Allison Transmission 3000, 4000 Troubleshooting Manual

3000 AND 4000 PRODUCT FAMILIES TROUBLESHOOTING MANUAL—ALLISON 4th GENERATION CONTROLS

3000 AND 4000 PRODUCT FAMILIES TROUBLESHOOTING MANUAL – ALLISON 4TH GENERATION CONTROLS

DIAGNOSTIC TROUBLE CODES (DTC)

W elcome to the TS3989EN T roubl eshooting Manual. We make every effort to keep our service information current and accurate. Because of the time lag involved with writing and printing processes, the transmission TCM may report a code that has not yet been added to this document. If you encounter a code that is not yet in this publication, please call Allison Transmission.

Go to the Table of Contents

PREFACE

2008 OCTOBER

Troubleshooting

TS3989EN

Manual

Allison Transmission

VOCATIONAL MODELS

3000 VOCATIONAL MODELS

3000 HS 3500 RDS B 300(P)(R) 3000 RDS 3500 EVS B 400(P)(R) 3000 EVS T 200 3000 MH T 300 3000 PTS 3000 TRV 3200 SP 3500 SP 3700 SP 3200 TRV

4000 VOCATIONAL MODELS

4000 EVS 4500 EVS 4700 EVS 4800 EVS B 500 4000 HS 4500 HS 4700 RDS B 500P 4000 MH 4500 RDS 4700 OFS B 500R 4000 RDS 4500 SP B 500PR 4000 TRV 4500 TRV T 425

T 450

Allison Transmission, Inc.

P.O. Box 894 Indianapolis, Indiana 46206-0894 www.allisontransmission.com

3000 AND 4000 PRODUCT FAMILIES TROUBLESHOOTING MANUAL—ALLISON 4th GENERATION CONTROLS

FOREWORD — How to Use This Manual

This manual provides troubleshooting information for the 3000 and 4000 Product Families Transmissions. Service Manuals SM4013EN and SM4014EN, plus Parts Catalogs PC2150EN and PC2456EN may be used in co njunction with this manual.

This manual includes:

• Description of the 3000 and 4000 Product Families Allison 4

• 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 in the lower left corner of the 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.

Generation Electronic Control system.

T ake 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 for service of wiring harnesses and wiring harness components as

follows:

• Repair parts for the internal wiring harness and for wiring harness components attached to the

shift selector 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 (AT) is responsible for warranty on these parts.

• Repair parts for the external harnesses and external harness components must be obtained from

St. Clair Technologies Inc. (SCTI). SCTI provides parts to any Allison customer or OEM and is responsible for warranty on these parts. SCTI recognizes AT, manufacturers, and SCTI part numbers. SCTI provides a technical HELPLINE at 519-627-1673 (Wallaceburg). SCTI will have parts catalogs available. The SCTI addresses and phone numbers for parts outlets are:

St. Clair Technologies, Inc. 920 Old Glass Road Wallaceburg, Ontario, N8A 4L8 Phone: 519-627-1673 Fax: 519-627-4227

St. Clair Technologies, Inc. Calle Damanti S/N Col Guadalupe—Guaymas Sonora, Mexico 85440 Phone: 011-526-2222-43834 Fax: 011-526 2222-43553

3000/4000 PRODUCT FAMILIES 4TH GENERATION ELECTRONIC CONTROLS TROUBLESHOOTING MANUAL

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 SER VICE PROCEDURE OR T OOL 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:

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

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.

3000 AND 4000 PRODUCT FAMILIES TROUBLESHOOTING MANUAL—ALLISON 4th GENERATION CONTROLS

TRADEMARKS USED IN THIS MANUAL

The following trademarks are the property of the companies indicated:

• Allison DOC

• DEXRON

• LPS

• Loctite

• MagiKey

• Teflon

• TranSynd

Cleaner is a registered trademark of LPS Laboratories.

is a trademark of General Motors Corporation.

is a registered trademark of General Motors Corporation.

is a registered trademark of the Loctite Corporation.

is a registered trademark of NEXIQ Technologies, Inc.

is a registered trademark of the DuPont Corporation.

is a trademark of Castrol Ltd.

SHIFT SELECTOR TERMS AND DISPLAY INDICATIONS

Shift selector terms and displays are represented in this manual as follows:

• Button Names — ↑, ↓, “display mode”, MODE, etc.

• Transmission Ranges — D (Drive), N (Neutral), R (Reverse), 1 (First), 2 (Second), etc.

• Displays — “o, L”; “o, K”, etc. (Display occurs one character at a time.)

3000 AND 4000 PRODUCT FAMILIES TROUBLESHOOTING MANUAL—ALLISON 4th GENERATION CONTROLS

Page

FOREWARD. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .ii

IMPORTANT SAFETY NOTICE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . iii

WARNINGS, CAUTIONS, AND NOTES. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . iii

TRADEMARKS USED IN THIS MANUAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . iv

SHIFT SELECTOR TERMS AND DISPLAY INDICATIONS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . iv

SECTION 1. GENERAL DESCRIPTION

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

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

1–3. SHIFT SELECTOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1–4

A. Pushbutton Shift Selector . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1–4

B. Lever Shift Selector . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1–5

1–4. THROTTLE POSITION SENSOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1–6

1–5. SPEED SENSORS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1–7

1–6. CONTROL MODULE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1–8

1–7. WIRING HARNESSES. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1–12

A. External Wiring Harness. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1–12

B. Internal Wiring Harness . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1–14

1–8. VEHICLE INTERFACE MODULE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1–16

1–9. AUTODETECT FEATURE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1–16

A. Retarder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1–17

B. Oil Level Sensor (OLS) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1–17

C. Throttle Source . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1–17

D. Engine Coolant Temperature . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1–18

1–10. TRANSID (TID) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1–18

1–11. SPECIAL ELECTRONIC/ELECTRICAL TOOLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1–19

SECTION 2. DEFINITIONS AND ABBREVIATIONS

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

2–2. ALLISON TRANSMISSION DIAGNOSTIC TOOL. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2–5

2–3. ABBREVIATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2–7

3000 AND 4000 PRODUCT FAMILIES TROUBLESHOOTING MANUAL—ALLISON 4th GENERATION CONTROLS

TABLE OF CONTENTS (cont’d)

Page

SECTION 3. BASIC KNOWLEDGE

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

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

3–3. SYSTEM OVERVIEW . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3–2

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

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

3–6. TCM DIAGNOSTIC PROCEDURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3–5

3–7. RESTTING OF TCM PARAMETERS TO SUPPORT ENGINE UPDATE. . . . . . . . . . . . . . . . . . 3–6

3–8. RESETTING TCM AUTOSELECT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3–6

3–9. HYDRAULIC OPERATION DURING ELECTRICAL INTERRUPTION. . . . . . . . . . . . . . . . . . 3–6

SECTION 4. WIRE CHECK PROCEDURES

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

4–2. TESTING AT TRANSMISSION FEEDTHROUGH CONNECTOR FOR INTERNAL

HARNESS OPENS, SHORTS BETWEEN WIRES, AND SHORTS-TO-GROUND . . . . . . . . . . 4–3

SECTION 5. FLUID CHECK PROCEDURES

5–1. OIL LEVEL SENSOR (OLS) INTRODUCTION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5–1

5–2. ELECTRONIC FLUID LEVEL READING (SHIFT SELECTOR) . . . . . . . . . . . . . . . . . . . . . . . . 5–3

A. Fluid Level Reading Procedure. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5–3

5–3. ELECTRONIC FLUID LEVEL CHECK (ALLISON DOC™ FOR PC–SERVICE TOOL) . . . . . 5–5

A. Fluid Level Check Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5–5

5–4. COLD CHECK. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5–6

A. Purpose . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5–6

B. Cold Check Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5–6

5–5 HOT CHECK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5–7

A. Hot Check Procedure. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5–7

5–6 KEEPING FLUID CLEAN . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5–8

A. Foreign Material . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5–8

5–7 FLUID RECOMMENDATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5–8

3000 AND 4000 PRODUCT FAMILIES TROUBLESHOOTING MANUAL—ALLISON 4th GENERATION CONTROLS

TABLE OF CONTENTS (cont’d)

