution

— 256-color palette

— Small fonts

— Internet connection (Internet Explorer 5.0 or greater)

— A media player program (Windows Media Player® is provided on the Allison DOC™ For

PC–Service Tool For PC CD)

— Adobe® Acrobat® Reader® (provided on the Allison DOC™ For PC–Service Tool CD)

— CD-ROM 16x minimum (48x preferred)

NOTE: Refer to the CD Readme.txt ﬁle for more information.

• The proper driver (electronic ﬁle) is installed for the Computer Interface Module.

• Power at the Deutsch 9-pin diagnostic connector (pin A is negative, pin B is positive).

• The proper connections exist for communicating with Allison DOC™ For PC–Service Tool (Figure 3–1

and Figure 3–2).

Presently there are two communication standards for Allison DOC™ For PC–Service Tool diagnostic software: J1939 and GMLAN J2284. Both standards are supported by Allison DOC™ For PC– Service Tool (versions 5.0).

1000 AND 2000 PRODUCT FAMILIES TROUBLESHOOTING MANUAL—ALLISON 4th GENERATION CONTROLS

BASIC KNOWLEDGE

ALLISON DOC™ FOR PC–SERVICE TOOL

J 47943-3 USB CONNECTOR (PART OF J 47943 KIT)

Dearborn Group

http:/ww

w.dgtech.com

J 47943-1 TRANSLATOR DEVICE (PART OF J 47943 KIT)

J 47943-2 (PART OF J 47943 KIT)

DB15 CONNNECTOR

DB15 CONNECTOR

SPX P/N: J 47949 GMLAN CABLE

(AVAILABLE FROM SPX/KENT-MOORE)

(NOT PART OF J 47943 KIT)

9-PIN CONNNECTOR

6-PIN CONNNECTOR

(NOT USED FOR

1000 AND 2000

PRODUCT FAMILIES

APPLICATIONS)

OBDII/16-PIN

CONNECTOR

J 1962/B

GMLAN

ALLISON 4TH GENERATION CONTROLS

1000 AND 2000 PRODUCT FAMILIES

(PRE-ALLISON 4TH GENERATION CONTROLS)

J1939

MEDIUM DUTY

ALLISON 4TH GENERATION CONTROLS

MEDIUM DUTY

V09232.01.00

Figure 3–1. Proper Allison DOC™ For PC–Service Tool Connections

4. Check DTCs by using Allison DOC™ For PC–Service Tool.

TCM/Load Box Setup

For “TCM/Load Box” setup (no connection to vehicle) use the J 47276 “T” Breakout and

TCM Reﬂashing Harness. This harness is required for bench-type reﬂashing of Allison 4

Generation

Controls TCMs. Use one of the following methods for TCM reﬂashing (Figure 3–2).

• J1939-13 connector (for J1939 communication) in combination with J 42455-A Load Box/Power

Supply

• J1962 connector (for GMLAN “high-speed CAN” communications) in combination with

J 42455-A Load Box/TCM

The Dearborn DPA4 USB Translator Device Kit (P/N: J 47943) is required to establish connection

between the PC and the TCM.

NOTE: To use the J1962 connector, an additional cable (J 47949) is required. J 47949 is available for purchase

from SPX/Kent-Moore.

1000 AND 2000 PRODUCT FAMILIES TROUBLESHOOTING MANUAL—ALLISON 4th GENERATION CONTROLS

BASIC KNOWLEDGE

J 47943-3 USB CABLE (PART OF J 47943 KIT)

SPX P/N: J 47949

GMLAN CABLE

(AVAILABLE FROM

Dearborn Group

htt

p:/ww

w.dgtech.com

SPX/KENT-MOORE)

(NOT PART OF J 47943 KIT)

OBDII/16-PIN

CONNECTOR

J 1962/B

ALLISON DOC™ FOR PC–SERVICE TOOL

TRANSLATOR DEVICE

(PART OF J 47943 KIT)

37-PIN CONNECTOR

J 42455-A

LOAD BOX

LOAD BOX POWER SUPPLY

NOTE:

Use Load Box (J 42455-A) when no connnection is made from J 47276 to the vehicle harness.

J 47943-1

J1939-13 (9-PIN)

CONNECTOR

(250 Kbps CAN)

J 47276 HARNESS

9-PIN CONNNECTOR

J 47943-2

(PART OF J 47943 KIT)

6-PIN CONNNECTOR

(NOT USED)

J1962 (16-PIN) GMLAN CONNECTOR (500 Kbps CAN “HIGH-SPEED CAN”)

80-WAY (M)

CONNECTOR

80-WAY (F)

CONNECTOR

TO TCM

EXISTING VEHICLE

HARNESS 80-WAY

CONNECTOR (F)

(NOT USED)

4TH GENERATION TCM

Figure 3–2. TCM/Load Box Setup

V09233.04.00

1000 AND 2000 PRODUCT FAMILIES TROUBLESHOOTING MANUAL—ALLISON 4th GENERATION CONTROLS

BASIC KNOWLEDGE

TCM/Vehicle Harness Setup

On the vehicle, use the J 47276 “T” Breakout and TCM Reﬂashing Harness to connect the Allison

DOC™ For PC–Service Tool directly to the TCM to bypass the Diagnostic Tool Connector.

Use the Dearborn DPA4 USB Translator Device Kit (P/N: J 47943) to establish connection between the

PC and the TCM.

Example: When communications are not available at the Diagnostic Tool Connector on the vehicle,

DTCs can be read directly from the TCM using the Diagnostic Tool Connectors on the J 47276 “T” Breakout and TCM Reﬂashing Harness.

Use one of the following Diagnostic Tool Connectors on the harness to establish a diagnostic connection

between the TCM and the Service Tool (refer to Figure 3–3):

• J1939-13 connector (for J1939 communication)

• J1962 connector (for GMLAN “high-speed CAN” communications)

NOTE: To use the J1962 connector, an additional cable (J 47949) is required. J 47949 is available for

purchase from SPX/Kent-Moore.

5. When a problem exists but a DTC is not indicated, refer to the General Troubleshooting Section

(Section 7) for a listing of various electrical and hydraulic problems, their causes, and remedies.

6. If a DTC is found in the TCM memory, save all available DTC and failure record information before

clearing the active indicator (refer to Section 5).

7. When certain DTCs are active, a range selection into reverse or forward may not be possible. To deter-

mine if a failure is electrical or hydraulic, perform the following “limp home” test.

Never remove electronic control connectors while the engine is running. Always

WARNING!

Limp Home Test

With the ignition in the OFF position (engine not running), the selector in N (Neutral), and the parking brake set, remove the 80-way connector at the TCM.

It will be necessary to provide battery power at pin 41 of the 80-way connector in order to energize the neutral start relay. This can be accomplished by using a jumper wire between pin 10 and 41 at the 80-way connector.

When the engine is restarted, the transmission will default to a “limp home” capability. In this state, PCS1 (de-energized) allows C3 clutch to be applied. If the selector valve is moved to the reverse range position, main pressure will be routed to C5 clutch, allowing reverse operation. If the selector valve is moved to the drive range position, main pressure will be routed to C1 clutch, allowing third range operation. This allows a technician to use “limp home” capability to determine if a hydraulic or an electrical problem exists. If reverse and third ranges are available in “limp home,” an electrical failure may be indicated. If only one of the two ranges or neither was obtainable, this may indicate an internal hydraulic failure (failed clutch, stuck valve, or solenoid failure). The clutches that could possibly have an indicated failure in “limp home” are C1, C3, and C5.

turn off the ignition, set parking brakes and chock the wheels. Failure to follow this procedure may result in unexpected vehicle movement.

1000 AND 2000 PRODUCT FAMILIES TROUBLESHOOTING MANUAL—ALLISON 4th GENERATION CONTROLS

BASIC KNOWLEDGE

J 47943-3 USB CABLE (PART OF J 47943 KIT)

SPX P/N: J 47949

GMLAN CABLE

(AVAILABLE FROM

Dearborn Group

http:/www.dgtech.com

SPX/KENT-MOORE)

(NOT PART OF J 47943 KIT)

OBDII/16-PIN

CONNECTOR

J 1962/B

ALLISON DOC™ FOR PC–SERVICE TOOL

37-PIN

CONNECTOR

NOTE:

37-Pin Connector is not used when J 47276 is connected to the vehicle harness.

TRANSLATOR DEVICE

J 47943-1

(PART OF J 47943 KIT)

J1939-13 (9-PIN)

J 47276 HARNESS

CONNECTOR

(250 Kbps CAN)

CONNECTOR

(PART OF J 47943 KIT)

80-WAY (F)

TO TCM

9-PIN CONNNECTOR

J 47943-2

6-PIN CONNNECTOR

(NOT USED)

J1962 (16-PIN) GMLAN CONNECTOR (500 Kbps CAN “HIGH-SPEED CAN”)

80-WAY (M)

CONNECTOR

EXISTING VEHICLE

HARNESS 80-WAY (F)

CONNECTOR

4TH GENERATION TCM

Figure 3–3. TCM/Vehicle Harness Setup

VEHICLE

V09234.06.00

1000 AND 2000 PRODUCT FAMILIES TROUBLESHOOTING MANUAL—ALLISON 4th GENERATION CONTROLS

BASIC KNOWLEDGE

NOTE: Removing the 80-way connector may induce several DTCs. Make sure all codes are cleared before

proceeding with further troubleshooting.

8. Test drive the vehicle to conﬁrm a DTC or performance complaint.

• If the DTC reappears, refer to the DTC section (refer to Section 5) and the appropriate DTC table.

The DTC section lists diagnostic codes and their description. Locate the appropriate troubleshooting table and follow the instructions.

• If the DTC does not reappear and the test has passed, it may be an intermittent problem. Use

Allison DOC™ For PC–Service Tool and the DTC (refer to Section 5). The DTC display procedure will identify possible causes of the problem.

• Appendix A deals with the identiﬁcation of potential circuit problems. Refer to Appendix A if a

circuit problem is suspected.

NOTE: Information concerning speciﬁc items is contained in the appendices located in the back of this

manual. The appendices are referred to throughout the manual.

3–6. TCM DIAGNOSTIC PROCEDURE

• Using Allison DOC™ For PC–Service Tool, verify the current calibration information number (CIN)

and record or print a report of the current customer modiﬁable constants (CMC) information for later reference.

• Remove the 80-way connector from the suspect TCM; inspect the 80-way connector for damaged or

bent pins.

• Replace TCM with a new or known good TCM from a similar vehicle.

• If the replacement TCM corrects the original complaint, reinstall the original TCM to verify the

complaint returns. If original complaint is conﬁrmed, reinstall a new TCM.

• If the complaint does not return, leave the original TCM installed.

• Clear any DTCs that may be present and test drive the vehicle to conﬁrm the repair.

NOTE: All 1000 and 2000 Product Families TCMs are designed to be isolated from the vehicle chassis ground.

Be sure that the TCM case is not contacting the vehicle frame or any other point that might provide a ground connection.

3–7. RESETTING OF TCM PARAMETERS TO SUPPORT ENGINE UPDATE

Shift Energy Management (SEM) Autoselect feature may be used on certain transmissions. Autoselect is deactivated following the ﬁrst 20 engine starts where engine and transmission communication are present. If during the ﬁrst 20 engine starts the TCM recognizes an engine to be on its list of certiﬁed engines, it will lock to the SEM active state. If the engine is not supported, the TCM will lock to a non-SEM state.

NOTE: Most engine upgrades are same type/rating; under normal circumstances there should be no reason to

reset the TCM Autoselect.

However, there may be a small chance that transmission performance, shift quality, or codes may result from the use of different engine models within the same engine family or when a recalibration of engine software has taken place. If a vehicle receives upgraded engine hardware or software it may become necessary to reactivate the Autoselect feature to redetect the engines current SEM status.

NOTE: Once TCM Autoselect locks, the only way to reactivate is to perform a reset procedure (refer to

paragraph 3–8).

1000 AND 2000 PRODUCT FAMILIES TROUBLESHOOTING MANUAL—ALLISON 4th GENERATION CONTROLS

BASIC KNOWLEDGE

3–8. RESETTING TCM SEM AUTOSELECT

Verify a new engine rating by checking the engine data tag. The engine must be compatible with the transmission rating. If the engine rating is not compatible, the vehicle must be returned to the OEM for engine recalibration. If the rating is correct for the transmission, perform the following steps.

Allison DOC™ For PC–Service Tool is used to reset Autoselect function.

• Click on the action requested button.

• On the drop down select Reset SEM Autoselect.

The TCM is now reset to Autoselect and will start looking for supporting engine software. Drive the vehicle; conﬁrm DTCs have not returned.

NOTE: Transmission shifts will now be in the unadaptive (base) state, so it will be necessary to drive the

vehicle to allow shifts to adapt.

1000 AND 2000 PRODUCT FAMILIES TROUBLESHOOTING MANUAL—ALLISON 4th GENERATION CONTROLS

SECTION 4—WIRE CHECK PROCEDURES

4–1. CHECKING OPENS, SHORTS BETWEEN WIRES, AND SHORTS-TO-GROUND

(Use Digital Volt/Ohmmeter J 34520-A and Jumper Wire Set J 39197-A)

NOTE: Please refer to Paragraph 3–5 to begin the troubleshooting process.

1. Make sure all connectors are tightly connected and re-check the circuit.

2. Disconnect and inspect all connectors.

3. Thoroughly clean corroded or dirty terminals. If dirty or corroded terminals are the probable cause of the

problems, reconnect the clean connectors and operate the vehicle normally. If the problem recurs, proceed with Step (4).

The cleaning solvent must not be chlorine based, contain petroleum distillates, or conduct electricity. The cleaning solvent should evaporate quickly to prevent the

CAUTION:

4. Review the wire numbering system described in Paragraph 3–4.

5. If all connectors are clean and properly seated, determine which wires in the chassis harness are indicated

by the DTC. For example, DTC P2727–P2729, indicates an open or a short-to-ground in the PCS1 circuit—wires 111 and 155.

a. Check continuity of wires 111 and 155 by performing the following (refer to Figure 4–1):

(1) Disconnect the 80-way connector from the TCM and disconnect the harness from the trans-

mission main connector. At one end of the harness, using jumper wire kit J 39197-A and the body connector probes in J 39775-CP, connect pin 14 and 15 to each other, being careful not to distort the terminals. Jumping the wires together creates a circuit between wires 111 and

155.

NOTE: Jumper wire kit J 39197-A adds a “female” probe J 47277.

TRANSMISSION CONNECTOR

WIRING HARNESS

TCM

80-WAY

CONNECTOR

DIGITAL

VOLT/OHM-METER

–

(DVOM)

0 OHMS OHMS

Circuit has continuity.

Jumper between wires produces

a complete circuit.

DVOM reading is near zero Ohms.

JUMPER

–

Circuit does not have continuity due

to a broken wire (open circuit).

DVOM reading is very high

(infinite Ohms or OL – overlimit).

V06478.03.00

Figure 4–1. Checking Continuity (External Harness)

ALLISON 1000 AND 2000 PRODUCT FAMILIES 4TH GENERATION CONTROLS TROUBLESHOOTING MANUAL

WIRE CHECK PROCEDURES

Do not insert test probes larger than 0.81 mm into the TCM 80-way and transmission 24-way connectors. Use the gray-colored 150 Series Metripack Flexible Male

CAUTION:

b. If the continuity check is good (0–2 Ohms resistance), remove the jumpers. Check the harness for

Connector probe contained in Jumper Wire Kit J 39197-A when testing the TCM and transmission mating connectors. Failure to do so may distort the socket terminals inside the connectors and cause them to lose the necessary tension to maintain ﬁrm contact.

(2) On the opposite end of the harness, check the continuity of the jumpered pair. No continuity in a

jumpered pair circuit (inﬁnite resistance reading) indicates an open in the wire being tested. Refer to OEM wiring harness repair procedure.

shorts between wires and shorts-to-ground by performing the following (refer to Figure 4–2):

(1) At the TCM end of the harness, touch one DVOM probe to one wire of the circuit being tested

and touch the other probe to each terminal in the same connector, then touch the probe to chassis ground and to the transmission main housing. Do this for both wires in the circuit being tested.

(2) If at any time the DVOM shows zero to low resistance, or the meter’s continuity beeper sounds,

there is a short between the two points being probed—wire-to-wire or wire-to-ground. Isolate and repair the short.

WIRING HARNESS

TCM

80-WAY

CONNECTOR

TRANSMISSION CONNECTOR

DIGITAL

VOLT/OHM-METER

(DVOM)

–

Two wires have frayed and are shorted

together. Continuity beeper of DVOM

will sound, or reading will go to

zero Ohms when these two wires

are probed with the DVOM.

Figure 4–2. Short Between Wires and to Ground (External Harness)

Wires shorted together

–

0 OHMS0 OHMS

Harness has been chafed and one or more

wires are shorted-to-ground. DVOM continuity

beeper will sound, or reading will go to

zero Ohms when meter is probing

between this wire and chassis ground.

Shorted to ground on metal frame rail

Ground to metal frame rail

V05734.02.00

ALLISON 1000 AND 2000 PRODUCT FAMILIES 4TH GENERATION CONTROLS TROUBLESHOOTING MANUAL

WIRE CHECK PROCEDURES

4–2. CHECKING AT TRANSMISSION CONNECTOR AND THE INTERNAL HARNESS

FOR OPENS, SHORTS BETWEEN WIRES, AND SHORTS-TO-GROUND

1. Disconnect the external wiring harness from the transmission.

2. Inspect the connectors. Any terminals which are corroded or dirty must be thoroughly cleaned.

The cleaning solvent must not be chlorine based, contain petroleum distillates, or conduct electricity. The cleaning solvent should evaporate quickly to prevent the

CAUTION:

3. If the connectors are clean and properly seated, determine which wires in the harness to test. Use

the diagnostic code system schematic to locate the wire terminals. For this example, DTC P2727 and P2729 indicate an open or a short-to-ground in the PCS1 circuit—wires 111 and 155 (refer to Figure 4–3 and Figure 4–4).

possibility of condensation within the connectors. Always blow or shake any excess cleaner from the connector before assembling it to its mating connector or hardware. Cleaner trapped in the connector can affect the connector seal. (Refer to SIL17-TR-94 for detailed information on the recommended cleaners.)

a. At the transmission connector, check the resistance of the PCS1 circuit. Resistance of a solenoid

circuit should be 5.5–8 Ohms—covering a temperature range of –18°C to 149°C (0°F to 300°F). Refer to Solenoid Resistance vs. Temperature chart in Appendix K. No continuity in the circuit (inﬁnite resistance) indicates an open in the internal harness, the feedthrough connector, or the solenoid coil. Replace the internal harness, replace the feedthrough connector, or replace the solenoid.

SOLENOID

TRANSMISSION

AT NORMAL OPERATING

MAIN

CONNECTOR

3.5

–

VOLT/OHM-

METER (DVOM)

5.5–8 OHMS

TEMPERATURE

Circuit has continuity.

–

INFINITE ( ) OHMS

Circuit does not have continuity due to a

broken wire (open circuit). DVOM reading is

very high (infinite ohms or OL–overlimit).

This could also be due to an open solenoid

coil or bad connection.

V05735.01.00

Figure 4–3. Checking Continuity (Internal Harness)

ALLISON 1000 AND 2000 PRODUCT FAMILIES 4TH GENERATION CONTROLS TROUBLESHOOTING MANUAL

WIRE CHECK PROCEDURES

b. If the resistance check is good, check the harness for shorts between wires and to ground by per-

forming the following (refer to Figure 4–4):

(1) At the transmission connector, touch one probe of the DVOM to one wire of the circuit being

tested and touch the other probe to each terminal in the connector and to chassis ground and the transmission main housing. Do this for both wires in the circuit being tested.

(2) If the DVOM shows zero to low resistance, or the continuity beeper sounds, there is a short

between the two points being probed, wire-to-wire or wire-to-ground. An indication of a short may be caused by a splice to the wire being checked. Check the wiring diagram in Appendix J for splice locations. If the short is not a splice, then isolate and repair the short.

Shorted to metal

TRANSMISSION

MAIN

CONNECTOR

–

VOLT/OHM-

METER

(DVOM)

Two wires have frayed and are shorted

together. Continuity beeper of DVOM will

sound, or reading will go to zero Ohms

when these two wires are probed with

the VOM.

Figure 4–4. Short Between Wires and to Ground (Internal Harness)

Bare wires touching each other

SOLENOIDS

–

0 OHMS0 OHMS

Harness has been chafed and one or more

wires are shorted to ground. DVOM continuity

beeper will sound or meter reading will go

to zero Ohms when meter is probing between

this wire and chassis ground.

V05736.02.00

1000 AND 2000 PRODUCT FAMILIES TROUBLESHOOTING MANUAL—ALLISON 4th GENERATION CONTROLS

SECTION 5—DIAGNOSTIC TROUBLE CODES (DTC)

5–1. DTC MEMORY

Diagnostic Trouble Codes (DTCs) are logged in a list in TCM memory. The DTCs contained in the list have information recorded as shown in Table 5–1 (DTC example). The TCM is capable of displaying all historical and active DTCs.

Table 5–1. DTC List

DTC

Active

Indicator Historic

Check

Trans

Failure

Record Description

P0713 Y Y N Y Transmission Fluid Temperature Sensor Circuit High Input

The following paragraphs deﬁne the different parts of the DTC list.

A. DTC. The number assigned to a given fault condition in accordance with SAE J2012.

B. Active Indicator. Indicates when a DTC is active. If a DTC is active, Allison DOC™ For PC–Service

Tool displays Y. If DTC is not active, N is displayed.

C. Historic. Indicates when an active DTC has had sufﬁcient activity to be stored to the TCM. If a DTC

has been stored to the TCM, Allison DOC™ For PC–Service Tool displays Y. If the DTC has not been stored to the TCM, N is displayed.

D. Check Trans. Indicates if CHECK TRANS Light is illuminated.

E. Failure Record. Indicates when a snapshot of transmission data has been stored in the TCM. The last

ﬁve DTC failure can be viewed. If the DTC can be viewed as part of the failure record, Allison DOC™ For PC–Service Tool displays Y. If the DTC cannot be displayed, N is displayed.

F. Description. Name assigned to a given fault condition in accordance with SAE J2012.

5–2. FAILURE RECORDS

Failure records contain a snapshot of transmission data that is stored in the TCM when DTCs are logged. A limit of ﬁve failure records can be stored. When an additional DTC is logged, the new failure record pushes the oldest record from the TCM memory. Table 5–2 illustrates the failure record data stored in the TCM when a DTC is set.

1000 AND 2000 PRODUCT FAMILIES TROUBLESHOOTING MANUAL—ALLISON 4th GENERATION CONTROLS

DIAGNOSTIC TROUBLE CODES (DTC)

Table 5–2. Failure Record Data

Data Description

Freeze Frame Diagnostic Trouble Code Distance at First Failure Distance at Last Failure Failure Record Fail Ignition Cycle Counter Failure Record Pass Ignition Cycle Counter Failure Record Not Run Ignition Cycle Counter Gear Selected Gear Commanded Current Gear Previous Gear TCM Battery Voltage Trans Fluid Temperature (TFT) Trans Input Shaft Speed Trans Output Shaft Speed Turbine Speed Diagnostic Transmission Gear Ratio Accelerator Effective Position Main Mod Solenoid Commanded Pressure PCS2 Commanded Pressure PCS1 Commanded Pressure TCC Pressure Control Solenoid Command Pressure Transmission Fluid Pressure Switch Status Shift Solenoid Status TCM Substrate Temperature Drive Demanded Engine Torque Engine Torque Requested Torque Normal Shift Pattern Cold Shift Pattern Hot Mode (Transmission) Trailering/Hauling Shift Pattern Engine in Default Mode Shift Pattern Main Modulation Solenoid Fail Shift Pattern Main Modulation Available Engine Run Time Driver Select Tap Up/Down Input AC Enabled Cruise Enabled IMS A IMS B IMS C IMS P Number of Current Malfunctions Transmission Input State #1 Transmission Input State #2 TCM Non-Volatile Inhibit Record

1000 AND 2000 PRODUCT FAMILIES TROUBLESHOOTING MANUAL—ALLISON 4th GENERATION CONTROLS

DIAGNOSTIC TROUBLE CODES (DTC)

5–3. DTC READING AND DTC CLEARING

DTCs can be read and cleared by using Allison DOC™ For PC–Service Tool. The use of Allison DOC™ For PC–Service Tool is described in the instruction manual furnished with each tool.

A. Clearing DTCs

• DTCs will automatically clear after 40 code-free warm-up cycles.

• DTCs can be manually cleared by the Allison DOC™ For PC–Service Tool.

B. Clearing Active Indicators

• A DTC’s active indicator can be cleared, which removes the DTC’s shift inhibitions while the

DTC remains in the queue as inactive.

• The active indicator clearing method is to power down (all active indicators are cleared at TCM

power down).

If an active indicator is cleared while the transmission is locked in a forward range or

CAUTION:

reverse (fail-to-range), the transmission will remain in the forward range or reverse after the clearing procedure is completed. N (Neutral) must be manually selected.

5–4. BEGINNING THE TROUBLESHOOTING PROCESS

A. Starting Procedure

NOTE: Review Paragraph 3–5, “Basic Troubleshooting Information” and check ﬂuid level and ignition

voltage before any troubleshooting is performed.

1. Begin troubleshooting by reading Paragraph 3–5, checking the transmission ﬂuid level, and checking the

TCM input voltage. Check for DTCs by using Allison DOC™ For PC–Service Tool.

2. When a problem exists, but a DTC is not indicated, refer to Section 7—General Troubleshooting Performance Complaint for a listing of various electrical and hydraulic problems, their causes, and remedies.

3. If a DTC is found in the TCM memory, record all available DTC information and failure record data before clearing the DTC (refer to Paragraph 5–3).

4. Test drive the vehicle to conﬁrm a DTC or performance complaint.

• If the DTC reappears, refer to the DTC paragraph (Paragraph 5–5) and the appropriate DTC

table. The DTC section lists DTCs and their description. Locate the appropriate troubleshooting table and follow the instructions.

• If the DTC does not reappear, it may be an intermittent problem. Use the Allison DOC™ For

PC–Service Tool and the DTC display procedure described in Section 5. Refer to the troubleshooting table for possible causes of the problem.

• Appendix A deals with the identiﬁcation of potential circuit problems. Refer to Appendix A if

a circuit problem is suspected.

NOTE: Information concerning speciﬁc items is contained in the appendices located in the back of this

manual. The appendices are referred to throughout the manual.

1000 AND 2000 PRODUCT FAMILIES TROUBLESHOOTING MANUAL—ALLISON 4th GENERATION CONTROLS

DIAGNOSTIC TROUBLE CODES (DTC)

B. Solenoid Locations

Solenoid locations in the control module are as illustrated in Figure 5–1. Refer to Figure 5–1 as necessary when using the DTC schematics.

SS1

PCS1

PCS2

SS3

MAIN MOD

TCC

SS2

V07476.02.01

Figure 5–1. Solenoid Locations

C. Wire/Terminal Numbering Scheme

Allison Transmission recommended wire numbers (i.e. 112) consist of three digits, where the ﬁrst digit indicates the TCM 80-way connector number, and the last two digits indicate the pin-out information (i.e. 12).

D. Available Diagnostic Adapters

Figures 5–2 and 5–3 show the J 47275 TCM Breakout Harness Adapter and J 47278 Transmission Breakout Harness that are available for use with the J 39700 Breakout Box. Figure 5–4 shows the J 47276 “T” Breakout and TCM Reﬂashing Harness.

1000 AND 2000 PRODUCT FAMILIES TROUBLESHOOTING MANUAL—ALLISON 4th GENERATION CONTROLS

DIAGNOSTIC TROUBLE CODES (DTC)

J 39700 BREAKOUT BOX

J 47275-1

18765432

916151413121110

17 24232221201918

25 32313029282726

33 40393837363534

41 48474645444342

49 56555453525150

57 64636261605958

65 72717069686766

73 80797877767574

Detail of

TCM Overlay

for use with

J 47275

TCM Breakout

Harness Adapter

16-Pin Bypass

Connector

80-Way Connector

To TCM

TCM

Figure 5–2. J 39700 Breakout Box and J 47275 TCM Breakout Harness Adapter

To Vehicle

V09225.00.00

1000 AND 2000 PRODUCT FAMILIES TROUBLESHOOTING MANUAL—ALLISON 4th GENERATION CONTROLS

DIAGNOSTIC TROUBLE CODES (DTC)

J 39700 BREAKOUT BOX

J 47278-1

ENGINE SPEED

SENSOR

18765432

916151413121110

17 24232221201918

TURBINE SPEED

SENSOR

Detail of

Transmission Overlay

for use with

J 47278

Transmission

Breakout Harness

OUTPUT SPEED

SENSOR

To Engine

Speed Sensor

To Turbine

Speed Sensor

24-Way Connector

To Main Transmission

To Output

24-Way Connector

Speed Sensor

To Main Transmission

Figure 5–3. J 39700 Breakout Box and J 47278 Transmission Breakout Harness

To Existing

Harness

Connector

To Existing

Harness

Connetcor

To Existing

Harness

Connetcor

V09226.00.00

1000 AND 2000 PRODUCT FAMILIES TROUBLESHOOTING MANUAL—ALLISON 4th GENERATION CONTROLS

DIAGNOSTIC TROUBLE CODES (DTC)

J1939-13 9-Pin

Deutsch Connector

J1962 Connector

To GM LAN

(GM Pickup Truck

Application)

TCM

24-Way Connector

To Vehicle

80-Way Connector

To TCM

V09227.00.00

Figure 5–4. J 47276 “T” Breakout and TCM Reﬂashing Harness

1000 AND 2000 PRODUCT FAMILIES TROUBLESHOOTING MANUAL—ALLISON 4th GENERATION CONTROLS

DIAGNOSTIC TROUBLE CODES (DTC)

NOTES

1000 AND 2000 PRODUCT FAMILIES TROUBLESHOOTING MANUAL—ALLISON 4th GENERATION CONTROLS

DIAGNOSTIC TROUBLE CODES (DTC)

TRANSMISSION

COMPONENT WIRING

DIAGRAMS AND

DIAGNOSTICS

1000 AND 2000 PRODUCT FAMILIES TROUBLESHOOTING MANUAL—ALLISON 4th GENERATION CONTROLS

DIAGNOSTIC TROUBLE CODES (DTC)

5–5. DIAGNOSTIC TROUBLE CODES (DTCs)

Table 5–3. DTC LIST AND DESCRIPTION INDEX

MIL

DTC Description

P0122 Pedal Position Sensor Circuit—Low Voltage — On 5–19

P0123 Pedal Position Sensor Circuit—High Voltage — On 5–23

P0218 Transmission Fluid Overtemperature Off Off 5–27

P0561 System Voltage—Performance Off Off 5–30

P0562 System Voltage—Low Off Off 5–34

P0563 System Voltage—High Off Off 5–37

P0602 TCM Not Programmed Off Off 5–40

P0606 TCM Internal—Performance — Off 5–41

P0610 TCM Vehicle Options (TransID) Error Off On 5–42

P0613 TCM Processor — Off 5–45

P0614 Torque Control Data Mismatch—ECM/TCM — On 5–46

P0634 TCM Internal Temperature Too High On Off 5–49

P0658 Actuator Supply Voltage 1 (HSD1)—Low On On 5–51

P0659 Actuator Supply Voltage 1 (HSD1)—High (batt) On On 5–55

P0701 Transmission Control System—Performance Off Off 5–59

P0702 Transmission Control System Electrical (TransID) Off On

P0703 Brake Switch Circuit Off — 5–64

P0706 Transmission Range Sensor Circuit—Performance On On 5–67

P0708 Transmission Range Sensor Circuit—High Input On On 5–71

P0711 Transmission Fluid Temperature (TFT) Sensor Circuit—

Performance

P0712 Transmission Fluid Temperature (TFT) Sensor Circuit—

Low Input

P0713 Transmission Fluid Temperature (TFT) Sensor Circuit—

High Input

P0716 Turbine Speed Sensor Circuit—Performance On On 5–90

P0717 Turbine Speed Sensor Circuit—No Signal On On 5–94

P0719 Brake Switch Circuit — Off 5–98

P0721 Output Speed Sensor Circuit—Performance On On 5–100

P0722 Output Speed Sensor Circuit—No Signal On On 5–104

P0726 Engine Speed Sensor Circuit—Performance On Off 5–108

P0727 Engine Speed Sensor Circuit—No Signal On Off 5–112

P0729 Incorrect 6th Gear Ratio On On 5–115

P0731 Incorrect 1st Gear Ratio On On 5–118

P0732 Incorrect 2nd Gear Ratio On On 5–121

P0733 Incorrect 3rd Gear Ratio On On 5–124

P0734 Incorrect 4th Gear Ratio On On 5–127

P0735 Incorrect 5th Gear Ratio On On 5–130

P0736 Incorrect Reverse Ratio On On 5–133

P0741 Torque Converter Clutch (TCC) System—Stuck Off On On 5–136

P0742 Torque Converter Clutch (TCC) System—Stuck On On On 5–138

(ODB II Strategy)