Page

SECTION 6.DIAGNOSTIC TROUBLE CODES (DTC)

6–1. DIAGNOSTIC CODE MEMORY. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6–1

6–2. CODE READING AND CODE CLEARING. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6–2

6–3. DIAGNOSTIC CODE RESPONSE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6–3

6–4. SHIFT SELECTOR DISPLAYS RELATED TO ACTIVE CODES . . . . . . . . . . . . . . . . . . . . . . . .6–4

6–5. DIAGNOSTIC CODE LIST AND DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6–4

6–6. DIAGNOSTIC CODE TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6–14

A. Beginning the Troubleshooting Process. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6–14

B. Solenoid Locations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6–14

C. Diagnostic Code Schematics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6–14

SECTION 7. INPUT AND OUTPUT FUNCTIONS

7–1. INPUT FUNCTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7–1

7–2. OUTPUT FUNCTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7–3

SECTION 8. GENERAL TROUBLESHOOTING OF PERFORMANCE COMPLAINTS

APPENDICES

A. IDENTIFICATION OF POTENTIAL CIRCUIT PROBLEMS . . . . . . . . . . . . . . . . . . . . . . . . . . . A–1

B. MEASURING CLUTCH AND RETARDER PRESSURES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B–1

C. SOLENOID AND CLUTCH CHART. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C–1

D. WIRE/CONNECTOR CHART . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D–1

E. CONNECTOR PART NUMBERS, TERMINAL PART NUMBERS, . . . . . . . . . . . . . . . . . . . . . . .E–1

TOOL PART NUMBERS, AND REPAIR INSTRUCTIONS

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

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

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

J. 3000 AND 4000 PRODUCT FAMILIES WIRING SCHEMATIC. . . . . . . . . . . . . . . . . . . . . . . . . . J–1

K. SOLENOID RESISTANCE CHARTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . K–1

L. EXTERNALLY-GENERATED ELECTRONIC INTERFERENCE. . . . . . . . . . . . . . . . . . . . . . . . .L–1

M. DIAGNOSTIC TREE—3000 AND 4000 PRODUCT FAMILIES HYDRAULIC SYSTEM . . . . M–1

N. ALLISON DOC™ FOR PC–SERVICE TOOL. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . N–1

P. INPUT/OUTPUT FUNCTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .P–1

Q. THERMISTOR TROUBLESHOOTING INFORMATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Q–1

R. SAE J1939 COMMUNICATION LINK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . R–1

3000 AND 4000 PRODUCT FAMILIES TROUBLESHOOTING MANUAL—ALLISON 4th GENERATION CONTROLS

NOTES

3000 AND 4000 PRODUCT FAMILIES TROUBLESHOOTING MANUAL—ALLISON 4th GENERATION CONTROLS

SECTION 1—GENERAL DESCRIPTION

1–1. TRANSMISSION

The Allison 4th Generation Controls feature closed-loop clutch control to provide superior shift quality over a wide range of operating conditions. The 3000 and 4000 Product Families transmissions configurations can be programmed to have up to six forward ranges, neutral, and one reverse range. The 3700 SP, 4700 RDS, 4700/ 4800 EVS, 4700/4800 SP, and 4700 OFS have up to seven forward ranges and one reverse.

Figure 1–1 is a block diagram of the basic system inputs and outpu t s.

SHIFT SELECTOR

MODE SWITCH

SPEED SENSORS

THROTTLE POSITION SENSOR

RETARDER MODULATION

VEHICLE/ENGINE

COMMUNICATION LINKS

RANGE AND

TCM

DISPLAY

DIAGNOSTIC PRESSURE SWITCH

VIM

INPUTS OUTPUTS

Figure 1–1. Transmission Control Module

Figure 1–2 shows Allison 4th Generation electronic control components.

Allison 4

Generation Controls consist of the following elements:

• Remote 12V or 12/24V Max Feature Sealed Transmission Control Module (TCM)

• Remote Pushbutton or Lever Shift Selector

• Optional Secondary Shift Selector

OIL LEVEL SENSOR

SOLENOIDS

TEMPERATURE SENSOR

(SUMP/RETARDER)

FILTER LIFE

SWITCH (PS2)

V09074.00.00

NOTE:

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

• Engine, Turbine, and Output Speed Sensors

• Control Module (Electro-Hydraulic Valve Body)

• Wiring Harnesses

• Vehicle Interface Module (VIM)

• Autodetect Feature

• TransID Feature

• Optional Retarder Controls

• Optional Engine Coolant Temperature Input

• Filter Life Switch (PS2)

• All external harnesses are OEM supplied.

• The VIM is an OEM option.

3000 AND 4000 PRODUCT FAMILIES TROUBLESHOOTING MANUAL—ALLISON 4th GENERATION CONTROLS

GENERAL DESCRIPTION

TRANSMISSION CONTROL MODULE (TCM)

ALLISON DOC™ FOR PC - SERVICE TOOL

COMPACT PUSHBUTTON SELECTOR

DIAGNOSTIC

TOOL

CONNECTOR

DEUTSCH 9-PIN

DIAGNOSTIC TOOL

CONNECTOR

SCI (J1587)

CONNECTOR

(OPTIONAL)

RE TARDER

MODULATION

REQUEST (RMR)

CONNECTOR

J1939 CONNECTOR

VIW

CONNECTOR

(OPTIONAL)

VIM CONNECTOR

RE TARDER ACCUMULATOR CONNECTOR

(3000 PRODUCT FAMILY 7-SPEED)

VEHICLE INTERFACE MODULE (VIM)

ORTRANSFER CASE CONNEC T

REMOTE LEVER SELEC TOR

REMOTE PUSHBUTTON SELEC TOR

STRIP PUSHBUTTON SHIFT SELEC TORS (EUROPEAN OEM)

SENSOR HARNESS

CONNECTOR (OPTIONAL)

SHIFT

SELEC TOR

CONNECTOR

THROTTLE POSITION

SENSOR (TPS)

CONNECTOR

THROTTLE

MODE

POSITION SENSOR (TPS)

OUTPUT SPEED SENSOR CONNECTOR

RE TARDER TEM P. SENSOR CONNECTOR

SPEED SENSOR

CONNECTOR

(4000 PRODUCT

TURBINE

FAMI

LY)

ENGINE

SPEED

SENSOR

CONNECTOR

Bulkhead Connector (Optional)

RE TARDER “PCS5”

SOLENOID

CONNECTOR

1 2

3 D

NOTE: Illustration is not to scale. Actual harness

conguration may dier from this illustration.

20-WAY TRANSMISSION FEEDTHROUGH

HARNESS

CONNECTOR

V09274.01.00A

Figure 1–2. Typical Allison 4th Generation Control Components

3000 AND 4000 PRODUCT FAMILIES TROUBLESHOOTING MANUAL—ALLISON 4th 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 12/24V configurations to match the configuration of the vehicle electrical system.

The TCM (Figure 1–3) contains the microcomputer which is the brain of the control system. The TCM receives and processes information defining:

• Shift selector

• Throttle position

• Sump/retarder temperature

• Pressure switch state

• Engine speed

• Turbine speed

• Transmission output speed.

The TCM uses the information to:

• Control transmission solenoids

• Supply system status

• Provide diagnostic information.

Each TCM has a date code laser etched on the outer case of the TCM. This is the date when the TCM passed final testing. This date is commonly used to denote the change configuration level of the TCM. It is normal for the TCM date displayed electronically to be a few days prior to the date shown on the label.

V09005.00.00

Figure 1–3. Transmission Control Module (TCM)

3000 AND 4000 PRODUCT FAMILIES TROUBLESHOOTING MANUAL—ALLISON 4th GENERATION CONTROLS

GENERAL DESCRIPTION

1–3. SHIFT SELECTOR

Pushbutton and lever shift selectors for the Allison 4th Generation Series are remote mounted from the TCM and communicate to the TCM via the J1939 communications data link. All shift selectors except the strip-type pushbutton have a dual digit vacuum fluorescent (VF) display and a mode indicator (LED). During normal transmission operation, illumination of the LED indicator shows that a secondary or special operating condition has been selected by pressing the MODE button. During diagnostic display mode, illumination of the LED indicator shows that the displayed Diagnostic Trouble Code (DTC) is active. Display brightness is regulated by the same vehicle potentiometer that controls dash light display brightness. More information on both types of shift selectors is continued below.