On Off 5–76

On Off 5–81

On Off 5–86

CHECK TRANS Light

(Non-ODB II Strategy) Page

1000 AND 2000 PRODUCT FAMILIES TROUBLESHOOTING MANUAL—ALLISON 4th GENERATION CONTROLS

DIAGNOSTIC TROUBLE CODES (DTC)

Table 5–3. DTC LIST AND DESCRIPTION INDEX (cont’d)

MIL

DTC Description

P0751 Shift Solenoid 1 (SS1) Valve Performance—Stuck Off On On 5–140

P0752 Shift Solenoid 1 (SS1) Valve Performance—Stuck On On On 5–146

P0756 Shift Solenoid 2 (SS2) Valve Performance—Stuck Off On On 5–152

P0757 Shift Solenoid 2 (SS2) Valve Performance—Stuck On On On 5–158

P0761 Shift Solenoid 3 (SS3) Valve Performance—Stuck Off On On 5–163

P0762 Shift Solenoid 3 (SS3) Valve Performance—Stuck On On On 5–169

P0776 Pressure Control Solenoid 2 (PCS2) Stuck Off On On 5–175

P0777 Pressure Control Solenoid 2 (PCS2) Stuck On On On 5–179

P0826 Up and Down Shift Switch Circuit Off — 5–183

P0827 Up and Down Shift Switch Circuit—Low Off — 5–186

P0828 Up and Down Shift Switch Circuit—High Off — 5–189

P0842 Transmission Pressure Switch 1 (PS1) Circuit—Low On On 5–192

P0843 Transmission Pressure Switch 1 (PS1) Circuit—High On On 5–197

P0847 Transmission Pressure Switch 2 (PS2) Circuit—Low On On 5–202

P0848 Transmission Pressure Switch 2 (PS2) Circuit—High On On 5–207

P0872 Transmission Pressure Switch 3 (PS3) Circuit—Low On On 5–212

P0873 Transmission Pressure Switch 3 (PS3) Circuit—High On On 5–217

P0877 Transmission Fluid Pressure Switch 4 (PS4) Circuit—Low On On 5–222

P0878 Transmission Fluid Pressure Switch 4 (PS4) Circuit—High On On 5–228

P0880 TCM Power Input Signal Off Off 5–234

P0881 TCM Power Input Signal—Performance Off On 5–237

P0882 TCM Power Input Signal—Low Off On 5–241

P0883 TCM Power Input Signal—High Off On 5–244

P0960 Pressure Control Solenoid Main Mod (MAIN MOD)

Control Circuit—Open

P0962 Pressure Control Solenoid Main Mod (MAIN MOD)

Control Circuit—Low

P0963 Pressure Control Solenoid Main Mod (MAIN MOD)

Control Circuit—High

P0964 Pressure Control Solenoid 2 (PCS2) Control Circuit—Open On On 5–260

P0966 Pressure Control Solenoid 2 (PCS2) Control—Low On On 5–265

P0967 Pressure Control Solenoid 2 (PCS2) Control—High On On 5–270

P0972 Shift Solenoid 1 (SS1) Control Circuit—Open On On 5–275

P0973 Shift Solenoid 1 (SS1) Control Circuit—Low On On 5–280

P0974 Shift Solenoid 1 (SS1) Control Circuit—High On On 5–284

P0975 Shift Solenoid 2 (SS2) Control Circuit—Open On On 5–289

P0976 Shift Solenoid 2 (SS2) Control Circuit—Low On On 5–294

P0977 Shift Solenoid 2 (SS2) Control Circuit—High On On 5–299

P0978 Shift Solenoid 3 (SS3) Control Circuit—Open On On 5–304

P0979 Shift Solenoid 3 (SS3) Control Circuit—Low On On 5–309

P0980 Shift Solenoid 3 (SS3) Control Circuit—High On On 5–314

P1688 Unmanaged Engine Torque Delivered to TCM Signal On On 5–318

P1779 Engine Torque Delivered to TCM Signal On On 5–320

(ODB II Strategy)

On On 5–247

On On 5–252

On On 5–256

CHECK TRANS Light

(Non-ODB II Strategy) Page

1000 AND 2000 PRODUCT FAMILIES TROUBLESHOOTING MANUAL—ALLISON 4th GENERATION CONTROLS

DIAGNOSTIC TROUBLE CODES (DTC)

Table 5–3. DTC LIST AND DESCRIPTION INDEX (cont’d)

MIL

DTC Description

P1891 Throttle Position Sensor (TPS) PWM Signal—Low Input — Off 5–323

P1892 Throttle Position Sensor (TPS) PWM Signal—High Input — Off 5–327

P2637 Torque Management Feedback Signal—SEM — On 5–331

P2641 Torque Management Feedback Signal—LRTP — On 5–334

P2670 Actuator Supply Voltage 2 (HSD2)—Low On On 5–337

P2671 Actuator Supply Voltage 2 (HSD2)—High (batt) On On 5–341

P2723 Pressure Control Solenoid 1 (PCS1)—Stuck Off On On 5–346

P2724 Pressure Control Solenoid 1 (PCS1)—Stuck On On On 5–349

P2727 Pressure Control Solenoid 1 (PCS1) Control Circuit—Open On On 5–352

P2729 Pressure Control Solenoid 1 (PCS1) Control Circuit—Low On On 5–357

P2730 Pressure Control Solenoid 1 (PCS1) Control Circuit—High On On 5–362

P2761 TCC PCS Control Circuit—Open On On 5–366

P2763 TCC PCS Control Circuit—High On On 5–371

P2764 TCC PCS Control Circuit—Low On On 5–376

P2771 4-Wheel Drive Lo Switch Circuit Off — 5–381

U0010 CAN 1 Bus Reset Counter Overrun On Off 5–385

U0073 CAN 2 Bus Reset Counter Overrun On Off 5–389

U0100 Lost Communication with ECM/PCM (CAN 2) Off Off 5–393

U0115 Lost Communication with ECM/PCM (CAN 1) Off On 5–398

U0400 Invalid J1939 Communications Off Off 5–403

U0442 Invalid Data Received from ECM/PCM B (CAN 1/J1939) Off Off 5–405

U1016 Class 2 Powertrain Controller State of Health Failure Off Off 5–407

U1041 Class 2 Anti-lock Brake Controller (ABS) State of Health Off Off 5–410

U1064 Class 2 Truck Body Controller (TBC) State of Health Off Off 5–413

U1096 Class 2 Instrument Panel Controller (IPC) State of Health Off Off 5–416

U1300 Serial Data Communication Link Low (Class 2) Off Off 5–419

U1301 Serial Data Communication Link High (Class 2) Off Off 5–422

(ODB II Strategy)

CHECK TRANS Light

(Non-ODB II Strategy) Page

1000 AND 2000 PRODUCT FAMILIES TROUBLESHOOTING MANUAL—ALLISON 4th GENERATION CONTROLS

DIAGNOSTIC TROUBLE CODES (DTC)

DTC REFERENCE TABLES

Table 5–4. Gear Ratio

Range Close Ratio Wide Ratio

1 3.10:1 3.51:1

2 1.81:1 1.90:1

3 1.41:1 1.44:1

4 1.00:1 1.00:1

5 0.71:1 0.74:1

6 0.61:1 0.64:1

R –4.49:1 –5.09:1

Table 5–5. Main Pressure Schedule

Range Main Pressure @ 600 rpm Main Pressure @ 2100 rpm

Forward/Reverse Converter with Main Mod Active (viewable in Allison DOC™)

Forward Converter with Main Mod Inactive 700–1380 kPa (101–200 psi) 1515–1795 kPa (220–260 psi)

Forward Lockup with Main Mod Active* 510–627 kPa (74–91 psi)

Forward Lockup with Main Mod Inactive* 1000–1170 kPa (145–170 psi)

Neutral/Park with Main Mod Active 590–720 kPa (85–105 psi)

Neutral/Park with Main Mod Inactive 800–1655 kPa (130–240 psi) 1515–1795 kPa (220–260 psi)

* Medium duty gasoline engines only.

590–720 kPa (85–105 psi) 634–758 kPa (92–110 psi)

Table 5–6. Allison DOC™ For PC–Service Tool Internal Mode Switch (IMS) Status

Selector Position A B C P Neutral Start

P OFF ON ON OFF ON

R OFF OFF ON ON OFF

N ON OFF ON OFF ON

D 5 5 5 ON OFF OFF ON OFF

*M 3 4 4 OFF OFF OFF OFF OFF

1223OFFONOFFONOFF

Blocked 1 1 1 ON ON OFF OFF OFF

When using a DVOM to check the IMS switch status of A, B, C, and P switches, note that the physical switch states are the opposite of Allison DOC™ For PC–Service Tool status shown above.

When using a DVOM to check the switch state of Neutral Start (NS), the switch state will be the same as the Allison DOC™ For PC– Service Tool status shown above.

The IMS Switch has four positions available in forward. Therefore, one range position will be omitted at the selector. The omitted position can be 2

*M mode allows tap-up tap-down feature functionally between 1

, 3rd, or 4th, depending upon chosen calibration.

through 6th ranges.

1000 AND 2000 PRODUCT FAMILIES TROUBLESHOOTING MANUAL—ALLISON 4th GENERATION CONTROLS

DIAGNOSTIC TROUBLE CODES (DTC)

Table 5–7. Solenoid and Clutch Apply

Clutch

Steady State Upshifts

Steady State

with Throttle

R — OFF; C5

Steady State at

Closed Throttle

R–N — ON; C3

N–R — OFF; C3

N–1 — OFF; C5

1–N — OFF; C5

1–2 C1 ON; C5

2–1 C1 OFF; C5

2–3 C1 OFF; C3

3–2 C1 ON; C3

3–4 C1 ON; C3

4–3 C1 OFF; C3

4–5 C2 OFF; C3

5–4 C2 ON; C3

5–6 C2 ON; C3

Main PCS1 PCS2 SS1 SS2 SS3 TCC Main Mod

— OFF; C3

Applied

Exhausting

Trimming on OFF; C5

Applied

C1 OFF; C5

Applied

Exhausting

Trimming on

C1 ON; C3

Exhausted

Trimming on

Exhausting

C1 OFF; C3

Applied

Exhausting

Trimming on

C2 ON; C3

Exhausted

Trimming on

Exhausting

C2 OFF;

C3 Applied

Exhausting

ON; C5 Applied

ON; C3 Applied

ON; C5 Applied

OFF; — Exhausted

ON; C1 Trimming on

OFF; — Exhausted

OFF; C4 Exhausted

ON; C4 Trimming on

OFF; C4 Exhausting

ON; C4 Applied

OFF; C4 Exhausting

ON; C4 Trimming on

OFF; C2 Exhausted

ON; C2 Trimming on

OFF; C2 Exhausting

ON; C1 Applied

OFF; C1 Exhausting

OFF; C1 Trimming on

OFF; C4 Exhausted

ON; Trimming on

ON ON ON OFF

OFF ON ON OFF ON

OFF ON ON OFF —

ON ON ON OFF —

ON ON ON OFF ON at closed throttle

ON ON ON OFF —

OFF ON OFF OFF ON at closed throttle

OFF ON OFF OFF —

OFF OFF OFF

ON;

dependent on

output speed

OFF OFF OFF ON —

ON OFF OFF ON Vocation

ON OFF OFF ON —

ON OFF ON ON

OFF OFF ON ON

OFF/ON

Solenoid Status is

Calibration Dependent on

Engine, Turbine, Output,

and other factors

Vocation

Dependent

Vocation

Dependent

—

Vocation

Dependent

—

1000 AND 2000 PRODUCT FAMILIES TROUBLESHOOTING MANUAL—ALLISON 4th GENERATION CONTROLS

DIAGNOSTIC TROUBLE CODES (DTC)

Table 5–7. Solenoid and Clutch Apply (cont’d)

Clutch

Steady State Upshifts

6–5 C2 OFF;

* The following throttle dependent conditions occur in reverse range:

At closed throttle (Idle) SS1 is OFF, PCS1 controls C5 clutch, PCS2 controls C3 clutch.

Above 20 percent throttle* SS1 is ON, PCS1 controls C3, PCS2 controls C5.

Under 10 percent throttle* TCM reverts back to the close throttle (Idle) schedule.

(N/O) (N/O) (N/O) (N/C)

PS1 PS2 PS3 PS4

Main PCS1 PCS2 SS1 SS2 SS3 TCC Main Mod

Trimming on

C2 ON;

C4 Applied

OFF; Trimming off

ON; C4 Applied

OFF OFF ON ON

—

Vocation

Dependent

Table 5–8. Pressure Switch Status

Switch

Range

* PS1 reverts to the CLOSED/ON state with throttle applied in reverse.