A. Pushbutton Shift Selector (Figure 1–4)

There are three full-function pushbutton shift selectors and a strip pushbutton shift selector. Strip pushbutton shift selectors are used primarily by non-North American OEMs. A full-function shift selector has a MODE button and diagnostic display capability through the dual digit vacuum fluorescent (VF) display. The strip pushbutton shift selector does not have a MODE button, diagnostic capability, or adjustable illumination. The full-function pushbutton shift selector has six (6) pushbuttons which are R (Reverse), N (Neutral), D (Drive), ↓ (Down), ↑ (Up), and MODE. Manual forward range downshifts and upshifts are made by pressing the ↓ (Down) or ↑ (Up) arrow buttons after selecting D (Drive). The N (Neutral) button has a raised lip to aid in finding it by touch. The MODE button is pressed to select a secondary or special operating condition, such as ECONOMY shift schedule. Diagnostic information is obtained by pressing the ↑ (Up) and ↓ (Down) arrow buttons at the same time.

The strip pushbutton shift selector has either three or six range selection positions as shown in Figure 1–4. When a strip pushbutton shift selector is used, diagnostic information must be obtained by using the Allison DOC™ For PC–Service Tool, or a customer-supplied remote display.

3000 AND 4000 PRODUCT FAMILIES TROUBLESHOOTING MANUAL—ALLISON 4th GENERATION CONTROLS

GENERAL DESCRIPTION

B. Lever Shift Selector (Figure 1–4)

The lever shift selector can have as many as six forward range positions (seven for the 7-speed models), as well as R (Reverse) and N (Neutral). There is a hold override button which must be

pressed and held in order to move between certain selector positions. The hold override button must be pressed when shifting between R, N, and D. The hold override button is released when the desired

selector position is reached. The selector lever can be moved freely between D and the numbered forward ranges without pressing the hold override button. The lever selector can be chosen with the lever on the left side or on the right side and with the R (Reverse) position toward the front or toward the rear of the selector. Diagnostic and oil level (if sensor is present) information is obtained from the LED display by pressing the “display mode” button.

1 2 3 4 5 D N R

SIX-SPEED, LEFT-HAND

LEVER SELECTOR

HOLD OVERRIDE

BUTTON

MODE ID

MODE

INDICATOR

(LED)

MODE BUTTON

DIGITAL DISPLAY

DISPLAY MODE

DIAGNOSTIC

BUTTON

MODE

R N D

R N D 6

5 4 3 2 1

SEVEN-SPEED,

RIGHT-HAND

LEVER SELECTOR

MODE

R N D

HOLD OVERRIDE

BUTTON

MODE

INDICATOR

(LED)

MODE BUTTON

MODE ID

DIGITAL

DISPLAY

DISPLAY MODE

DIAGNOSTIC

BUTTON

MODE

CONTOURED

BEZEL

DIGITAL DISPLAY MODE ID

MODE INDICATOR (LED)

MODE BUTTON Push simultaneously

to enter diagnostic mode and fluid level check

PUSHBUTTON SELECTORS

*NOTE:

The first number displayed in the digital display is the highest forward range available and second number is range attained in selected position.

Visually confirm that the range selected was attained. If display is flashing, shift is inhibited.

SERVICE ICON

Location of service icon on vertical and horizontal digital display

Figure 1–4. Typical Allison 4th Generation Shift Selectors

V11058.00.00

3000 AND 4000 PRODUCT FAMILIES TROUBLESHOOTING MANUAL—ALLISON 4th GENERATION CONTROLS

GENERAL DESCRIPTION

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

The Throttle Position Sensor (TPS) can be mounted to the engine, chassis, or transmission. The TPS contains a pul l 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.

Figure 1–5. Throttle Position Sensor (Without Mounting Brackets)

THROTTLE POSITION SENSOR

V00628

3000 AND 4000 PRODUCT FAMILIES TROUBLESHOOTING MANUAL—ALLISON 4th GENERATION CONTROLS

GENERAL DESCRIPTION

1–5. SPEED SENSORS (Figure 1–6)

Three speed sensors—engine speed, turbine speed, and output speed—provide information to the TCM. The engine speed signal is generated by ribs on the shell of the torque converter pump. The turbine speed signal is generated by the rotating-clutch housing spline contours. The output speed signal is generated by a toothed member attached to the output shaft (except for the 3000 Product Family 7-speed models, where the toothed member is the transfer case idler gear). The speed ratios between the various speed sensors allow the TCM to determine if the transmission is in the selected range. Speed sensor information is also used to control the timing of clutch apply pressures, resulting in the smoothest shifts possible. Hydraulic problems are detected by comparing the speed sensor information for the current range to that range’s speed sensor information stored in the TCM memory.

FORMER (BEFORE JANUARY, 2006)

3000 AND 4000

PRODUCT FAMILIES

ENGINE

(EXTERNAL)

3000/4000

PRODUCT FAMILIES

ENGINE

(EXTERNAL)

4000

PRODUCT FAMILY

TURBINE

(EXTERNAL)

4000

PRODUCT FAMILY

TURBINE

(EXTERNAL)

3000

PRODUCT FAMILY

TURBINE

(INTERNAL)

3000

PRODUCT FAMILY

(EXCEPT 7-SPEED)

RETARDER OUTPUT

(EXTERNAL)

CURRENT (JANUARY, 2006)

3000

PRODUCT FAMILY

TURBINE

(INTERNAL)

3000

PRODUCT FAMILY

(EXCEPT 7-SPEED)

RETARDER OUTPUT

(EXTERNAL)

Figure 1–6. Speed Sensors

3000

PRODUCT FAMILY

7-SPEED OUTPUT

(INTERNAL)

3000

PRODUCT FAMILY

7-SPEED OUTPUT

(INTERNAL)

3000 AND 4000

PRODUCT FAMILIES

OUTPUT (EXTERNAL),

4000 PRODUCT FAMILY

RETARDER

3000 AND 4000

PRODUCT FAMILIES

OUTPUT (EXTERNAL),

4000 PRODUCT FAMILY

RETARDER

V09819.00.00

3000 AND 4000 PRODUCT FAMILIES TROUBLESHOOTING MANUAL—ALLISON 4th GENERATION CONTROLS

GENERAL DESCRIPTION

1–6. CONTROL MODULE (Figures 1–7 and 1–8)

The Allison 4 body assembly , which are mounted to an aluminum channel plate. The TCM issues commands to various solenoids in the two valve bodies to govern fluid flow to the clutches (including torque converter clutch). The solenoids produce an output pressure that is proportional to current from the TCM. Hence, the solenoids are referred to as pressure control solenoids (PCS).

Generation Series transmission control module contains a main body assembly and solenoid valve

6-SPEED

3000 PRODUCT FAMILY

CONTROL MODULE

6-SPEED

4000 PRODUCT FAMILY

CONTROL MODULE

7-SPEED

3000 PRODUCT FAMILY

CONTROL MODULE

7-SPEED

4000 PRODUCT FAMILY

CONTROL MODULE

Figure 1–7. Allison 4th Generation Control Modules

V09276.00.00

3000 AND 4000 PRODUCT FAMILIES TROUBLESHOOTING MANUAL—ALLISON 4th GENERATION CONTROLS

GENERAL DESCRIPTION

6-SPEED W/PROGNOSTICS

3000 PRODUCT FAMILY

CONTROL MODULE

6-SPEED W/PROGNOSTICS

4000 PRODUCT FAMILY

CONTROL MODULE

Figure 1–8. Allison 4th Generation Control Mudules with Prognostics

V09276.00.00.A

3000 AND 4000 PRODUCT FAMILIES TROUBLESHOOTING MANUAL—ALLISON 4th GENERATION CONTROLS

GENERAL DESCRIPTION

The main valve body assembly contains the following:

• Main pressure regulator valve

• Control main regulator valve

• Converter flow valve

• Lube regulator valve

• Converter regulator valve

• Exhaust backfill valve

• Two latching logic valves

• On/Off solenoid SS1.