Status

R Open Exhausted/OFF* Closed Pressurized/ON Closed Pressurized/ON Closed Exhausted/ON

N Closed Pressurized/ON Closed Pressurized/ON Closed Pressurized/ON Open Pressurized/OFF

1 Open Exhausted/OFF Closed Pressurized/ON Open Exhausted/OFF Open Pressurized/OFF

2 Open Exhausted/OFF Open Exhausted/OFF Open Exhausted/OFF Open Pressurized/OFF

3 Closed Pressurized/ON Open Exhausted/OFF Open Exhausted/OFF Open Pressurized/OFF

4 Closed Pressurized/ON Open Exhausted/OFF Closed Pressurized/ON Open Pressurized/OFF

5 Open Exhausted/OFF Open Exhausted/OFF Closed Pressurized/ON Open Pressurized/OFF

6 Open Exhausted/OFF Open Exhausted/OFF Closed Pressurized/ON Open Pressurized/OFF

N/O = Normally Open, N/C = Normally Closed

Allison DOC™

Status

Switch

Status

Allison DOC™

Status

Switch

Status

Allison DOC™

Status

Switch

Status

Allison DOC™

Status

1000 AND 2000 PRODUCT FAMILIES TROUBLESHOOTING MANUAL—ALLISON 4th GENERATION CONTROLS

DIAGNOSTIC TROUBLE CODES (DTC)

Table 5–9. Calculated Solenoid Resistance vs. Temperature

Sump Temperature

°°°°C) (°°°°F) Minimum Nominal Maximum Minimum Nominal Maximum

(

–65 –85 3.23 3.36 3.50 13.98 14.65 15.32

–40 –40 3.71 3.86 4.01 16.05 16.81 17.58

–30 –22 3.90 4.06 4.22 16.87 17.68 18.48

–20 –4 4.09 4.26 4.42 17.70 18.54 19.38

–10 14 4.28 4.45 4.63 18.52 19.41 20.29

0 32 4.47 4.65 4.84 19.35 20.27 21.19

10 50 4.66 4.85 5.04 20.17 21.14 22.10

20 68 4.85 5.05 5.25 21.00 22.00 23.00

30 86 5.04 5.25 5.46 21.83 22.86 23.90

40 104 5.23 5.45 5.66 22.65 23.73 24.81

50 122 5.42 5.65 5.87 23.48 24.59 25.71

60 140 5.61 5.84 6.08 24.30 25.46 26.62

70 158 5.80 6.04 6.28 25.13 26.32 27.52

TCC, PCS1, PCS2 (

ΩΩ

) SS1, SS2, SS3, MAIN MOD (ΩΩΩΩ)

80 176 5.99 6.24 6.49 25.95 27.19 28.42

90 194 6.18 6.44 6.69 26.78 28.05 29.33

100 212 6.37 6.64 6.90 27.60 28.92 30.23

110 230 6.57 6.84 7.11 28.43 29.78 31.14

120 248 6.76 7.03 7.31 29.25 30.65 32.04

130 266 6.95 7.23 7.52 30.08 31.51 32.94

140 284 7.14 7.43 7.73 30.90 32.38 33.85

150 302 7.33 7.63 7.93 31.73 33.24 34.75

160 320 7.52 7.83 8.14 32.55 34.10 35.65

165 329 7.61 7.93 8.24 32.97 34.54 36.11

1000 AND 2000 PRODUCT FAMILIES TROUBLESHOOTING MANUAL—ALLISON 4th GENERATION CONTROLS

DIAGNOSTIC TROUBLE CODES (DTC)

Table 5–10. Speed Sensor vs. Temperature

Temperature Resistance

(°°°°C) (°°°°F)

–25 –13 1929 2143 2358

0 32 2157 2397 2637

25 77 2340 2600 2860

50 122 2614 2904 3195

75 167 2842 3158 3474

100 212 3071 3412 3753

125 257 3299 3666 4032

150 302 3483 3870 4257

Minimum (

ΩΩ

) Nominal (ΩΩΩΩ) Maximum (ΩΩΩΩ)

Table 5–11. Transmission Fluid Temperature (TFT) Sensor Resistance vs. Temperature

Temperature Resistance

(°°°°C) (°°°°F)

–45 –49 128 565 141 951 155 338

–40 –40 95 826 100 735 105 644

–35 –31 68 952 72 315 75 679

–30 –22 50 153 52 480 54 807

–25 –13 36 854 38 478 40 103

–20 –4 27 345 28 488 29 631

–15 5 20 476 21 286 22 097

–10 14 15 467 16 045 16 624

–5 23 11 781 12 197 12 612

0 32 9045 9345 9646

5 41 6998 7219 7441

10 50 5458 5623 5787

15 59 4291 4413 4536

20 68 3398 3490 3582

25 77 2710 2779 2849

30 86 2173 2228 2282

35 95 1754 1797 1840

40 104 1424 1459 1493

45 113 1163 1191 1218

50 122 955.0 977.1 999.2

55 131 788.6 806.5 824.5

Minimum (

ΩΩ

) Nominal (ΩΩΩΩ) Maximum (ΩΩΩΩ)

1000 AND 2000 PRODUCT FAMILIES TROUBLESHOOTING MANUAL—ALLISON 4th GENERATION CONTROLS

DIAGNOSTIC TROUBLE CODES (DTC)

Table 5–11. Transmission Fluid Temperature (TFT) Sensor Resistance vs. Temperature (cont’d)

Temperature Resistance

(

°°°°C) (°°°°F)

60 140 654.7 669.3 683.9

65 149 546.3 558.3 570.2

70 158 458.1 467.9 477.8

75 167 385.9 394.1 402.2

80 176 326.6 333.3 340.1

85 185 277.5 283.2 288.9

90 194 236.5 241.6 246.7

95 203 202.4 206.9 211.5

100 212 173.8 177.9 182.0

105 221 149.8 153.6 157.3

110 230 129.7 133.0 136.4

115 239 112.6 115.6 118.7

120 248 98.17 100.88 103.6

125 257 85.87 88.29 90.71

130 266 75.35 77.52 79.69

135 275 66.34 68.27 70.21

140 284 58.58 60.31 62.04

145 293 51.88 53.42 54.97

150 302 46.08 47.46 48.84

155 311 41.04 42.27 43.50

160 320 36.65 37.74 38.84

Minimum (

ΩΩ

) Nominal (ΩΩΩΩ) Maximum (ΩΩΩΩ)

Table 5–12. TPS—Distance (mm) of Travel vs. Volts

mm Volts mm Volts mm Volts mm Volts

0 0 12 1.317 24 2.634 36 3.951

1 0.110 13 1.427 25 2.744 37 4.061

2 0.220 14 1.537 26 2.854 38 4.171

3 0.329 15 1.646 27 2.964 39 4.281

4 0.439 16 1.756 28 3.073 40 4.390

5 0.549 17 1.866 29 3.183 41 4.500

6 0.659 18 1.976 30 3.293 42 4.610

7 0.768 19 2.085 31 3.403 43 4.720

8 0.878 20 2.195 32 3.512 44 4.829

9 0.988 21 2.305 33 3.622 45 4.939

10 1.098 22 2.415 34 3.732 46 5.049

11 1.207 23 2.524 35 3.842

1000 AND 2000 PRODUCT FAMILIES TROUBLESHOOTING MANUAL—ALLISON 4th GENERATION CONTROLS

DIAGNOSTIC TROUBLE CODES (DTC)

DTC P0122 Pedal Position Sensor Circuit—Low Voltage

END VIEW OF

80-WAY CONNECTOR

TPS

CONNECTOR

THROTTLE

POSITION

SENSOR

(TPS)

112

TCM

144

158

ANALOG INTERFACE

V08820.00.00

Circuit Description

The Transmission Control Module (TCM) receives input on throttle position from either a Throttle Position Sensor (TPS) or a signal transmitted by the engine electronic controls.

Vehicles not equipped with electronically-controlled engines have a TPS attached to the engine fuel control linkage. The TPS continuously sends the exact throttle position to the transmission TCM.

The TPS is a sliding resistor sensor (potentiometer) actuated by a mechanical linkage. The TCM delivers a constant voltage to one terminal of the TPS resistive strip. The other TPS terminal connects to ground. The resistor contacts of the TPS are connected to provide a regulated voltage signal input to the TCM.

When actuated by the mechanical throttle cable, the contacts of the resistor move along the resistive strip. As the contacts slide along the resistive strip, a voltage is sent to the TCM. At each increment of 0.178 mm (0.007 inch) along the resistive strip, the contacts deliver a different voltage to the TCM. The different voltages are interpreted as throttle sensor movement. The TCM converts travel distance (mm) into throttle opening percentage.

Conditions for Running the DTC

• The components are powered and ignition voltage is greater than 9V and less than 18V (12V TCM) or greater than 18V and less than 32V (24V TCM).

• DTC P0123 Pedal Position Sensor Circuit—High Voltage is not active.

1000 AND 2000 PRODUCT FAMILIES TROUBLESHOOTING MANUAL—ALLISON 4th GENERATION CONTROLS

DIAGNOSTIC TROUBLE CODES (DTC)

Conditions for Setting the DTC

DTC P0122 sets when the TCM detects a throttle position sensor voltage less than 0.55V for 5 seconds.

Action Taken When the DTC Sets

• DTC P0122 is stored in the TCM history.

• The TCM uses the default throttle value, based on engine torque and speed.

• The TCM freezes shift adapts (DNA).

• The TCM inhibits TCC engagement.

• The CHECK TRANS light illuminates (Non-OBD II Strategy).

Conditions for Clearing the DTC/CHECK TRANS Light

Allison DOC™ For PC–Service Tool can be used to clear the DTC from the TCM history. The TCM automatically clears the DTC from the TCM history if the vehicle completes 40 warm-up cycles without the DTC recurring.

Diagnostic Aids

• Inspect the wiring for poor electrical connections at the TCM. Look for the following conditions:

— A bent terminal

— A backed-out terminal

— A damaged terminal

— Poor terminal tension

— A chafed wire

— A broken wire inside the insulation.

• When diagnosing for an intermittent short or open circuit condition, massage the wiring harness while watching the test equipment for a change.

• You may have to drive the vehicle in order to experience a fault.

Test Description

The numbers below refer to the step numbers on the diagnostic table.

2. This step tests for the proper ignition voltage.

3. This step tests for the proper reference voltage from TCM.

4. This step tests shorting condition or opens in TPS harness.

5. This step tests for proper TPS adjustment.

6. This step tests for internal TPS intermittent shorts or open conditions.

1000 AND 2000 PRODUCT FAMILIES TROUBLESHOOTING MANUAL—ALLISON 4th GENERATION CONTROLS

DIAGNOSTIC TROUBLE CODES (DTC)

DTC P0122 Pedal Position Sensor Circuit—Low Voltage

Step Action Value(s) Yes No

1 Was the Beginning the Troubleshooting Process

(refer to Section 5–4) performed?

2 1. Install Allison DOC™.

2. Start the engine.

3. Record the DTC Failure Record data.

4. Using Allison DOC™, measure ignition voltage. Is voltage within the speciﬁed value?

3 1. Turn the ignition OFF.

2. Disconnect the 80-way connector from the TCM and install J 39700 Breakout Box and J 47275 TCM Breakout at the TCM. (To perform the following test the 16 pin bypass connector located on J 47275 TCM Breakout must be disconnected.)

3. With the engine OFF turn the ignition to the RUN position.

4. Using a digital volt/ohmmeter (DVOM), measure the voltage at pins 12 and 58.

Is the voltage within the speciﬁed value?

4 1. With the J 39700 Breakout Box and J 47275

TCM Breakout installed as in Step 3, reconnect the 16 pin breakout connector.

2. With the engine OFF turn the ignition to the RUN position.

3. Using a DVOM, measure the voltage at pins 12 and 58.

Is the voltage reading within speciﬁed value?

5 1. With the J 39700 Breakout box and J 47275 TCM

Breakout installed as in Step 4, refer to Appendix F, Section B.

2. Using a DVOM, measure the voltage at pins 44 and 58.

3. Perform a voltage reading at Idle and full throttle.

Is the voltage reading at Idle and Full Throttle within the speciﬁed value?

6 1. With the engine OFF and the ignition in the ON

position, measure the voltage at pins 44 and 58.

2. Slowly increase the throttle from Idle to Full throttle.

3. The increase in voltage should be steady, without dropouts, as throttle is increased.

Was the voltage steady?

9–18V (12V TCM)

18–32V (24V TCM)

4.75–5.0V Go to Step 4 Go to Step 10

4.75–5.0V Go to Step 5 Go to Step 7

Idle > 0.98V

Full Throttle

< 3.921V

Go to Step 2 Go to

Beginning the

Troubleshooting

Process

(Section 5–4)

Go to Step 3 Resolve

voltage problem

(Refer to DTC P0562 and P0563)

Go to Step 6 Go to Step 8

Go to

Diagnostic Aids

Go to Step 9

1000 AND 2000 PRODUCT FAMILIES TROUBLESHOOTING MANUAL—ALLISON 4th GENERATION CONTROLS

DIAGNOSTIC TROUBLE CODES (DTC)

DTC P0122 Pedal Position Sensor Circuit—Low Voltage (cont’d)

Step Action Value(s) Yes No

7 With the J 39700 Breakout Box and J 47275 TCM

Breakout unplugged at the TCM and the TPS connector unplugged at the TPS, use a jumper wire between pins A, B, and C. Using a DVOM at J 39700 Breakout Box check the TPS harness continuity at pin locations 112, 144, and 158.

Were there any opens or short between the three wires?

8 Repair the wiring harness (refer to OEM wiring

harness repair procedure).

Is the repair complete?

9 Replace the (TPS) throttle position sensor.

Is the repair complete?

10 NOTE: In most cases, the TCM is not at fault.

Investigate thoroughly before replacing the TCM. Refer to TCM diagnostic procedure (Section 3–6).

Is Section 3–6 complete?

11 In order to verify your repair:

1. Clear the DTC.

2. Operate the vehicle under normal driving conditions.

Did the DTC return?

Go to Step 8 Go to Step 9

Go to Step 11

Begin the

diagnosis again.

Go to Step 1

System OK

1000 AND 2000 PRODUCT FAMILIES TROUBLESHOOTING MANUAL—ALLISON 4th GENERATION CONTROLS

DIAGNOSTIC TROUBLE CODES (DTC)

DTC P0123 Pedal Position Sensor Circuit—High Voltage

END VIEW OF

80-WAY CONNECTOR

TPS

CONNECTOR

THROTTLE

POSITION

SENSOR

(TPS)

112

TCM

144

158

ANALOG INTERFACE

V08820.00.00

Circuit Description

The Transmission Control Module (TCM) receives input on throttle position from either a Throttle Position Sensor (TPS) or a signal transmitted by the engine electronic controls.

Vehicles not equipped with electronically-controlled engines have a TPS attached to the engine fuel control linkage. The TPS continuously sends the exact throttle position to the transmission TCM.

1000 AND 2000 PRODUCT FAMILIES TROUBLESHOOTING MANUAL—ALLISON 4th GENERATION CONTROLS

DIAGNOSTIC TROUBLE CODES (DTC)

Conditions for Running the DTC

• The components are powered and ignition voltage is greater than 9V and less than 18V (12V TCM) or greater than 18V and less than 32V (24V TCM).

• DTC P0122 Pedal Position Sensor Circuit—Low Voltage is not active.

Conditions for Setting the DTC

DTC P0123 sets when the TCM detects a throttle position sensor voltage greater than 4.75 for 5 seconds.

Action Taken When the DTC Sets

• DTC P0123 is stored in the TCM history.

• The TCM uses the default throttle value, based on engine torque and speed.

• The TCM freezes shift adapts (DNA).

• The TCM inhibits TCC engagement.

• The CHECK TRANS light illuminates (Non-OBD II Strategy).

Conditions for Clearing the DTC/CHECK TRANS Light

Allison DOC™ For PC–Service Tool may be used to clear the DTC from the TCM history. The TCM automatically clears the DTC from the TCM history if the vehicle completes 40 warm-up cycles without the DTC recurring.

Diagnostic Aids

• Inspect the wiring for poor electrical connections at the TCM. Look for the following conditions:

— A bent terminal

— A backed-out terminal

— A damaged terminal

— Poor terminal tension

— A chafed wire

— A broken wire inside the insulation.

• When diagnosing for an intermittent short or open circuit condition, massage the wiring harness while watching the test equipment for a change.

• You may have to drive the vehicle in order to experience a fault.

Test Description

The numbers below refer to the step numbers on the diagnostic table.

2. This step tests for the proper ignition voltage.

3. This step tests for the proper reference voltage from TCM.

4. This step tests shorting condition or opens in TPS harness.

5. This step tests for proper TPS adjustment.

6. This step tests for internal TPS intermittent shorts or open conditions.

1000 AND 2000 PRODUCT FAMILIES TROUBLESHOOTING MANUAL—ALLISON 4th GENERATION CONTROLS

DIAGNOSTIC TROUBLE CODES (DTC)

DTC P0123 Pedal Position Sensor Circuit—High Voltage

Step Action Value(s) Yes No

1 Was the Beginning the Troubleshooting Process

(refer to Section 5–4) performed?

2 1. Install Allison DOC™.

2. Start the engine.

3. Record the DTC Failure Record data.

4. Using Allison DOC™, measure ignition voltage. Is voltage within the speciﬁed value?

3 1. Turn the ignition OFF.

3. With the engine OFF turn the ignition to the RUN position.

4. Using a digital volt/ohmmeter (DVOM), measure the voltage at pins 12 and 58.

Is the voltage within the speciﬁed value?

4 1. With the J 39700 Breakout Box and J 47275

TCM Breakout installed as in Step 3, reconnect the 16 pin breakout connector.

2. With the engine OFF turn the ignition to the RUN position.

3. Using a DVOM, measure the voltage at pins 12 and 58.

4. Is the voltage reading within speciﬁed value?

5 1. With the J 39700 Breakout box and J 47275 TCM

Breakout installed as in Step 4, refer to Appendix F, Section B.

2. Using a DVOM, measure the voltage at pins 44 and 58.

3. Perform a voltage reading at Idle and full throttle.

Is the voltage reading at Idle and Full Throttle within the speciﬁed value?

6 1. With the engine OFF and the ignition in the ON

position, measure the voltage at pins 44 and 58.