The solenoid valve body assembly contains the following:

• Pressure control solenoid MAIN MOD

• PCS1 (A trim)

• PCS2 (B trim)

• PCS3 (C trim)

• PCS4 (D trim)

• TCC (lockup)

• Diagnostic pressure switch PS1

• Filter Life Switch (PS2)

• Five solenoid regulator valves

• One diagnostic valve.

The low valve body assembly (in 3000 and 4000 Product Families 7-speed mod els) contains solenoid PCS6 (C6) and one ON/OFF solenoid SS2 (C6 enable). Refer to the appropriate service manual for valve locations.

The Allison 4 in improved cooler flow and reduced pump losses when throttle position and output speed is low. The Allison 4

Generation controls system includes a main modulation solenoid. Modulated main pressure results

Generation Controls TCM commands the main mod solenoid ON when all of the following conditions are simultaneously met:

• Sump temperature is greater than –80ºC (–112ºF) and less than 150ºC (302ºF).

• Engine speed less than 1200 rpm in all ranges except neutral. There are no restrictions on engine speed

in neutral.

• Throttle percentage less than 15 percent in reverse, low (7-speed), first, or second range. Main mod may

be commanded ON in neutral at any throttle position.

• Output speed is less than 250 rpm in neutral, reverse, low (7-speed), first, or second range.

• The PTO input to the TCM indicates the PTO is OFF.

• Shift not in progress.

The TCM may activate the main mod solenoid for improved clutch control and transmission response during other unusual operating situations.

A temperature sensor (thermistor) is located in the internal wiring harness. Changes in sump fluid temperature are indicated by changes in sensor resistance, which changes the signal sent to the TCM. Refer to the chart in Appendix Q.

The oil level sensor (OLS) is a float type device mounted on the control module channel plate. The OLS senses transmission fluid level by electronically measuring the buoyancy forces on the float. The sensor operates on

3000 AND 4000 PRODUCT FAMILIES TROUBLESHOOTING MANUAL—ALLISON 4th GENERATION CONTROLS

GENERAL DESCRIPTION

5VDC supplied by the TCM. The oil level sensor is available on any 3000 and 4000 Product Families transmissions except the 3000 7-speed transmissions.

The diagnostic pressure switch PS1 is mounted on the solenoid valve body assembly and performs the following two functions:

• When the C5 clutch is filled, PS1 senses the PCS2 solenoid regulator valve position to verify proper C3

clutch control in reverse, neutral, and first range.

• When the C5 clutch is exhausted, as in second through sixth ranges, PS1 verifies the position of the C1

and C2 latch valves.

The turbine speed sensor is mounted on the control module for the 3000 Product Family transmissions. The turbine speed sensor is directed at the rotating-clutch housing. The turbine speed sensor on the 4000 Product Family transmission is located on the outside of the main housing.

A. Control System Prognostics Operation and Display

The Prognostics Package includes the following functions:

• Oil Life Monitor

• Filter Life Monitor

• Transmission Health Monitor

Use the Allison DOC™ For PC–Service Tool to review the current status of any of these functions and a history of indicator resets. Use the Allison shift selector to review the current status of any of these functions, provided the function being checked is in its specific display mode. See the selector information section for that procedure.

When a specified threshold is detected for any of the prognostic functions, the SERVICE TRANS indicator (an open-ended wrench icon located between the range select and range monitor digits in the Allison shift selector) illuminates to alert the operator . The lamp strategy for the icon varies, either flashing, or steady, to indicate to the operator which function detected the threshold value was reached.

NOTE: Failure to attend to a service condition indicated by an illuminated lamp and then reset the SERVICE

TRANS indicator within a defined operating period results in illumination of the CHECK TRANS light and an active Diagnostic Trouble Code (DTC)—indicating the increased probability that the service condition will develop into a more serious condition.

B. Filter Life Valve Body

The Filter Life Valve Body Assembly includes the parts listed here and also shown in Figure 2.

• Filter Life Valve Body

• Filter Life Valve

• Return Spring

• Valve Stop

• Retaining Clip

• Pressure Switch 2 (Filter Life)

• M6 x 45 Long Screws (4)

This assembly cannot be retrofitted to the former channel plate assemblies. Make sure all updates listed in this section and all other requirements are met prior to using the Prognostics features.

3000 AND 4000 PRODUCT FAMILIES TROUBLESHOOTING MANUAL—ALLISON 4th GENERATION CONTROLS

GENERAL DESCRIPTION

1–7. WIRING HARNESSES

A. External Wiring Harness (Figure 1–9)

The TCM uses a single 80-way connector, which is used to receive input from the following:

Transmission TPS Diagnostic tool connector Engine Vehicle interface module (VIM) Retarder Turbine Retarder control module Retarder temperature sensor Output speed sensor Shift selector Accumulator

Filter life switch (PS2)

Many harnesses will include a bulkhead fitting to separate cab and chassis components. Also, many different styles and materials for harnesses are likely to be encountered.

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

follows:

• Repair parts for the internal wiring harness and for wiring harness components attached to the

• Repair parts for the external harnesses and external harness components must be obtained from

St. Clair Technologies Inc. (SCTI). SCTI provides parts to any Allison customer or OEM and is responsible for warranty on these parts. SCTI recognizes Allison Transmission, manufacturers, and SCTI part numbers. SCTI provides a technical HELPLINE at 519-627-1673 (Wallaceburg). SCTI will have parts catalogs available. The SCTI addresses and phone numbers for parts outlets are:

St. Clair Technologies, Inc. 920 Old Glass Road Wallaceburg, Ontario, Canada N8A 4L8 Phone: 519-627-1673 Fax: 519-627-4227

St. Clair Technologies, Inc. Calle Damanti S/N Col Guadalupe—Guaymas Sonora, Mexico 85440 Phone: 011-526 2222-43834 Fax: 011-526-2222-43553

• SCTI is the source for external harness repair parts.

3000 AND 4000 PRODUCT FAMILIES TROUBLESHOOTING MANUAL—ALLISON 4th GENERATION CONTROLS

GENERAL DESCRIPTION

TRANSMISSION CONTROL MODULE (TCM)

ALLISON DOC™ FOR PC - SERVICE TOOL

COMPACT PUSHBUTTON SELECTOR

DIAGNOSTIC

TOOL

CONNECTOR

DEUTSCH 9-PIN

DIAGNOSTIC TOOL

CONNECTOR

SCI (J1587)

CONNECTOR

(OPTIONAL)

RE TARDER

MODULATION

REQUEST (RMR)

CONNECTOR

J1939 CONNECTOR

VIW

CONNECTOR

(OPTIONAL)

VIM CONNECTOR

RE TARDER ACCUMULATOR CONNECTOR

(3000 PRODUCT FAMILY 7-SPEED)

VEHICLE INTERFACE MODULE (VIM)

ORTRANSFER CASE CONNEC T

REMOTE LEVER SELEC TOR

REMOTE PUSHBUTTON SELEC TOR

MODE

STRIP PUSHBUTTON SHIFT SELEC TORS (EUROPEAN OEM)

SENSOR HARNESS

CONNECTOR (OPTIONAL)

SELEC TOR

CONNECTOR

SHIFT

THROTTLE POSITION

SENSOR (TPS)

CONNECTOR

THROTTLE POSITION SENSOR (TPS)

OUTPUT SPEED SENSOR CONNECTOR

RE TARDER TEM P. SENSOR CONNECTOR

SPEED SENSOR

CONNECTOR

(4000 PRODUCT

TURBINE

FAMI

LY)

ENGINE

SPEED

SENSOR

CONNECTOR

Bulkhead Connector (Optional)

RE TARDER “PCS5”

SOLENOID

CONNECTOR

1 2

3 D

NOTE: Illustration is not to scale. Actual harness

conguration may dier from this illustration.

20-WAY TRANSMISSION FEEDTHROUGH

HARNESS

CONNECTOR

V09274.01.00A

Figure 1–9. Typical 4th Generation Electronic Controls External Wiring Harnesses

3000 AND 4000 PRODUCT FAMILIES TROUBLESHOOTING MANUAL—ALLISON 4th GENERATION CONTROLS

GENERAL DESCRIPTION

B. Internal Wiring Harness (Figure 1–10)

The internal wiring harness provides connection between the following:

• External harness

• Pressure control and shift solenoids

• Oil level sensor

• Diagnostic pressure switch

• Temperature sensor

• Turbine speed sensor.

PS1 DIAGNOSTIC

PRESSURE SWITCH

NT1 TURBINE

SPEED SENSOR

(3000 ONLY)

MAIN MOD

PCS6

(C6, 7-SPEED)

PCS4 (C4)

PCS3 (C3\C5)

(3000 AND 4000 PRODUCT

FAMILIES 7-SPEED C6 ENABLE)

SS2

TCC (LOCKUP)

OIL LEVEL SENSOR

OIL LEVEL SENSOR (3000, EXCEPT 7-SPEED)

SS1

ON/OFF

(4000 ONLY)

PCS1 (C1)

PCS2 (C2/C3)

OIL TEMPERATURE SENSOR

V09251.00.00

Figure 1–10. Allison 4th Generation Internal Wiring Harness

3000 AND 4000 PRODUCT FAMILIES TROUBLESHOOTING MANUAL—ALLISON 4th GENERATION CONTROLS

GENERAL DESCRIPTION

PS1 DIAGNOSTIC

PRESSURE SWITCH

NT1 TURBINE

SPEED SENSOR

(3000 ONLY)

MAIN MOD

PS2

FILTER LIFE

PCS4 (C4)

PCS3 (C3\C5)

SS2

(3000 AND 4000 PRODUCT

FAMILIES 7-SPEED C6 ENABLE)

TCC (LOCKUP)

OIL LEVEL SENSOR

OIL LEVEL SENSOR (3000, EXCEPT 7-SPEED)

SS1

ON/OFF

(4000 ONLY)

PCS1 (C1)

PCS2 (C2/C3)

OIL TEMPERATURE SENSOR

V09251.00.00.A

Figure 1–11. Allison 4th Generation Inter nal Wiring Harness with Prognostics

3000 AND 4000 PRODUCT FAMILIES TROUBLESHOOTING MANUAL—ALLISON 4th GENERATION CONTROLS

GENERAL DESCRIPTION

1–8. VEHICLE INTERFACE MODULE (Figure 1–12)

The vehicle interface module (VIM) provides relays, fuses, and connection points for interface with the output side of the vehicle electrical system. VIMs are available for both 12V and 24V electrical systems. The VIM for 12V systems uses all 12V relays. The VIM for 24V systems has all 24V relays. Refer to the appropriate parts catalog for the transmission assembly number that you are servicing for detailed parts information. Refer to Pages D–15 and D–16 for VIM wire number and terminal information.

Some OEMs may provide their own equivalent for the VIM which performs the same functions as the VIM shown in Figure 1–12.

V00631.02

Figure 1–12. Vehicle Interface Module (VIM)

1–9. AUTODETECT FEATURE

Autodetect is active on the first 25 engine starts and, in the case of throttle source detection logic, may continue past 25 ignition cycles until a valid source is determined (details follow in A through D below). Autodetect takes place within the first 30 seconds of each engine start monitored. Autodetect searches for the presence of the following transmission components or data inputs in the priority listed:

Retarder Present, Not Present Oil Lever Sensor (OLS) Present, Not Present Throttle TPS, J1587, J1939 * Engine Coolant Temperature Sensor, J1939, J1587 * No Throttle Autodetect with MY09

Even after autodetect has been completed, it can be reset to monitor an additional group of engine starts. Reset may be necessary if a device known to be present is not detected or if an autodetectable component or sensor was added after the initial vehicle build. Reset is accomplished by using Allison DOC™ For PC–Service Tool. To use the Allison DOC™ For PC–Service Tool, select “RESET AUTODETECT” to search for all four devices. Select “RESET AUTODETECT RETARDER” to search for a retarder only. Selecting “RESET ADAPTIVE SHIFT PARAMETERS” will not reset autodetect logic.

The Allison DOC™ For PC–Service Tool can also be used to override autodetect and manually enter the component or sensor to be recognized by the TCM by changing appropriate “customer modifiable constants” (CMC). The four items above are the only CMCs that are autodetectable. Other CMCs can be changed at any time

and are not related to autodetect. Consult the Allison DOC related to Allison 4

Generation Controls CMC. Additional details for each of the four autodetectable features are

User’s Guide, GN3433EN, for, detailed instructions

given below.

3000 AND 4000 PRODUCT FAMILIES TROUBLESHOOTING MANUAL—ALLISON 4th GENERATION CONTROLS

GENERAL DESCRIPTION

A. Retarder

Autodetect searches for the presence of pressure control solenoid 5 (PCS5) to the retarder during the first 35 engine ignition cycles. Retarder autodetect will countdown for a maximum of 35 ignition cycles while recording detections of a retarder. A retarder will be identified as present and the ret arder autodetect logic will stop once it is detected for three consecutive ignition cycles. If the ignition cycle counter completes the 35 cycles before there are three consecutive detections of a retarder, the software will log that there is no retarder and the retarder autodetect logic will stop. If the autodetect logic is not satisfied during the first 35 engine starts, the retarder is not detected and will not function on subsequent engine starts.

If a retarder is present but is not detected by autodetect, the retarder will not

WARNING:

function. Be sure to determine that the retarder is functioning properly immediately after the 35 PCS5 solenoid for an open, short-to-ground, or short-to-battery condition. Use the Allison DOC™ For PC–Service Tool to reset retarder autodetect or to manually select the presence of the retarder after the PCS5 circuit is repaired.

engine start. If the retarder is not functioning, test

B. Oil Level Sensor (OLS)

NOTE: If an OLS is known to be present but has not been detected, a possible cause is that the transmission

fluid level is too low. Determine the fluid level before beginning the OLS troubleshooting.

Oil level sensor autodetect will countdown for a maximum of 25 engine starts while recording detections of an OLS. The TCM monitors the OLS input voltage on wire 116. OLS input voltage

must exceed a predetermined level for the TCM to record a detection. Additionally, OLS detection must occur within 12.5 seconds on any given engine start. An OLS will be identified as present and

the OLS autodetect logic will stop once it is detected during any single engine start. If the engine start counter completes 25 cycles before the TCM records one detection of an OLS, the

software will log that there is no OLS present and the OLS autodetect logic will stop. Then the TCM concludes that no OLS is present.

No OLS diagnostics take place until the OLS is detected. Frequently test for the presence of oil level diagnostics if the transmission is known to contain an OLS. If an OLS is known to be present, but has not been detected, troubleshooting the OLS circuit is required. After the OLS circuit is repaired, reset autodetect or manually select the OLS function using the Allison DOC™ For PC–Service Tool.

C. Throttle Source

Throttle autodetect will increment a counter for a throttle source on each engine start during which the possible throttle source is detected. When the counter for any of the sources indicates five consecutive detections, the software will set a “confidence flag” to indicate that this is an available throttle source. Multiple throttle sources can be detected on a single engine start and multiple confidence flags can be set. There is no limit to the number of engine starts for autodetection of the throttle source until a confidence flag is set for a source. Once a confidence flag is set for any one of the sources, a counter begins to countdown for 15 additional engine starts. During the entire autodetect period, the software will use the highest priority source as the throttle source if multiple sources are detected before any confidence flags are set. Once a confidence flag is set, that source is used as the source for the throttle signal. When the countdown period is complete, the software will use the highest priority throttle source having a confidence flag set and the autodetect logic will stop.

3000 AND 4000 PRODUCT FAMILIES TROUBLESHOOTING MANUAL—ALLISON 4th GENERATION CONTROLS

GENERAL DESCRIPTION

D. Engine Coolant Temperature

Engine coolant temperature sensor autodetect will countdown for a total of 25 engine starts while recording detections of engine coolant temperature sources. A “confidence flag” will be set once a source is detected for five consecutive engine starts. Multiple sources detected before a confidence flag is set or multiple confidence flags will result in the highest priority source being used as the engine coolant temperature source. Multiple sources can be detected on a single engine start cycle.