2. Slowly increase the throttle from Idle to Full throttle. The increase in voltage should be steady, without dropouts, as throttle is increased.

Was the voltage steady?

9–18V (12V TCM)

18–32V (24V TCM)

4.75–5.0V Go to Step 4 Go to Step 10

Idle > 0.98V

Full Throttle

< 3.921V

Go to Step 2 Go to

Beginning the

Troubleshooting

Process

(Section 5–4)

Go to Step 3 Resolve

voltage problem

(Refer to DTC P0562 and P0563)

Go to Step 5 Go to Step 7

Go to Step 6 Go to Step 8

Go to

Diagnostic Aids

Go to Step 9

1000 AND 2000 PRODUCT FAMILIES TROUBLESHOOTING MANUAL—ALLISON 4th GENERATION CONTROLS

DIAGNOSTIC TROUBLE CODES (DTC)

DTC P0123 Pedal Position Sensor Circuit—High Voltage (cont’d)

Step Action Value(s) Yes No

7 1. With the J 39700 Breakout Box and J 47275

TCM Breakout unplugged at the TCM and the TPS connector unplugged at the TPS, use a jumper wire between pins A, B, and C.

2. Using a DVOM at J 39700 Breakout Box check the TPS harness continuity at pin locations 112, 144, and 158.

Were there any opens or short between the three wires?

8 Repair the wiring harness (refer to OEM wiring

harness repair procedure).

Is the repair complete?

9 Replace the (TPS) throttle position sensor.

Is the replacement complete?

10 NOTE: In most cases, the TCM is not at fault.

Investigate thoroughly before replacing the TCM. Refer to TCM diagnostic procedure (Section 3–6).

Is Section 3–6 complete?

11 In order to verify your repair:

1. Clear the DTC.

2. Operate the vehicle under normal driving conditions.

Did the DTC return?

Go to Step 8 Go to Step 9

Go to Step 11

Begin the

diagnosis again.

Go to Step 1

System OK

1000 AND 2000 PRODUCT FAMILIES TROUBLESHOOTING MANUAL—ALLISON 4th GENERATION CONTROLS

DIAGNOSTIC TROUBLE CODES (DTC)

DTC P0218 Transmission Fluid Over Temperature

REFER TO HYDRAULIC SCHEMATICS (APPENDIX H)

Circuit Description

The ﬂow of transmission ﬂuid starts in the transmission pan. Fluid is then drawn through the ﬁlter and internal passages into the oil pump assembly. The oil pump pressurizes the ﬂuid into main-pressure that is regulated at the main-pressure regulator valve. From this point, ﬂuid is directed to the TCC solenoid and to the control-main regulator and control-main relief valve into the control-main ﬁlter assembly and on to all solenoids for use as control pressure. Hot ﬂuid leaving the torque converter is routed through the converter ﬂow valve to cooler lines and into the cooler assembly. The transmission oil cooler is located in the radiator. The vehicle may be equipped with an auxiliary oil cooler. The cooled ﬂuid is returned to the transmission through the return cooler line and to the transmission lube circuit. The automatic transmission ﬂuid temperature (TFT) sensor, which is part of the PSM, is located in the oil pan.

If the Transmission Control Module (TCM) detects a high TFT for an extended period of time, then DTC P0218 sets.

Conditions for Running the DTC

• DTCs P0711, P0712, P0713 are not active.

• The components are powered and ignition voltage is greater than 9V and less than 18V (12V TCM) or greater than 18V and less than 32V (24V TCM).

• Engine speed is greater than 200 rpm for more than 5 seconds.

Conditions for Setting the DTC

DTC P0218 sets when the TCM detects a transmission sump temperature greater than 122°C (251°F) for 10 seconds.

Action Taken When the DTC Sets

• The TCM does not illuminate the CHECK TRANS light (Non-OBD II Strategy).

• The TCM does not illuminate the MIL (OBD II Strategy).

• The TCM freezes shift adapts (DNA).

• The TCM records the operating conditions when the conditions for setting the DTC are met. The TCM stores this information as Failure Records.

• DTC P0218 is stored in the TCM history.

• The TCM defaults to “hot mode” shift schedule where 4 speed and improve cooler ﬂow.

range is held and TCC is inhibited to increase engine

Conditions for Clearing the DTC/CHECK TRANS Light

• Allison DOC™ For PC–Service Tool may be used to clear the DTC from the TCM history.

• The TCM automatically clears the DTC from the TCM history if the vehicle completes 40 warm-up cycles without the DTC recurring.

• The TCM cancels the DTC default actions when the fault no longer exists and the DTC passes test.

1000 AND 2000 PRODUCT FAMILIES TROUBLESHOOTING MANUAL—ALLISON 4th GENERATION CONTROLS

DIAGNOSTIC TROUBLE CODES (DTC)

Diagnostic Aids

• Verify the customer’s driving habits, such as trailer towing, etc.

• Using Allison DOC™ For PC–Service Tool, monitor transmission ﬂuid temperature (TFT). TFT should rise

steadily during warm-up cycles and then stabilize.

• DTC P0218 may set after DTC P0711 (not active) has set. Follow the diagnostic table for DTC P0711 before proceeding to the diagnostic for DTC P0218. Repairing the condition that set DTC P0711 will likely eliminate DTC P0218.

• DTC P0218 sets ﬁrst, before DTCs P0711 and P0712.

• If DTC P0711 is set, temperature is defaulted and diagnostics are shut off, P0218 cannot be set.

Test Description

The numbers below refer to the step numbers on the diagnostic table.

3. This step inspects for air restriction and loss of transmission ﬂuid ﬂow, causing an extremely high TFT.

4. This step tests main-pressure.

5. This step inspects for a stuck torque converter stator.

DTC P0218 Transmission Fluid Over Temperature

Step Action Value(s) Yes No

1 Was the Beginning the Troubleshooting Process

(refer to Section 5–4) performed?

2 1. Install Allison DOC™.

2. Turn ON the ignition, with the engine OFF.

3. Record the DTC Failure Record data.

4. Clear the DTC.

5. Perform the Allison Transmission Fluid Checking Procedure (Appendix R).

Was the Allison Transmission fluid level check performed?

3 1. Inspect the engine cooling system for the

following conditions:

• Air ﬂow restrictions

• Air ﬂow blockage

• System ﬂuid level and condition

• Debris

2. Inspect the transmission cooling system for the following conditions:

• Air ﬂow restrictions

• Air ﬂow blockage

• System ﬂuid level and condition

• Debris

• Damaged cooler lines or hoses

Did you ﬁnd and correct the condition?

Go to Step 2 Go to

Beginning The

Troubleshooting

Process

(Section 5–4)

Go to Step 3 Go to Allison

Transmission Fluid

Checking

Procedure

(Appendix R)

Go to Step 6 Go to Step 4

1000 AND 2000 PRODUCT FAMILIES TROUBLESHOOTING MANUAL—ALLISON 4th GENERATION CONTROLS

DIAGNOSTIC TROUBLE CODES (DTC)

DTC P0218 Transmission Fluid Over Temperature (cont’d)

4 Perform the Main Pressure Check Procedure (refer

to Appendix B). Did you ﬁnd and correct a pressure problem?

5 Check for a possible torque converter stator

malfunction.

A stuck stator would be indicated by no cool-down in neutral after stalling the transmission (refer to Section 7).

Did you ﬁnd and correct the condition?

6 Perform the following procedure in order to verify

your repair:

1. Clear the DTC.

2. Using Allison DOC™, monitor the transmission

ﬂuid temperature (TFT).

3. Operate the vehicle under the following conditions.

• Turn ON the ignition, with the engine OFF.

• The TFT must be less than 126°C (258°F) for

at least 10 seconds.

4. Using Allison DOC™, verify that the test to detect this DTC has run.

Has the test run and passed?

Go to Step 6 Go to Step 5

Go to Step 6 Go to General

Troubleshooting

(Section 7)

Begin the

diagnosis again.

Go to Step 1

System OK

1000 AND 2000 PRODUCT FAMILIES TROUBLESHOOTING MANUAL—ALLISON 4th GENERATION CONTROLS

DIAGNOSTIC TROUBLE CODES (DTC)

DTC P0561 System Voltage—Performance

IGN

SWITCH

TCM

10a

15a

+–

12V/24V

BATTERY

163

170

110

169

109

END VIEW OF

80-WAY CONNECTOR

IGNITION

POWER

BATTERY

POWER

BATTERY

POWER

GND

TCM

V08905.00.00

Circuit Description

The Transmission Control Module (TCM) requires a switched ignition voltage input and a direct battery voltage input. This switched ignition voltage signal originates from the ignition switch or an ignition relay to supply voltage to pin 163 in the 80-way connector at the TCM. Battery direct voltage is supplied to pins 110 and 170 at the 80-way connector.

Conditions for Running the DTC

• The test becomes enabled when the engine has been running above 400 rpm for at least 0.5 seconds.

• The components are powered and ignition voltage is greater than 9V and less than 18V (12V TCM) or greater than 18V and less than 32V (24V TCM).

Conditions for Setting the DTC

P0561 sets when the TCM detects a large variation in ignition voltage or battery direct voltage. When an ignition or battery direct voltage variation of 4.0V or greater is detected for 0.5 seconds, a fault pending is reported. After

1.0 second of 4.0V or greater variation, a DTC is set with a failure response.

1000 AND 2000 PRODUCT FAMILIES TROUBLESHOOTING MANUAL—ALLISON 4th GENERATION CONTROLS

DIAGNOSTIC TROUBLE CODES (DTC)

Action Taken When the DTC Sets

When DTC P0561 is active, the following conditions will occur:

• DTC P0561 is stored in the TCM history.

• Hydraulic default is commanded. Shift selector position and hydraulic state of logic valves determine the range

attained.

• The TCM does not illuminate the CHECK TRANS light (Non-OBD II Strategy).

• The TCM does not illuminate the MIL (OBD II Strategy).

• The TCM inhibits TCC engagement.

• The TCM freezes shift adapts (DNA).

Conditions for Clearing the DTC/CHECK TRANS Light

Diagnostic Aids

• You may have to drive the vehicle in order to experience a fault.

• This DTC indicates a variation in ignition voltage or battery direct voltage. Common ignition circuit problems for

this DTC are a fault in the feed wires to the TCM, a defective ignition switch, or a large vehicle accessory load on the ignition circuit. Battery direct voltage problems may be due to loose or corroded battery cables, a bad connection at the battery direct feed terminal (110 and 170), or an internal TCM failure due to a burnt trace.

• A vehicle charging system failure may cause this DTC under certain circumstances.

• This DTC may indicate that an internal voltage problem has occurred inside the TCM. The use of a substitute

TCM would be a good way to diagnose this problem.

• A defective vehicle battery may induce this DTC.

• Inspect the wiring for poor electrical connections at the TCM. Look for the following conditions:

— A bent terminal

— A backed-out terminal

— A damaged terminal

— Poor terminal tension

— A chafed wire

— A broken wire inside the insulation.

• When diagnosing for an intermittent short or open circuit condition, massage the wiring harness while

watching the test equipment for a change.

Test Description

The numbers below refer to the step numbers on the diagnostic table.

2. This step tests for an active DTC after clearing.

3. This step tests for the proper battery direct input voltage.

4. This step tests for the proper ignition input voltage.

5. This step tests for shorts or open conditions at battery direct input circuit.

6. This step tests for shorts or open conditions at ignition input circuit.

1000 AND 2000 PRODUCT FAMILIES TROUBLESHOOTING MANUAL—ALLISON 4th GENERATION CONTROLS

DIAGNOSTIC TROUBLE CODES (DTC)

DTC P0561 System Voltage—Performance

Step Action Value(s) Yes No

1 Was the Beginning the Troubleshooting Process

(refer to Section 5–4) performed?

2 1. Install Allison DOC™.

2. Turn ON the ignition, with the engine OFF.

3. Record the DTC Failure Record data.

4. Clear the DTC.

5. Start vehicle and test drive.

6. Duplicate same operating conditions observed in failure records.

NOTE: This DTC indicates that a voltage variation exists in the ignition voltage or at the battery direct input. This variation is measured from min. and max. voltage values. If the voltage variation is present for a predetermined amount of time, this DTC sets.

Did DTC P0561 return?

3 1. Turn the ignition OFF.

2. Disconnect TCM 80-way connector at the TCM.

3. Install J 39700 Breakout Box and J 47275 TCM Breakout at the 80-way connector.

4. Using a digital volt/ohmmeter (DVOM), measure voltage at 80-way connector pins 9, 10, and 70.

Is the voltage within the speciﬁed value?

4 1. Using a digital multimeter (DVOM), sequentially

measure voltage at 80-way connector pin 63 using 80-way connector pins 9 or 69 as ground return.

2. Turn ON the ignition, with the engine OFF.

Is the voltage within the speciﬁed value?

5 NOTE: The vehicle OEM has responsibility for all

external wiring harness repair. Harness repairs performed by Allison Transmission distributors and dealers are not covered by Allison Transmission warranty.

Inspect battery direct circuits 110 and 170 for one of the following conditions:

• Intermittent open or short

• Loose or corroded connections at battery or

connection points

• Defective battery.

Was one of these conditions discovered and repaired?

11.5–12.5V (12V TCM)

18.5–24.0V (24V TCM)

11.5–12.5V (12V TCM)

18.5–24.0V (24V TCM

Go to Step 2 Go to

Beginning The

Troubleshooting

Process

(Section 5–4)

Go to Step 3 Go to Step 4

Go to Step 4 Go to Step 5

Go to

Diagnostic Aids

Go to Step 8 Go to Step 7

Go to Step 6

1000 AND 2000 PRODUCT FAMILIES TROUBLESHOOTING MANUAL—ALLISON 4th GENERATION CONTROLS

DIAGNOSTIC TROUBLE CODES (DTC)

DTC P0561 System Voltage—Performance (cont’d)

Step Action Value(s) Yes No

6 NOTE: The vehicle OEM has responsibility for all

external wiring harness repair. Harness repairs performed by Allison Transmission distributors and dealers are not covered by Allison Transmission warranty.

Inspect the TCM ignition input circuit for one of the following conditions:

• Intermittent open or short at ignition input circuits 109, 169, or 163.

• Loose or corroded connections at ignition switch or ignition relay assembly.

• Defective ignition switch or relay.

• Loading of ignition circuit by defective vehicle accessories.

Was one of these conditions discovered and repaired?

7 NOTE: In most cases, the TCM is not at fault.

Investigate thoroughly before replacing the TCM. Refer to TCM diagnostic procedure (Section 3–6).

Is Section 3–6 complete?

8 In order to verify your repair:

1. Clear the DTC.

2. Drive the vehicle under conditions shown in failure records.

Did the DTC return?

Go to Step 8 Go to Step 7

Go to Step 8

Begin the

diagnosis again.

Go to Step 1

System OK

1000 AND 2000 PRODUCT FAMILIES TROUBLESHOOTING MANUAL—ALLISON 4th GENERATION CONTROLS

DIAGNOSTIC TROUBLE CODES (DTC)

DTC P0562 System Voltage—Low

IGN

SWITCH

TCM

10a

15a

+–

12V/24V

BATTERY

163

170

110

169

109

END VIEW OF

80-WAY CONNECTOR

IGNITION

POWER

BATTERY

POWER

BATTERY

POWER

GND

TCM

V08905.00.00

Circuit Description

The Transmission Control Module (TCM) requires a switched ignition voltage input to operate. This switched ignition voltage signal originates from the ignition switch or an ignition relay to supply voltage to pin 163 in the 80-way connector at the TCM.

Conditions for Running the DTC

• The components are powered and ignition voltage is greater than 9V and less than 18V (12V TCM) or greater than 18V and less than 32V (24V TCM).

• The engine speed is greater than 450 rpm for 10 seconds.

Conditions for Setting the DTC

DTC P0562 sets when the TCM detects the following condition:

• 12V TCM—Ignition voltage is detected below 8V at 0°C (32°F) for a total of 5 out of 7 seconds. The voltage threshold is temperature dependent varying from 5V at –60°C (–75°F) to 9V at 20°C (68°F).