1–10. TRANSID (TID)

The TransID feature enables the TCM to recognize various transmission hardware configurations and select an appropriate software calibration. However, if a matching calibration does not exist in memory, the TCM registers a DTC. Furthermore, TID only works when the controller and transmission have the same generation controls. Thus, TID will not allow an Allison 4 TID allow a WTEC III ECU to recognize a transmission with Allison 4

The TCM senses the transmission configuration using TID wire 176. In initial versions of Allison 4 Controls, wire 176 is connected to high side driver 1 (HSD1), wire 111, in the internal wiring harness. HSD1 supplies power to PCS6 and MAIN MOD solenoids. This wiring configuration is designated TID A.

Generation TCM to recognize a transmission with WTEC III controls, nor will

Generation Controls.

Generation

Whenever a TID level change is to be made, the new TID level calibration will be added to the PROM Calibration Configurator System (PCCS) before the change (s) is (are) made in production to the transmissions. All TCMs programmed and sold after that date will be loaded with the new TID calibration. These TCMs will contain calibrations for the new level transmission and all previous TID levels and will automatically load the correct calibration for the transmission based on the TID signal sensed by Autodetect during the first 25 engine starts.

3000 AND 4000 PRODUCT FAMILIES TROUBLESHOOTING MANUAL—ALLISON 4th GENERATION CONTROLS

GENERAL DESCRIPTION

1–11. SPECIAL ELECTRONIC/ELECTRICAL TOOLS

All tools listed are essential for overhaul, maintenance, and/or recalibration of the 3000 and 4000 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 39700

J 34520-A

Digital

Volt/Ohmmeter

J 39700

Univeral Breakout Box

TCM Breakout

Harness Adapter

NOTE: Used with J 39700.

J 47275

J 47276

“T” Breakout and TCM

Reflashing Harness

J 47276

J 47277

Terminal Probe

J 42455-A

J 47275

Load Box

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

J 42455-A

J 47277

J 44950

Allison DOC™ For

PC–Service Tool

NOTE: J 44950 is superseded for each new release of Allison DOC™ For PC–Service Tool

NOTE: 4000 Product Family

3000 and 4000 Product

Families Breakout Harness

V09224.01.00

J 44950

J 47279

3000 AND 4000 PRODUCT FAMILIES TROUBLESHOOTING MANUAL—ALLISON 4th GENERATION CONTROLS

GENERAL DESCRIPTION

Table 1–1. Essential Tools (cont’d)

J 47943

J 39197-A

J 47943-A

J 47943

DPA4 (Plus) USB

Translator Device Kit

J 39197

J 39197-A

Jumper Kit

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

Table 1–2. Available Tools

J 47949-A

J 47949

GMLAN Cable

J 47949

J 38125-12A

Terminal Remover (80-way connector) GM P/N: 12094429

J 38125-12A J 47139

J 47139 (Former)

63811-6000 (Current)

Crimper

3000 AND 4000 PRODUCT FAMILIES TROUBLESHOOTING MANUAL—ALLISON 4th GENERATION CONTROLS

SECTION 2—DEFINITIONS AND ABBREVIATIONS

2–1. CHECK TRANS LIGHT

When the TCM detects a serious fault, the CHECK TRANS light (usually located on the vehicle instrument panel) illuminates and action is automatically taken to protect operator, vehicle, and the transmission. A Diagnostic Trouble Dode (DTC) will nearly always be registered when the CHECK TRANS light is on; however, not all DTCs will turn on the CHECK TRANS light. Codes related to the CHECK TRANS light are detailed in the diagnostic trouble code chart (refer to Section 6).

Illumination of the CHECK TRANS light indicates that a condition was detected that requires service attention. Operation may or may not be restricted. Even when operation is restricted, the vehicle can be operated to reach a service assistance location. Depending upon the cause for the CHECK TRANS light illumination, the TCM may or may not respond to shift selector requests. The transmission may be locked in a range. That range will be shown on the shift selector display. Both upshifts and downshifts may be restricted when the CHECK TRANS light is illuminated. Seek service assistance as soon as possible.

Each time the engine is started, the CHECK TRANS light illuminates briefly and then goes off. This momentary lighting shows the light circuit is working properly. If the light does not come on during engine start, request service immediately.

A. Oil Life Monitor (OM)

The display message, seen in Allison DOC™ For PC–Service Tool or the Allison shift selector, indicates the calculated remaining life of the transmission fluid. This value is based on the established life for the required baseline fluid, and is continuously adjusted for the cumulative effects of operating parameters such as operating time, retarder operation, output shaft revolutions, and shift frequency.

OM Display: The selector display is a two-digit number, showing the percentage of fluid life remaining. New fluid is displayed as 99 percent. Minimum value displayed is 00 percent. Allison DOC™ For PC–Service Tool displays from 100 percent down to minus (–) 100 percent.

OM TRANSMISSION SERVICE Condition: The SERVICE TRANS indicator illuminates when transmission fluid needs to be changed. This occurs when the remaining fluid life is approximately 1 percent. The indicator is lit upon each initialization of the TCM, and remains on for approximately 1– 2 minutes after the first selection of a drive range, until service is performed and the indicator is reset.

Failure to perform maintenance and reset the SERVICE TRANS indicator within a specified period results in the illumination of the CHECK TRANS light and DTC P0897, Transmission Fluid Deteriorated, being set. P0897 indicates the remaining fluid life has reached 1 percent.

OM Reset: The function may be reset by one of the following methods:

NOTE: Prognostic information can only be reset in the higher of two shift schedules, if applicable.

• Message over the SAE J1939 communication interface.

• With the ignition ON and the engine OFF, shift between N D N D N R N, pausing briefly (less

than 3 seconds) between shifts, to reset the value displayed on the shift selector to 99 percent.

• Display the Oil Life Monitor information and press and hold the MODE button of the Allison

shift selector for 10 seconds.

• Reset by using the specific Action Request in the Allison DOC™ For PC–Service Tool .

The SERVICE TRANS indicator illuminates briefly following a reset to acknowledge the reset was successful.

3000 AND 4000 PRODUCT FAMILIES TROUBLESHOOTING MANUAL—ALLISON 4th GENERATION CONTROLS

DEFINITIONS AND ABBREVIATIONS

Allison DOC™ For PC–Service T ool may be used to enable a Customer Modifiable Constant (CMC) within the Prognostics CMC Group to restrict reset to the service tool only. If resets are restricted to the service tool, the selector will not be able to reset the function.

OM History: A historical record of the last 6 resets, including mileage at the time of each reset, may be viewed using the Allison DOC™ For PC–Service Tool .

NOTE: Required calendar-based fluid change intervals are not monitored by this function and those intervals

remain applicable to all vehicle installations in addition to the above.

B. Filter Life Monitor (FM)

Filter Life Monitor indicates when the filters require changing. The display message indicates the operating status of the transmission main filter, based on the measured pressure drop across the filter. The Prognostics pressure switch is activated when fluid exiting the main filter drops below a predetermined pressure. Both the main and lube filters must be changed when the SERVICE TRANS indicates the main filter should be changed. The differential pressure limit is verified for a period of time to make sure there is no false filters change indication. This feature is not functional until transmission sump temperatures are between 40º–150ºC (105–302ºF). This feature is not available with 7-speed transmission models.

FM Display: An acceptable filter life status is displayed as OK in the shift selector; an unacceptable filter life status is displayed as LO. Allison DOC™ For PC–Service To ol indicates the Filter Life Monitor expired as YES or NO.

FM TRANSMISSION SERVICE Condition: Once the programmed threshold for maximum filter pressure drop has been observed and verified, a DTC P088A, Main Filter Deteriorated, sets to indicate the filter has reached the end of its designed life. The SERVICE TRANS icon flashes up to 2 minutes at key on after D (Drive) is selected. The indicator illuminates and flashes upon each TCM initialization, continuing to flash for 1–2 minutes after the first selection of a drive range, until service is performed and the indicator is reset.