• 24V TCM—Ignition voltage is detected below 17V at 0°C (32°F) for a total of 5 out of 7 seconds. The voltage threshold is temperature dependent varying from 14V at –60°C (–75°F) to 18V at 20°C (68°F).

1000 AND 2000 PRODUCT FAMILIES TROUBLESHOOTING MANUAL—ALLISON 4th GENERATION CONTROLS

DIAGNOSTIC TROUBLE CODES (DTC)

Action Taken When the DTC Sets

• If the DTC is active while vehicle is in a forward range, transmission shifts to neutral, 1

• If the DTC is active while in reverse or neutral, transmission shifts to neutral.

• If the shift selector is moved to forward range, transmission shifts to neutral, 1

, 3rd, or 5th range.

• If the shift selector is moved to R (Reverse) or N (Neutral), transmission shifts to neutral. Diagnostic response

honors the inhibit latched at the time the DTC is set. If a latched inhibit is present and PRNDL is incorrect, transmission shifts to neutral range. GPI request is responded to if PRNDL is correct.

• The TCM does not illuminate the CHECK TRANS light (Non-OBD II Strategy).

• The TCM does not illuminate the MIL (OBD II Strategy).

• The TCM inhibits TCC engagement.

• The TCM freezes shift adapts (DNA).

Conditions for Clearing the DTC/CHECK TRANS Light

, 3rd, or 5th range.

Diagnostic Aids

• A defective vehicle battery may allow this DTC to set. Test the vehicle battery to verify proper voltage and load

capacity.

• A defective vehicle charging system may cause this DTC.

• Vehicle components such as an ignition switch or TCM ignition relay may cause this DTC to set and not be

active, this indicates that an intermittent condition may exist in these components.

• Inspect the wiring for poor electrical connections at the TCM. Look for the following conditions:

— A bent terminal

— A backed-out terminal

— A damaged terminal

— Poor terminal tension

— A chafed wire

— A broken wire inside the insulation.

• When diagnosing for an intermittent short or open, massage the wiring harness while watching the test

equipment for a change.

Test Description

The numbers below refer to the step numbers on the diagnostic table.

2. This step tests for the proper ignition input voltage.

3. This step tests for an active DTC after clearing.

4. This step tests vehicle battery per OEM guidelines.

5. This step tests vehicle charging system per OEM guidelines.

1000 AND 2000 PRODUCT FAMILIES TROUBLESHOOTING MANUAL—ALLISON 4th GENERATION CONTROLS

DIAGNOSTIC TROUBLE CODES (DTC)

DTC P0562 System Voltage—Low

Step Action Value(s) Yes No

1 Was the Beginning the Troubleshooting Process

(refer to Section 5–4) performed?

2 1. Install Allison DOC™.

2. Turn ON the ignition, with the engine OFF.

3. Record the DTC Failure Record data.

4. Clear the DTC.

5. Inspect the ignition voltage value on Allison DOC™.

NOTE: This DTC sets when ignition voltage drops below a predetermined level that is temperature dependent for 5 out of 7 seconds.

Is the ignition voltage below speciﬁed value?

3 1. Start the vehicle, if possible.

2. If the DTC is not active, drive the vehicle. Attempt to duplicate the same operating conditions observed in the failure records.

Did the DTC return?

4 Test the vehicle battery per OEM instructions,

including a voltage test and a load test.

Does test indicate the battery is good?

5 Test the vehicle charging system per the OEM

recommended testing procedure.

Is the charging system operating properly?

6 In order to verify your repair:

1. Clear the DTC.

2. Drive the vehicle under conditions shown in the failure records when the DTC set.

Did the DTC return?

Voltage should be

above

9V (12V TCM) or

18V (24V TCM) at

20°C (68°F).

See conditions for

setting the DTC.

See OEM for

correct battery

speciﬁcations

See OEM for

correct charging

system

speciﬁcations

Go to Step 2 Go to

Beginning The

Troubleshooting

Process

(Section 5–4)

Go to Step 4 Go to Step 3

Go to Step 4 Go to

Diagnostic Aids

Go to Step 5 Replace the vehicle

battery and go to

Step 6

Go to

Diagnostic Aids

Begin the

diagnosis again.

Go to Step 1

Repair the charging system and go to Step 6

System OK

1000 AND 2000 PRODUCT FAMILIES TROUBLESHOOTING MANUAL—ALLISON 4th GENERATION CONTROLS

DIAGNOSTIC TROUBLE CODES (DTC)

DTC P0563 System Voltage—High

IGN

SWITCH

TCM

10a

15a

+–

12V/24V

BATTERY

163

170

110

169

109

END VIEW OF

80-WAY CONNECTOR

IGNITION

POWER

BATTERY

POWER

BATTERY

POWER

GND

TCM

V08905.00.00

Circuit Description

Conditions for Running the DTC

• The engine speed is greater than 450 rpm for one second.

• The components are powered and ignition voltage is greater than 9V and less than 18V (12V TCM) or greater than 18V and less than 32V (24V TCM).

Conditions for Setting the DTC

DTC P0563 sets when the TCM detects the following condition:

• 12V TCM—Ignition voltage is above 18V for 6 out of 10 seconds.

• 24V TCM—Ignition voltage is above 32V for 6 out of 10 seconds.

1000 AND 2000 PRODUCT FAMILIES TROUBLESHOOTING MANUAL—ALLISON 4th GENERATION CONTROLS

DIAGNOSTIC TROUBLE CODES (DTC)

Action Taken When the DTC Sets

• If the DTC is active while the vehicle is in a forward range, the transmission shifts to neutral, 1

• If the DTC is active while in reverse or neutral, the transmission shifts to neutral.

• If the shift selector is moved to a forward range, the transmission shifts to neutral, 1

, 3rd, or 5th range. If the

shift selector is moved to R (Reverse) or N (Neutral), the transmission shifts to neutral. Diagnostic response honors the inhibit latched at the time the DTC is set. If a latched inhibit is present and PRNDL is incorrect, the transmission shifts to neutral range. GPI request is responded to if PRNDL is correct.

• The TCM does not illuminate the CHECK TRANS light (Non-OBD II Strategy).

• The TCM does not illuminate the MIL (OBD II Strategy).

• The TCM inhibits TCC engagement.

• The TCM freezes shift adapts (DNA).

Conditions for Clearing the DTC/CHECK TRANS Light

, 3rd, or 5th range.

Diagnostic Aids

• A defective vehicle charging system that is overcharging may cause this DTC.

• Inspect the wiring for poor electrical connections at the TCM. Look for the following conditions:

— A bent terminal

— A backed-out terminal

— A damaged terminal

— Poor terminal tension

— A chafed wire

— A broken wire inside the insulation.

• When diagnosing for an intermittent short or open, massage the wiring harness while watching the test equipment for a change.

• This DTC can set if an A40–A42 model TCM is installed in a 24V system, when an A43 TCM is required.

Test Description

The numbers below refer to the step numbers on the diagnostic table.

2. This step tests for the proper ignition input voltage.

3. This step tests for an active DTC after clearing.

4. This step tests vehicle charging system per OEM guidelines.

1000 AND 2000 PRODUCT FAMILIES TROUBLESHOOTING MANUAL—ALLISON 4th GENERATION CONTROLS

DIAGNOSTIC TROUBLE CODES (DTC)

DTC P0563 System Voltage—High

Step Action Value(s) Yes No

1 Was the Beginning the Troubleshooting Process

(refer to Section 5–4) performed?

2 1. Install Allison DOC™.

2. Turn ON the ignition, with the engine OFF.

3. Record the DTC Failure Record data.

4. Clear the DTC.

5. Start vehicle engine and inspect the ignition voltage value on Allison DOC™.

NOTE: This DTC sets when ignition voltage is detected above 18V for 12V systems or 32V for 24V systems for 6 out of 10 seconds.

Is the ignition voltage above speciﬁed value?

3 1. Start the vehicle, if possible.

2. If the DTC is not active, drive the vehicle. Attempt to duplicate the same operating conditions observed in failure records.

Did the DTC return?

4 Test the vehicle charging system per the OEM

recommended testing procedure.

Is the charging system operating properly?

5 In order to verify your repair:

1. Clear DTC.

2. Drive vehicle under conditions shown in failure records when DTC set.

Did the DTC return?

—

See Conditions for

Setting the DTC

—

Go to Step 2 Go to

Beginning The

Troubleshooting

Process

(Section 5–4))

Go to Step 4 Go to Step 3

Go to Step 4 Go to

Diagnostic Aids

Go to

Diagnostic Aids

Begin the

diagnosis again.

Go to Step 1

Repair the charging system and go to Step 5

System OK

1000 AND 2000 PRODUCT FAMILIES TROUBLESHOOTING MANUAL—ALLISON 4th GENERATION CONTROLS

DIAGNOSTIC TROUBLE CODES (DTC)

DTC P0602 TCM Not Programmed

NO SCHEMATIC FOR THIS DTC

Circuit Description

At the power up and after clearing DTCs, the Transmission Control Module (TCM) performs a self-test to determine if the calibration in memory is valid.

Conditions for Running the DTC

• The components are powered and ignition voltage is greater than 9V and less than 18V (12V TCM) or greater than 18V and less than 32V (24V TCM).

• This test will run before any TCM functions.

Conditions for Setting the DTC

DTC P0602 sets if the TCM determines the present calibration is invalid.

Action Taken When the DTC Sets

• DTC P0602 is stored in the TCM history.

• The TCM does not illuminate the CHECK TRANS light (Non-OBD II Strategy).

• The TCM does not illuminate the MIL (OBD II Strategy).

• The TCM returns to the boot program, and then waits to be recalibrated.

• The TCM inhibits TCC engagement.

Conditions for Clearing the DTC/CHECK TRANS Light

TCM must be recalibrated.

DTC P0602 TCM Not Programmed

Step Action Value(s) Yes No

1 Was the Beginning the Troubleshooting Process

(refer to Section 5–4) performed?

2 1. Install Allison DOC™.

2. If DTC P0602 is present, the TCM must be recalibrated.

Is recalibration complete?

3 NOTE: In most cases, the TCM is not at fault.

Investigate thoroughly before replacing the TCM. Refer to TCM diagnostic procedure (Section 3–6).

Is Section 3–6 complete?

4 1. Install Allison DOC™.

2. Start the vehicle.

Did the DTC return?

Go to Step 2 Go to

Beginning The

Troubleshooting

(Section 5–4)

Go to Step 4

Go to Step 3 System OK

Process

1000 AND 2000 PRODUCT FAMILIES TROUBLESHOOTING MANUAL—ALLISON 4th GENERATION CONTROLS

DIAGNOSTIC TROUBLE CODES (DTC)

DTC P0606 TCM Internal—Performance

NO SCHEMATIC FOR THIS DTC

Circuit Description

The Transmission Control Module (TCM) completes numerous scheduled tasks during normal operation. If one of the scheduled tasks fails to complete within a speciﬁc time limit the TCM will re-attempt this task.

NOTE: The presence of DTC P0606 indicates a TCM software error has occurred and the Allison

Transmission Service Department should be contacted at 1-800-252-5283.

Conditions for Running the DTC

• The components are powered and ignition voltage is greater than 9V and less than 18V for a 12V TCM, or greater than 18V and less than 32V for a 24V TCM.

• This test is run during the entire ignition cycle.

Conditions for Setting the DTC

DTC P0606 sets if a task fails to complete after two consecutive attempts.

Action Taken When the DTC Sets

• When DTC P0606 is active, the transmission will lock in N (Neutral).

• DTC P0606 is stored in the TCM history.

• The TCM does not illuminate the CHECK TRANS light (Non-OBD II Strategy).

• The TCM freezes shift adapts (DNA).

• The TCM inhibits TCC engagement.

Conditions for Clearing the DTC/CHECK TRANS Light

Allison DOC™ For PC–Service Tool can clear the DTC from the TCM history. The TCM automatically clears the DTC from the TCM history if the vehicle completes 40 warm-up cycles without failure.

1000 AND 2000 PRODUCT FAMILIES TROUBLESHOOTING MANUAL—ALLISON 4th GENERATION CONTROLS

DIAGNOSTIC TROUBLE CODES (DTC)

DTC P0610 TCM Vehicle Options (TransID) Error

20-WAY

TRANSMISSION

HARNESS

CONNECTOR

T L

20-WAY

TRANSMISSION

BULKHEAD

CONNECTOR

K D

A E

NOTE: Letters I, O, and Q are not used.

24-WAY

TRANSMISSION

HARNESS

CONNECTOR

24-WAY

TRANSMISSION

BULKHEAD

CONNECTOR

T L

1 6

12 13

14 20

20-WAY

CONNECTOR

1 6

1213

19 24

24-WAY CONNECTOR

END VIEW OF

80-WAY CONNECTOR

TRANSMISSION TCM

TRANSID

HSD1

MAIN MOD

PCS1

TCC

24 76

14 11

15 55

19 74

J78

176

111

155

174

178

(HSD1)

ANALOG

INTERFACE

V BATTERY

NOT USED with 20-Way Transmission Connector.

V09581.01.00

Circuit Description

The TransID feature enables the TCM to recognize various transmission hardware conﬁgurations and verify that the proper compatible calibration is used. The TCM senses the transmission conﬁguration by using TID wire 176. In the initial versions of Allison 4™ Generation Controls, wire 176 is connected to the High Side Driver 1 (HSD1) via wire 111. This wiring conﬁguration is designated TID A.

Conditions for Running the DTC

The test is enabled by the TCM calibration.

Conditions for Setting the DTC

DTC P0610 sets when the TCM determines the TCM software level is incompatible with transmission hardware.

Action Taken When the DTC Sets

• The CHECK TRANS light illuminates (Non-OBD II Strategy).

• DTC P0610 will be stored in the TCM history.

• The TCM defaults to TID A.

1000 AND 2000 PRODUCT FAMILIES TROUBLESHOOTING MANUAL—ALLISON 4th GENERATION CONTROLS

DIAGNOSTIC TROUBLE CODES (DTC)

Conditions for Clearing the MIL/DTC

Allison DOC™ For PC can clear the DTC from the TCM history. The TCM automatically clears the DTC from the TCM history if the vehicle completes 40 warm-up cycles without failure.

Diagnostic Aids

This DTC indicates that TCM software and the internal harness are not compatible. If this DTC occurs after a TCM recalibration, inspect for incorrect TCM software level.

DTC P0610 TCM Vehicle Options (TransID) Error

Step Action Value(s) Yes No

1 Was the Beginning the Troubleshooting Process

(refer to Section 5–4) performed?

1. Install Allison DOC™.

Turn ON the ignition.

3. Using Allison DOC™, determine the highest

available TransID level supported by the TCM calibration.

3. Consult the transmission bill of material or

the build history to determine the actual TransID level of the transmission.

3. Compare the highest available TransID level

in the calibration to the actual transmission hardware.

Is the highest available TransID level greater than or equal to the actual TransID of the transmission?

1. Reset Autoselect using Allison DOC™.

2. Monitor “TransID level used” on Allison DOC™.

3. Compare the TransID level indicated on Allison DOC™ to the actual TransID level of the transmission.

Did the TCM detect the correct TransID level?

4 Recalibrate the TCM with a TransID calibration that

matches the actual TransID level of the transmission.

Is the calibration complete?

5 NOTE: In most cases, the TCM is not at fault.

Investigate thoroughly before replacing the TCM. Refer to TCM diagnostic procedure (Section 3–6).

Is Section 3–6 complete?

6 In order to verify your repair:

1. Clear the DTC.

Using Allison DOC™, reset Autoselect.

3. Verify the TCM detects the correct TransID

level.

Did the DTC return?

Go to Step 2 Go to

Beginning The

Troubleshooting

Process

(Section 5–4)

Go to Step 3 Go to Step 4

Go to Step 6 Go to Step 5

Go to Step 6

Begin the diagnosis again. Go to Step 1

System OK

1000 AND 2000 PRODUCT FAMILIES TROUBLESHOOTING MANUAL—ALLISON 4th GENERATION CONTROLS

DIAGNOSTIC TROUBLE CODES (DTC)

DTC P0613 TCM Processor

NO SCHEMATIC FOR THIS DTC

Circuit Description

The Transmission Control Module (TCM) continually performs a series of processing steps known as a “processing loop” during normal operation. The TCM must complete the processing loop within a speciﬁc time limit. The TCM will reset if it does not complete two consecutive loops inside a predetermined time interval.

NOTE: The presence of DTC P0613 indicates a TCM processing error has occurred. Contact the Allison

Transmission Service Department at 1-800-252-5283.

Conditions for Running the DTC

• The components are powered and ignition voltage is greater than 9V and less than 18V (12V TCM) or greater than 18V and less than 32V (24V TCM).

• This test is run during the entire ignition cycle.

Conditions for Setting the DTC

DTC P0613 sets if the TCM does not complete two processing loops within the allotted time.

Actions taken when the DTC Sets

• When DTC P0613 is active, the TCM commands OFF all solenoids (SOL OFF).

• The TCM does not illuminate the CHECK TRANS light (Non-OBD II Strategy).

• DTC is stored in TCM history.

• The TCM freezes shift adapts (DNA).

• TCM inhibits TCC engagement.

Conditions for Clearing the DTC/CHECK TRANS Light

1000 AND 2000 PRODUCT FAMILIES TROUBLESHOOTING MANUAL—ALLISON 4th GENERATION CONTROLS

DIAGNOSTIC TROUBLE CODES (DTC)

DTC P0614 Torque Control Data Mismatch—ECM/TCM

NO SCHEMATIC FOR THIS DTC

Circuit Description

Shift Energy Management (SEM) allows the Transmission Control Module (TCM) to request torque reduction from the engine controller. By reducing torque, shifts can be made quicker, at a more consistent output torque which reduces clutch temperatures and increases clutch life. When an engine torque rating exceeds certain limits, Lower Range Torque Protection (LRTP) is used. This feature limits engine torque in lower ranges to protect the transmission from damage if a stall condition occurs.

Conditions for Running the DTC

• No DTC U0115 CAN bus error.

• Engine speed is greater than 200 rpm and less than 7500 rpm for 5 seconds.

• The components are powered and ignition voltage is greater than 9V and less than 18V (12V TCM) or greater

than 18V and less than 32V (24V TCM).

• This test runs for 30 seconds for the ﬁrst 20 engine starts after the engine is detected on the J1939 CAN. If

P0614 is active, the test runs for an unlimited number of engine starts.

• Engine must be identiﬁed by the TCM (via J1939 communications) as an approved make and model.

NOTE: Engines identified during the cal ordering process (PCCS/CSS) as “low torque” will operate without

setting a P0614.

Conditions for Setting the DTC

P0614 sets when the TCM detects one of the following conditions:

• The PCCS/CSS calibration process has determined that the particular engine rating and transmission

conﬁguration requires SEM/LRTP but the TCM detects the ECM software is not supporting all the messaging necessary for SEM and/or LRTP, or the engine is not on the SEM/LRTP validation list

• All engine ratings that have been identiﬁed during the PCCS/CSS calibration process as requiring SEM/LRTP

must have software that is compatible with SEM and LRTP or a P0614 is set.

NOTE: Valid engines with a torque rating exceeding 580 lb ft (786 N·m) must have software that is compatible

with LRTP or a P0614 is set.

Action Taken When the DTC Sets

• The CHECK TRANS light illuminates (Non-OBD II Strategy).

• If the TCM and engine ECM software are not compatible, the transmission will be restricted to reverse, neutral,

Conditions for Clearing the DTC/CHECK TRANS Light

and 3

range.

1000 AND 2000 PRODUCT FAMILIES TROUBLESHOOTING MANUAL—ALLISON 4th GENERATION CONTROLS

DIAGNOSTIC TROUBLE CODES (DTC)

Diagnostic Aids

• If DTC P0614 is set in combination with DTCs P2637 and/or P2641, engine control software is not correct. Verify that the proper software is installed then reset the SEM Autoselect parameters with Allison DOC™ For PC–Service Tool.

• This DTC may set if attempting to reﬂashing the TCM with the engine running; always reﬂash with the engine off, ignition on.

Test Description

The numbers below refer to the step numbers on the diagnostic table.

3. This step veriﬁes the engine is on the recognized list of SEM/LRTP engines.

4. This step veriﬁes the engine supports SEM.

5. This step veriﬁes the engine supports LRTP.

DTC P0614 Torque Control Data Mismatch—ECM/TCM

Step Action Value(s) Yes No

1 Was the Beginning the Troubleshooting Process

(refer to Section 5–4) performed?

2 If a DTC U0115 is present, troubleshoot and resolve

before going to the next step.

Is a DTC U0115 present?

3 1. Install Allison DOC™.

2. Turn ON the ignition.

3. Refer to Engine Hardware Status in SEM/LRTP AND AUTODETECT INFO display of Allison DOC™.

Is the engine recognized as a SEM/LRTP engine?

4 Refer to SEM Validated Status in SEM/LRTP AND

AUTODETECT INFO display of Allison DOC™.

Does the ECM support SEM?

5 Refer to LRTP Validated Status in SEM/LRTP AND

AUTODETECT INFO display of Allison DOC™.

Does the ECM support LRTP?

LRTP Recognized”

or “Not SEM/LRTP

supports SEM” or

supports LRTP” or

— Go to Step 2 Go to

— Go to DTC U0115

and resolve before

proceeding to

Step 7

Allison DOC™

indicates “SEM/

Recognized”

Allison DOC™

indicates “ECM

“ECM doesn’t support SEM”

Allison DOC™

indicates “ECM

“ECM doesn’t

support LRTP”

Go to Step 4 Go to Step 7

Go to Step 5 Go to Step 7

Go to Step 6 Go to Step 7

Beginning The

Troubleshooting

Process

(Section 5–4)

Go to Step 3

1000 AND 2000 PRODUCT FAMILIES TROUBLESHOOTING MANUAL—ALLISON 4th GENERATION CONTROLS

DIAGNOSTIC TROUBLE CODES (DTC)

DTC P0614 Torque Control Data Mismatch—ECM/TCM (cont’d)

Step Action Value(s) Yes No

6 This indicates that engine torque values are above

the transmission ratings set in the TCM calibration.

1. Inspect the TCM for proper calibration to support SEM and LRTP. If proper TCM calibration is installed, the engine rating is too high for the transmission.

2. Recalibrate the engine to a lower torque rating.

Was one of the above conditions found and resolved?

7 Turn the vehicle over to the engine manufacturer to

verify proper software and calibration are installed to support SEM and/or LRTP.

Has the proper software and calibration been installed?

8 In order to verify your repair:

1. Clear P2637 or P2641, if present.

2. Using Allison DOC™, reset Autoselect (refer to Section 3–8).

3. Clear P0614.

4. Drive the vehicle under normal operating conditions.

5. Refer to Allison DOC™ “Test Passed” section and conﬁrm the test was run.

Did the DTC return?

— Go to Step 8 —

— Go to Step 8

Begin the

diagnosis again.

Go to Step 1

System OK

1000 AND 2000 PRODUCT FAMILIES TROUBLESHOOTING MANUAL—ALLISON 4th GENERATION CONTROLS

DIAGNOSTIC TROUBLE CODES (DTC)

DTC P0634 TCM Internal Temperature Too High

NO SCHEMATIC FOR THIS DTC

Circuit Description

The Transmission Control Module (TCM) is equipped with an internal temperature sensor mounted directly to its circuit board. The TCM will take action to protect against damage from overheat.

Conditions for Running the DTC

• The components are powered and ignition voltage is greater than 9V and less than 18V (12V TCM) or greater than 18V and less than 32V (24V TCM).

• Engine speed is greater than 200 rpm and less than 7500 rpm for more than 10 seconds.

Conditions for Setting the DTC

DTC P0634 sets if the TCM internal temperature is greater than or equal to 140 engine running.

C (284ºF) for 10 seconds with

Actions taken when the DTC Sets

• The TCM does not illuminate the CHECK TRANS light (Non-OBD II Strategy).

• The MIL illuminates (OBD II Strategy).

• DTC is stored in TCM history.

• The TCM commands OFF all solenoids (SOLOFF).

• TCM inhibits TCC engagement.

Conditions for clearing the DTC/CHECK TRANS Light

Diagnostic Aids

Clean the TCM if necessary. Excessive road debris will reduce the effectiveness of the heat sink on the TCM and could cause internal temperature to rise.

1000 AND 2000 PRODUCT FAMILIES TROUBLESHOOTING MANUAL—ALLISON 4th GENERATION CONTROLS

DIAGNOSTIC TROUBLE CODES (DTC)

DTC P0634 TCM Internal Temperature Too High

Step Action Value(s) Yes No

1 Was the Beginning the Troubleshooting Process

(refer to Section 5–4) performed?

1. Install Allison DOC™.

2. Turn the ignition ON.

3. Record the DTC Failure Record data.

4. Clear the DTCs.

5. Drive the vehicle and monitor TCM internal temperature on Allison DOC™.

Did DTC P0634 return?

1. Inspect the TCM and surrounding area.

2. Make sure there are no high temperature components such as exhausted lines mounted in the vicinity of the TCM.

3. Shield or relocate the TCM, if possible.

Do you ﬁnd and correct the problem?

NOTE: In most cases, the TCM is not at fault.

Investigate thoroughly before replacing the TCM. Refer to TCM diagnostic procedure (Section 3–6).

Is Section 3–6 complete?

1. Install Allison DOC™.

2. Monitor TCM internal temperature.

3. Drive the vehicle under conditions noted in failure records.

Did the DTC return?

Go to Step 2 Go to

Beginning The

Troubleshooting

Process

(Section 5–4)

Go to Step 3 Go to

Diagnostic Aids

Go to Step 5 Go to Step 4

Go to Step 5

Begin the

diagnosis again.

Go to Step 1

System OK

1000 AND 2000 PRODUCT FAMILIES TROUBLESHOOTING MANUAL—ALLISON 4th GENERATION CONTROLS

DIAGNOSTIC TROUBLE CODES (DTC)

DTC P0658 Actuator Supply Voltage 1 (HSD1)—Low

20-WAY

TRANSMISSION

HARNESS

CONNECTOR

T L

20-WAY

TRANSMISSION

BULKHEAD

CONNECTOR

K D

A E

NOTE: Letters I, O, and Q are not used.

TRANSMISSION

CONNECTOR

K D

T L

TRANSMISSION

CONNECTOR

1 6

12 13

14 20

TRANSMISSION

PCS1

MAIN MOD

TCC

PCS2

SS1

SS2

SS3

24-WAY

HARNESS

24-WAY

BULKHEAD

14L

15M

19S

10J

16N

17P

END VIEW OF

1 6

1213

19 24

24-WAY CONNECTOR20-WAY CONNECTOR

80-WAY CONNECTOR

TCM

176

111

155

174

178

171

136

152

133

151

(HSD1)

(HSD2)

ANALOG

INTERFACE

V BATT

V08976.01.00

Circuit Description

High Side Driver 1 (HSD1) supplies battery voltage to the Main Mod, TCC and PCS1 solenoids via wire 111. HSD1 is continuously ON during normal operation except during brief circuit tests. The TCM regulates control current to the solenoids by switching the appropriate low-side driver ON and OFF. DTC P0658 indicates the TCM has detected that all solenoids connected to the HSD1 are inactive with a supply voltage in the HSD1 circuit of 6V or less. DTC P0658 indicates a short-to-ground has occurred in the high side wiring attached to HSD1 (wire 111) or TransID (wire124).

Conditions for Running the DTC

• Components are powered and the ignition voltage is greater than 9V and less than 18V (12V TCM) or greater than 18V and less than 32V (24V TCM).

• HSD1 is commanded ON.

1000 AND 2000 PRODUCT FAMILIES TROUBLESHOOTING MANUAL—ALLISON 4th GENERATION CONTROLS

DIAGNOSTIC TROUBLE CODES (DTC)

Conditions for Setting the DTC

DTC P0658 is set when the TCM detects all the solenoids connected to the HSD1 are inactive and the high-side voltage is less then 6V. These conditions indicate a short-to-ground has occurred at the high-side wire 111 or TransID wire 176.

Actions taken when the DTC Sets

When DTC P0658 is active, the following conditions will occur:

• If the failure occurs while in a forward range a shift to ﬁrst, third, or ﬁfth range is made.

• While diagnostic response is active, if shift selector is moved to neutral, transmission will shift to neutral; if the

shift selector is moved to reverse, transmission shifts to reverse. If the shift selector is moved to forward range or reverse and transmission is compromised be overspeeding or direction change, transmission shifts to neutral.

• TCC engagement is inhibited.

• Main Modulation is inhibited.

• DTC is stored in TCM history.

• The CHECK TRANS light illuminates.

Conditions for clearing the DTC/CHECK TRANS Light

The Allison DOC™ For PC–Service Tool can be used to clear the DTC from the TCM history. The TCM automatically clears the DTC from the TCM history if the vehicle completes 40 warm-up cycles without failure.

Diagnostic Aids

• HSD1 and HSD2 will reset opening the high side circuit whenever a short-to-ground is detected.

• You may have to drive the vehicle in order to experience a fault. Use the data obtained from failure records to

determine transmission range and/or certain vehicle operating variables such as temperature, run time etc. This data can be useful in reproducing the failure mode when DTC was set.

• Inspect the wiring for poor electrical connections at the TCM and transmission connector. Look for the

following conditions:

— A bent terminal — A backed-out terminal — A damaged terminal — Poor terminal tension — A chafed wire — A broken wire inside the insulation

• Inspect OEM wiring harness routing, look for possible contact points where chafﬁng could occur leading to an

open circuit condition. Moving parts on the vehicle could be contacting the harness; this includes parking brake drum, suspension components, etc.

• When diagnosing for an intermittent short or open, massage the wiring harness while watching the test

equipment for a change.

• A short-to-ground at TransID wire 176 could allow this DTC to set. To check for this condition, isolate wire

176 by removing pin 24 at the transmission connector and pin 76 at the 80-way TCM connector. Clear DTCs and watch for an active DTC P0658 to return.

NOTE: Be aware that a TransID DTC P0702 will be set by performing this test.

If P0658 code does not return inspect wire 176 for possible shorting concern.

1000 AND 2000 PRODUCT FAMILIES TROUBLESHOOTING MANUAL—ALLISON 4th GENERATION CONTROLS

DIAGNOSTIC TROUBLE CODES (DTC)

Test Description

2. This step tests for the proper ignition voltage.

3. This step tests for an active DTC.

4. This step tests for wire-to-wire shorts or short-to-ground in the wire 111 of the OEM chassis harness.

6. This step tests for wiring defects in the transmission internal harness.

DTC P0658 Actuator Supply Voltage 1 (HSD1)—Low

Step Action Value(s) Yes No

1 Was the Beginning the Troubleshooting Process

(refer to Section 5–4) performed?

1. Install Allison DOC™.

2. Start the engine.

3. Record the DTC Failure Record data.

4. Monitor ignition voltage.

Is the voltage within the speciﬁed values?

1. Clear the DTC.

2. Start the engine and test-drive the vehicle.

3. Attempt to duplicate the same conditions observed in the failure records (range attained, temperature, etc.).

NOTE: This DTC is intended to detect a short-toground condition in the HSD1 electrical circuit.

Did DTC P0658 return?

1. Turn ignition OFF.

2. Disconnect the 80-way connector at the TCM.

3. Install TCM Breakout J 47275 to the OEM 80-way connector. Leave the TCM 80-way connector disconnected.

4. Disconnect the OEM 24-way connector from the transmission.

5. Inspect the routing of wire 111 in the chassis harness between the TCM and the transmission connector.

6. At TCM Overlay J 47275-1, test for wire-to-wire shorts between pin 11 and all other pins in the 80-way connector.

Were any wire-to-wire shorts found?