Failure to perform maintenance and reset the monitor after a calibration-defined number of warnings results in the illumination of the CHECK TRANS light. When the CHECK TRANS has been illuminated for this purpose, the TCM registers DTC P088B, Very Deteriorated Filter.

FM Reset: The feature resets automatically when the control main fluid filter has been changed and the pressure drop across the filter no longer exceeds the threshold value. The lube filter must be changed with the main filter.

The SERVICE TRANS indicator illuminates briefly following a reset to acknowledge the reset was successful.

Manual resets may also be performed by one of the following methods:

• With the ignition ON and the engine OFF, shift between N R N R N D N to reset the value

displayed on the shift selector to OK.

• Display the Filter Life Monitor information and press and hold the MODE button of the Allison

shift selector for 10 seconds.

• Message over the SAE J1939 communication interface.

NOTE: The Filter Life Monitor triggers the SERVICE TRANS icon following a reset if the Filter Life

indicator switch reopens.

3000 AND 4000 PRODUCT FAMILIES TROUBLESHOOTING MANUAL—ALLISON 4th GENERATION CONTROLS

DEFINITIONS AND ABBREVIATIONS

Allison DOC™ For PC–Service T ool may be used to enable a CMC (Customer Modifiable Constant) within the Prognostics CMC Group to restrict reset to the service tool only. If resets are restricted to the service tool, the selector will not be able to reset the function.

FM History: Use the Allison DOC™ For PC–Service Tool to display the amount of transmission operation from the initial service indication until the service reset.

NOTE: Required calendar-based filter change intervals are not monitored by this feature and remain

applicable to all vehicle installations in addition to the above.

C. Operation of Filter Life Valve and Pressure Switch (PS2)

Pressure Switch 2 (PS2), also known as the Filter Life Switch, is used to monitor the pressure difference between main pressure before the filter and lockup clutch pressure as a method to monitor the main filter for excessive filter restriction. See Figure 1.

When the main filter is in an unrestricted state and lockup clutch pressure is applied, the switch is depressurized and in its Normally closed (NC) position which completes a circuit between wire 118 and analog returns wire 158. Allison DOC™ For PC–Service Tool shows PS2 EXHAUSTED. The Filter Life Valve is de-stroked off the return spring in this condition because lockup pressure is high enough to keep main pressure (before the filter) from stroking the valve.

When the main filter gets excessively restricted by debris, lockup pressure drops. The Filter Life Valve strokes because of the higher main pressure (before the filter). This acts on the other end of the Filter Life Valve, compressing the return spring and allowing control main pressure through the valve to PS2, which pressurizes the switch. This opens the PS2 and voltage is sensed on wire 118. Allison DOC™ For PC–Service Tool shows PS2 PRESSURIZED.

3000 AND 4000 PRODUCT FAMILIES TROUBLESHOOTING MANUAL—ALLISON 4th GENERATION CONTROLS

DEFINITIONS AND ABBREVIATIONS

MAIN CIRCUIT FILTER

FILTER LIFE VALVE

MAIN PRESSURE

(BEFORE FILTER)

PUMP

SUCTION FILTER

SUMP

FILTERED

MAIN

FILTER LIFE VALVE HYDRAULIC SCHEMATIC

Figure 2–1. Filter Life Valve Hydraulic Schematic

D. Transmission Health Monitor (TM)

MAIN FLOW

PS 2

CONTROL MAIN

TCC FLOW

FILTERED MAIN

LUBE

V11111.00.00

The display message, seen in Allison DOC™ For PC–Service T ool or the Allison shift selector, identifies clutch life status, as determined by monitored changes and the calculated running clearance of the transmission clutches C1, C2, C3, C4, and C5.

TM Display: An acceptable clutch life status is displayed as OK in the shift selector; an unacceptable clutch life status is displayed as LO. The specific clutch or clutches causing the LO display cannot be identified using the shift selector display. Allison DOC™ For PC–Service Tool displays clutch condition as OK or NOT OK for each clutch, C1 through C5. Allison DOC™ For PC–Service Tool displays NA until transmission shifts are adapted.

TM TRANSMISSION SERVICE Condition: The SERVICE TRANS indicator illuminates, indicating the need for clutch maintenance. This occurs when the remaining clutch life reaches

3000 AND 4000 PRODUCT FAMILIES TROUBLESHOOTING MANUAL—ALLISON 4th GENERATION CONTROLS

DEFINITIONS AND ABBREVIATIONS

approximately 10 percent or the running clearance exceeds a maximum value, which may indicate a non-wear-related issue. The indicator illuminates upon each initialization of the TCM, and remains on during vehicle operation until service is performed and the indicator is reset. Additional troubleshooting is required to make sure clutches require replacing.

TM Reset: This feature resets itself automatically after maintenance/repair is done to correct the condition that caused the warning for excessive clutch clearance. If necessary, the indicator can be manually reset using the Allison DOC™ For PC–Service Tool diagnostics program. After a number of warnings occur from the SERVICE TRANS indicator without correcting the condition, the CHECK TRANS light illuminates and DTC P2789, Clutch Adaptive Learning at Limit, activates.

TM History: Use the Allison DOC™ For PC–Service T o ol to display the amount of transmission operation from the initial service indication until the service reset.

2–2. ALLISON TRANSMISSION DIAGNOSTIC TOOL

Allison DOC™ (Diagnostic Optimized Connection) For PC–Service Tool is a PC-based diagnostic tool for use with 3000 and 4000 Product Families transmissions. The Allison DOC™ For PC–Service Tool is a full-feature diagnostic software application supporting the Allison 4 own PC, it will allow the technician to acquire data from the transmission’s control system and through the use of embedded troubleshooting manuals, conduct systematic troubleshooting of transmission complaints.

Generation Control System. When installed on the user’s

Basic Features

Allison DOC™ For PC–Service Tool uses a Windows

• User selected views of multiple transmission parameters

• Active and historical diagnostic trouble codes (DTCs)

• Graphical instrument panel view of transmission parameters

• Strip chart function

• User configurable Snapshot function

• User configurable Print function

• Code driven links to embedded Allison 4

• Reprogramming capability (available after satisfying Allison Transmission training certification

requirements)

• Demo Mode which allows the user to practice the program without being connected to a vehicle

• New animated screen by screen help support (found in Help, V ideo-based training materials, Allison

DOC™ For PC–Service To ol Training Videos)

• Application Configuration—This menu function serves as the platform for three different features:

(1) General tab, which allows the user to select language (English only at this time), and unit of measure. (2) TCM Reprogramming tab, used to enable the reprogramming capability of the Allison DOC™ For

PC–Service Tool .

(3) Update Application tab, which provides access to a URL containing minor updates for the diagnos-

tic tool to support changes in the various transmission control systems.

• Data Bus Viewer allows the user to capture (see and save) the raw data transmitted on the various

vehicle data buses supported by Allison DOC™ For PC–Service Tool (J 1939 and J 2284)

• Printed user’s manual and laminated Job Aid Card

• Adobe

• Microsoft



Acrobat Reader® bundled on the CD for reading the Troubleshooting Manual



Media Player bundled on the CD for displaying various and updated training videos

(available from the application Help menu).

 style graphical user interface (GUI) and includes:

Generation Control System Troubleshooting Manuals

3000 AND 4000 PRODUCT FAMILIES TROUBLESHOOTING MANUAL—ALLISON 4th GENERATION CONTROLS

DEFINITIONS AND ABBREVIATIONS

PC Platform Definition

Allison DOC™ For PC–Service Tool V7.x.x has been tested with and is known to operate on PCs with the following configurations*:

• Microsoft Windows XP® Professional, Wind ows 2000 (SP4 or later) Professional, and Windows

Vista™ Home Basic (or better)

NOTE: In order to install and run Allison DOC for PC–Service Tool V7.x.x on Windows Vista™, the user

must have full administrator privileges and must have the User Acount Control feature turned OFF.

• 20 GB Hard Drive (40 GB or greater recommended)

• 600 MB free hard drive space required to install the program (after software installation, the operating

system requires sufficient free hard disk dpace to run the program)

• 1 GHz (or greater) 32-bit (x86) or 64-bit (x64) processor

• 512 MB of RAM system memory (1 GB recommended)

• One available USB port—USB 1.1 (USB 2.0 recommended)

• 16x CD-ROM (48x or greater recommended)

• Full administrative privileges are required to install, update, and run Allison DOC™ For PC–Service

Tool

• Internet connection capability with Internet Explorer® 5.0.1 or greater.