9–18V (12V TCM)

18–32V (24V TCM)

Go to Step 2 Go to

Beginning The

Troubleshooting

Process

(Section 5–4)

Go to Step 3 Resolve voltage

problem

Go to Step 4 Go to

Diagnostic Aids

Go to Step 5 Go to Step 6

1000 AND 2000 PRODUCT FAMILIES TROUBLESHOOTING MANUAL—ALLISON 4th GENERATION CONTROLS

DIAGNOSTIC TROUBLE CODES (DTC)

DTC P0658 Actuator Supply Voltage 1 (HSD1)—Low (cont’d)

Step Action Value(s) Yes No

5 NOTE: The vehicle OEM has responsibility for all

external wiring harness repair. Harness repairs performed by Allison Transmission distributors and dealers are not covered by Allison Transmission warranty.

Coordinate with the vehicle OEM to repair or replace the chassis harness.

Is the repair complete?

1. Turn the ignition OFF.

2. Disconnect the OEM 24-way connector from Transmission Breakout J 47278. Connect the transmission 24-way connector to the J 39700 Breakout Box.

3. Using a digital volt/ohmmeter multimeter (DVOM), test for wire-to-wire shorts between pin 14 and all other pins in the 24-way connector.

NOTE: The resistance value between pins 14 and pins 10, 15, and 19 should read normal solenoid resistance.

Were any wire-to-wire shorts or shorts-to-ground found?

1. Remove the transmission oil pan.

2. Repair or replace the internal wiring harness (refer to the 1000 and 2000 Product Families Service Manual, SM4006EN or In-Chassis Maintenance, GN4008EN).

Is the repair complete?

8 NOTE: In most cases, the TCM is not at fault.

Investigate thoroughly before replacing the TCM. Refer to TCM diagnostic procedure (Section 3–6).

Is Section 3–6 complete?

9 In order to verify your repair:

1. Clear the DTC.

2. Drive the vehicle under conditions noted in failure records.

Did the DTC return?

Go to Step 9

Go to Step 7 Go to Step 8

Go to Step 9

Begin the

diagnosis again.

Go to Step 1

System OK

1000 AND 2000 PRODUCT FAMILIES TROUBLESHOOTING MANUAL—ALLISON 4th GENERATION CONTROLS

DIAGNOSTIC TROUBLE CODES (DTC)

DTC P0659 Actuator Supply Voltage 1 (HSD1)—High (batt)

20-WAY

TRANSMISSION

HARNESS

CONNECTOR

T L

20-WAY

TRANSMISSION

BULKHEAD

CONNECTOR

K D

A E

NOTE: Letters I, O, and Q are not used.

TRANSMISSION

CONNECTOR

TRANSMISSION

CONNECTOR

T L

1 6

12 13

14 20

TRANSMISSION

PCS1

MAIN MOD

TCC

PCS2

SS1

SS2

SS3

24-WAY

HARNESS

24-WAY

BULKHEAD

14L

15M

19S

10J

16N

17P

END VIEW OF

1 6

1213

19 24

24-WAY CONNECTOR20-WAY CONNECTOR

80-WAY CONNECTOR

TCM

176

111

155

174

178

171

136

152

133

151

(HSD1)

(HSD2)

ANALOG

INTERFACE

V BATT

V08976.01.00

Circuit Description

High Side Driver 1 (HSD1) supplies battery voltage to the Main Mod, TCC and PCS1 solenoids via wire 111. HSD1 is continuously ON during normal operation except during brief circuit tests. The TCM regulates control current to the solenoids by switching the appropriate low-side driver ON and OFF. DTC P0659 indicates the TCM has detected a greater than or equal to 6V in the HSD1 circuit when HSD1 is OFF during initialization. DTC P0659 could be caused by a short-to-battery or open condition in the high side wiring attached to HSD1 (wire 111).

Conditions for Running the DTC

• Components are powered and the ignition voltage is greater than 9V and less than 18V (12V TCM) or greater than 18V or less than 32V (24V TCM).

• HSD1 is commanded ON.

1000 AND 2000 PRODUCT FAMILIES TROUBLESHOOTING MANUAL—ALLISON 4th GENERATION CONTROLS

DIAGNOSTIC TROUBLE CODES (DTC)

Conditions for Setting the DTC

DTC P0659 is set when the TCM detects a high voltage condition (greater than or equal to 6V) in three solenoids in the HSD1 circuit.

Actions taken when the DTC Sets

When DTC P0659 is active, the following conditions will occur:

• If the failure occurs while in a forward range a shift to 1

• While diagnostic response is active, if shift selector is moved to N (Neutral), transmission will shift to neutral;

if the shift selector is moved to R (Reverse), transmission shifts to reverse. If the shift selector is moved to D (Forward) range or R (Reverse) and transmission is compromised be overspeeding or direction change, transmission shifts to neutral.

• TCC engagement is inhibited.

• Main Modulation is inhibited.

• DTC is stored in TCM history.

• The CHECK TRANS light illuminates (Non-OBD II Strategy).

• The MIL illuminates (OBD II Strategy).

• The TCM freezes shift adapts (DNA).

, 3rd or 5th range is made.

Conditions for clearing the DTC/CHECK TRANS Light

Diagnostic Aids

• You may have to drive the vehicle in order to experience a fault. Use the data obtained from failure records to

determine transmission range and/or certain vehicle operating variables such as temperature, run time, etc. This data can be useful in reproducing the failure mode when DTC was set.

• Inspect the wiring for poor electrical connections at the TCM and transmission connector. Look for the

following conditions:

— A bent terminal — A backed-out terminal — A damaged terminal — Poor terminal tension — A chafed wire — A broken wire inside the insulation.

• Inspect OEM wiring harness routing, look for possible contact points where chaﬁng could occur leading to an

open circuit condition. Moving parts on the vehicle could be contacting the harness; this includes parking brake drum, suspension components, etc.

• When diagnosing for an intermittent short or open, massage the wiring harness while watching the test

equipment for a change.

Test Description

The numbers below refer to the step numbers on the diagnostic table.

2. This step tests for the proper ignition voltage.

3. This step tests for an active DTC.

4. This step tests the OEM harness for an excessive voltage drop caused by an open condition in wire 111 of the OEM chassis harness.

5. This step tests for a wire-to-wire short in wire 111 of the OEM chassis harness.

7. This step tests for wiring defects in the transmission internal harness.

1000 AND 2000 PRODUCT FAMILIES TROUBLESHOOTING MANUAL—ALLISON 4th GENERATION CONTROLS

DIAGNOSTIC TROUBLE CODES (DTC)

DTC P0659 Actuator Supply Voltage 1 (HSD1)—High

Step Action Value(s) Yes No

1 Was the Beginning the Troubleshooting Process

(refer to Section 5–4) performed?

1. Install Allison DOC™.

2. Start the engine.

3. Record the DTC Failure Record data.

4. Monitor ignition voltage.

Is the voltage within the speciﬁed values?

1. Clear the DTC.

2. Start the engine and test-drive the vehicle.

3. Attempt to duplicate the same conditions observed in the failure records (range attained, temperature, etc.).

NOTE: This DTC is intended to detect a short-tobattery condition in the HSD1 electrical circuit.

Did DTC P0659 return?

4 NOTE: Review Section 4, Wire Check Procedures

before performing steps.

1. Turn ignition OFF.

2. Install TCM Breakout J 47275 between the OEM and TCM 80-way connector.

3. Install Transmission Breakout J 47278 between the OEM and transmission 24-way connector.

4. Turn ignition ON, leave engine OFF.

5. Using Allison DOC™, enter Solenoid Test mode and command PCS1 ON.

6. Determine the voltage drop in the high side of the PCS1 circuit as follows:

• At TCM Overlay J 47275-1, measure voltage

between pin 11 and an isolated ground.

• At Transmission Overlay J 47278-1 measure

voltage between pin 14 and ground. It will be necessary to use J 39700 Breakout Box at TCM Breakout J 47275 and Transmission Breakout J 47278.

• Subtract the two voltage measurements to

obtain the voltage drop in the circuit.

NOTE: A voltage drop of more than 0.5V across either circuit indicates an excessive voltage loss in the OEM harness.

Did the high-side voltage drop exceed 0.5VDC?

9–18V (12V TCM)

18–32V (24V TCM)

Go to Step 2 Go to Beginning the

Troubleshooting

Process

(Section 5–4)

Go to Step 3 Resolve voltage

problem

Go to Step 4 Go to

Diagnostic Aids

Go to Step 6 Go to Step 5

1000 AND 2000 PRODUCT FAMILIES TROUBLESHOOTING MANUAL—ALLISON 4th GENERATION CONTROLS

DIAGNOSTIC TROUBLE CODES (DTC)

DTC P0659 Actuator Supply Voltage 1 (HSD1)—High (cont’d)

Step Action Value(s) Yes No

5 1. Turn the ignition OFF.

2. Disconnect the TCM Breakout J 47275 from the TCM. Leave the OEM 80-way connector connected.

3. Disconnect the OEM 24-way connector from Transmission Breakout J 47278.

4. Inspect the routing of wire 111 in the chassis harness between the TCM and the transmission connector.

5. At TCM Overlay J 47275-1, test for wire-to-wire shorts between pin 11 and all other pins in the 80-way connector, and shorts-to-ground between pin 11 and chassis ground.

Were any wire-to-wire shorts found?

6 NOTE: The vehicle OEM has responsibility for all

external wiring harness repair. Harness repairs performed by Allison Transmission distributors and dealers are not covered by Allison Transmission warranty.

Coordinate with the vehicle OEM to repair or replace the chassis harness.

Is the repair complete?

7 1. Turn the ignition OFF.

2. If not performed in Step 5 above, disconnect the OEM 24-way connector from Transmission Breakout J 47278. Leave the transmission 24-way connector connected to the Breakout Box.

3. Using a digital volt/ohmmeter (DVOM), test for wire-to-wire shorts between pin 14 and all other pins in the 24-way connector, and shorts-toground between pin 14 and chassis ground.

NOTE: The resistance value between pins 14 and pins 10, 15, and 19 should read normal solenoid resistance.

Were any wire-to-wire shorts found?

8 1. Remove the oil pan.

2. Repair or replace the internal wiring harness.

Is the repair complete?

9 NOTE: In most cases, the TCM is not at fault.

Investigate thoroughly before replacing the TCM. Refer to TCM diagnostic procedure (Section 3–6).

Is Section 3–6 complete?

10 In order to verify your repair:

1. Clear the DTC.

2. Drive the vehicle under conditions noted in failure records.

Did the DTC return?

Go to Step 6 Go to Step 7

Go to Step 10

Go to Step 8 Go to Step 9

Go to Step 10

Begin the

diagnosis again.

Go to Step 1

System OK

1000 AND 2000 PRODUCT FAMILIES TROUBLESHOOTING MANUAL—ALLISON 4th GENERATION CONTROLS

DIAGNOSTIC TROUBLE CODES (DTC)

DTC P0701 Transmission Control System—Performance

NO SCHEMATIC FOR THIS DTC

Circuit Description

The Transmission Control Module (TCM) monitors the status of the pressure switches at start-up to detect the presence of hydraulic pressure.

Conditions for Running the DTC

• The components are powered and ignition voltage is greater than 9V and less than 18V (12V TCM).

• Engine speed is greater than 200 rpm and less than 7500 rpm for 5 seconds.

• This test is run after engine start-up and runs as part of the transmission hydraulic initialization.

Conditions for Setting the DTC

DTC P0701 sets when transmission ﬂuid temperature is above –25°C (–13°F) with an engine speed above 500 rpm for 6 seconds or 400 rpm for 15 seconds and forward or reverse range is selected and all the pressure switches do not indicate pressure.

Action Taken When the DTC Sets

• DTC P0701 is stored in the TCM history.

• The TCM inhibits TCC engagement.

• The TCM does not illuminate the CHECK TRANS light (Non-OBD II Strategy).

• The TCM does not illuminate the MIL (OBD II Strategy).

Conditions for Clearing the MIL/DTC

Diagnostic Aids

• DTC P0701 may be logged if a forward or reverse range is selected immediately after the engine is started and before the TCM detects pressure at the switches (2 to 6 seconds after engine start).

• A plugged control main ﬁlter may cause this DTC to set. The control main ﬁlter is to be changed after the ﬁrst 8000 km (5000 miles). Failure to change the ﬁlter at this interval may cause this DTC and other pressure switch DTCs to set.

• A cracked internal suction ﬁlter tube or damaged tube seal may cause this DTC to set.

• A stuck lube regulator valve (located in the front support) may cause this DTC to set. A high static oil level with the vehicle running is often a good indication of this complaint. Often pressure switch DTCs are set in this scenario.

• You may have to drive the vehicle in order to experience a fault.

1000 AND 2000 PRODUCT FAMILIES TROUBLESHOOTING MANUAL—ALLISON 4th GENERATION CONTROLS

DIAGNOSTIC TROUBLE CODES (DTC)

Test Description

The numbers below refer to the step numbers on the diagnostic table.

2. This step tests for proper ﬂuid level.

5. This step tests for main pressure.

DTC P0701 Transmission Control System—Performance

Step Action Value Yes No

1 Was the Beginning the Troubleshooting Process

(refer to Section 5–4) performed?

2 1. Install Allison DOC™.

2. Turn the ignition to ON, with the engine OFF.

3. Record the DTC Failure Record data.

4. Clear the DTC.

5. Start the engine; check the transmission ﬂuid

level.

Is the ﬂuid at the appropriate level?

3 This DTC can be set after performing ﬂuid service

and ﬁlter change, after replacement of the PSM, or after a long period of storage.

Have any of these conditions occurred?

4 Add ﬂuid to the proper level.

Is the ﬂuid at the appropriate level?

5 Check main pressure (refer to Main Pressure Check

Procedure, Appendix B). Is the pressure within the speciﬁed value?

6 No main pressure at idle may be an indication of the

following:

• Stuck or sticking lube regulator valve

• Stuck or sticking main pressure regulator valve

• Loose or damaged suction ﬁlter

• Defective suction ﬁlter seal

Was the reason for no main pressure condition found and repaired?

7 In order to verify your repair:

1. Clear the DTC.

2. Start the vehicle.

3. Use Allison DOC™, in the test passed section, to

conﬁrm the diagnostic test was run.

Did the DTC return?

Go to Step 2 Go to

Beginning The

Troubleshooting

Process

(Section 5–4)

Go to Step 3 Go to Step 4

Go to Step 7 Go to Step 5

Go to Step 5 —

Go to Step 7 Go to Step 6

Go to Step 7 Go to General

Troubleshooting

(Section 7)

Go to Step 1 System OK

1000 AND 2000 PRODUCT FAMILIES TROUBLESHOOTING MANUAL—ALLISON 4th GENERATION CONTROLS

DIAGNOSTIC TROUBLE CODES (DTC)

DTC P0702 Transmission Control System Electrical (TransID)

20-WAY

TRANSMISSION

HARNESS

CONNECTOR

T L

20-WAY

TRANSMISSION

BULKHEAD

CONNECTOR

K D

A E

NOTE: Letters I, O, and Q are not used.

TRANSMISSION TCM

T L

TRANSID

HSD1

MAIN MOD

24-WAY

TRANSMISSION

HARNESS

CONNECTOR

24-WAY

TRANSMISSION

BULKHEAD

CONNECTOR

1 6

12 13

14 20

20-WAY

CONNECTOR

24 76

14 11

PCS1

TCC

15 55

19 74

J78

1 6

1213

19 24

24-WAY CONNECTOR

176

111

155

174

178

END VIEW OF

80-WAY CONNECTOR

ANALOG

(HSD1)

INTERFACE

V BATTERY

NOT USED with 20-Way Transmission Connector.

V09581.01.00

Circuit Description

The TransID (TID) feature enables the TCM to identify the current transmission hardware conﬁguration level and verify that compatible software calibration is used. The TCM senses the transmission conﬁguration using TID wire

176. Initially, wire 176 will be connected to the High Side Driver (HSD1) via wire 111 in Allison 4

Generation

Controls. This wiring conﬁguration is designated TID A.

Condition for Running the DTC

The test is enabled by the TCM calibration.

Condition for Setting the DTC

DTC P0702 sets if the TCM is unable to determine the TransID level of the transmission.

Allison Transmission 1000, 2000 Troubleshooting Manual

Specifications and Main Features

Frequently Asked Questions

User Manual