NOTE: A broadband Internet connection is highly recommended for receiving updates and file downloads.

• Windows Media® Player is installed by default

• Adobe® Acrobat Reader® is installed by default

NOTE: Error messages, sudden disconnections, and poor performance are some of the results users will



experience if Allison DOC

For PC-Service Tool V7.x.x is installed on PCs that do not meet one or

more of the above specifications.

NOTE: For the latest requirements, please refer to www.allisontransmission.com/Service/Electronic

(Diagnostic) Tools/Requirements or the latest revision of Service Information Letter 12-TR-07, Rev. A.

3000 AND 4000 PRODUCT FAMILIES TROUBLESHOOTING MANUAL—ALLISON 4th GENERATION CONTROLS

DEFINITIONS AND ABBREVIATIONS

2–3. 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 Unit of electrical current API Application Program Interface AT Allison Transmission

C1...C6 Clutch 1....Clutch 6

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

(engine, transmission, ABS, etc.) CIN Calibration Identification Number CMC Customer Modified Constant CPA Connector Position Assurance CT Closed Throttle DCE Direction Change Enable DMM Digital Multimeter 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 DOC Diagnostic Optimized Connection DPA Dearborn Protocol Adapter DTC Diagnostic Trouble Code DVOM Digital Volt/Ohmmeter ECM Engine Control Module EMI ElectroMagnetic Interference FBO F eature Based Ordering FCC Federal Communications Commission FM Filter Life Monitor GPI General Purpose Input—Input signal to the TCM to request a special operating mode or

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 GUI Graphical User Interface HSD High Side Driver J1587 Engine/transmission serial data communications link J1939 High-speed vehicle serial data communications link

3000 AND 4000 PRODUCT FAMILIES TROUBLESHOOTING MANUAL—ALLISON 4th GENERATION CONTROLS

DEFINITIONS AND ABBREVIATIONS

2–3. ABBREVIATIONS (cont’d)

LED Light-Emitting Diode—Electronic device used for illumination LRTP Low Range Torque Protection LSD Low Side Driver MB Mega Byte NNC Neutral No Clutches—Neutral commanded with no clutches applied NVL Neutral Very Low—The TCM has sensed turbine speed below 150 rpm when output speed

is below 100 rpm and engine speed is above 400 rpm when N (Neutral) was selected. This is usually caused by a dragging C1 or C3 clutch or a failed turbine speed sensor. NVL is attained by turning D solenoid “ON” (in addition to E solenoid) and the C4 and C5

clutches are applied to lock the transmission output. OEM Original Equipment Manufacturer—Maker of vehicle or equipment Ohm Unit of electrical resistance OL Over Limit or Oil Level—For Over Limit see “”. Indicates Oil Level is being displayed

on a shift selector OLS Oil Level Sensor—Electronic device (optional) on control module for indicating

transmission fluid level OM Oil Life Monitor PC Personal Computer PCCS PROM Calibration Configurator System PCS Pressure Control Solenoid PLR Primary Lock Reinforcement (Connector) P/N Part Number PROM Programmable Read Only Memory PSS Primary Shift Selector—Main shift selector in a two-selector control system. PTO Power Takeoff PWM Pulse Width Modulation RELS Reduced Engine Load at Stop RFI Radio Frequency Interference RMR Retarder Modulation Request—Signal from a retarder control device RPR Return to Previous Range—Diagnostic response in which the transmission is commanded

to return to previously commanded range RTDR Retarder SCI Serial Communication Interface—Used to transmit data and messages between the

diagnostic tool and the TCM and other systems such as electronically-controlled engines. SCTI St. Clair Technologies, Inc. SEM Shift Energy Management

3000 AND 4000 PRODUCT FAMILIES TROUBLESHOOTING MANUAL—ALLISON 4th GENERATION CONTROLS

DEFINITIONS AND ABBREVIATIONS

2–3. ABBREVIATIONS (cont’d)

S/N Serial Number SOH State Of Health SOL OFF All SOLenoids OFF SPI Serial Peripheral Interface—The means of communication between the microprocessor

and the interface circuits SS Shift Solenoid SSS Secondary Shift Selector—Alternate shift selector in a two-selector control system TCC Torque Converter Clutch TCM Transmission Control Module TFT Transmission Fluid Temperature TID TransID—A feature which allows the TCM to know the transmission configuration and

provide the corresponding calibration required TM Transmission Health Monitor TPA Terminal Position Assurance TPS Throttle Position Sensor—Potentiometer for signaling the position of the engine fuel

control lever V Version—Abbreviation used in describing TCM software levels VDC Volts Direct Current (DC) VF Vacuum Fluorescent VIM Vehicle Interface Module—A watertight box containing relays and fuses—interfaces the

transmission electronic control system with components on the vehicle VIW Vehicle Interface Wiring—Interfaces TCM programmed input and output functions with

the vehicle wiring Volt Unit of electrical force WOT Wide Open Throttle  Infinity—Condition of a circuit with higher resistance than can be measured, effectively an

open circuit

3000 AND 4000 PRODUCT FAMILIES TROUBLESHOOTING MANUAL—ALLISON 4th GENERATION CONTROLS

DEFINITIONS AND ABBREVIATIONS

3000 AND 4000 PRODUCT FAMILIES TROUBLESHOOTING MANUAL—ALLISON 4th GENERATION CONTROLS

SECTION 3—BASIC KNOWLEDGE

3–1. BASIC KNOWLEDGE REQUIRED

To service Allison 4th Generation Controls, the technician must understand basic electrical concepts. Most troubleshooting tests consist of determining resistance, continuity, and testing for shorts between wires and to ground. Technicians need to know how to use a digital volt/ohmmeter (DVOM) to make resistance and continuity tests. The technician should be able to use jumper wires and breakout harnesses and connectors. Technicians unsure of making the required tests 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—Determining Clutch and Retarder Pressures.

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 the Allison 4

Generation Controls vehicle installation is

necessary in troubleshooting installation-related problems. Refer to Section 8 for information concerning performance complaints (non-code) troubleshooting. A complete

wiring schematic is shown in Appendix J. Refer to the Allison 4

Generation Controls and General Information Tech Data Book for information concerning electronic controls installation and the Installation Checklist. Reliable transmission operation and performance depend upon a correctly installed transmission. Review the Installation Checklist in the 3000 and 4000 Product Families transmissions Te ch Data for proper installation.

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

follows:

• Repair parts for the internal wiring harness and for wiring harness components attached to the

• Repair parts for the external harnesses and external harness components must be obtained from

St. Clair Technologies, Inc. 920 Old Glass Road Wallaceburg, Ontario, Canada N8A 4L8 Phone: 519-627-1673 Fax: 519-627-4227

St. Clair Technologies, Inc. Calle Damanti S/N Col Guadalupe—Guaymas Sonora, Mexico 85440 Phone: 011-526 2222-43834 Fax: 011-526-2222-43553

3–2. USING THE TROUBLESHOOTING MANUAL

Use this manual as an aid to troubleshooting the 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 be sure of 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.

3000 AND 4000 PRODUCT FAMILIES TROUBLESHOOTING MANUAL—ALLISON 4th GENERATION CONTROLS

BASIC KNOWLEDGE

3–3. SYSTEM OVERVIEW

Allison 4th Generation Control functions are controlled by the TCM. The TCM reads the following to determine when to command a shift:

• Shift selector range selection

• Output speed

• Throttle position.

In order to control the oncoming and off-going clutches during a shift, the TCM monitors:

• Turbine speed

• Output speed

• Throttle position.

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.

3–4. IMPORTANT INFORMATION IN THE TROUBLESHOOTING PROCESS

A. Before Beginning Troubleshooting

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

• Allison Transmission recommended wire numbers (i.e. 158) all use a “1” for the first digit and the

pin-out information at the TCM for the second and third digits.

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

• Remember to do the following when testing 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 the pulling force is applied to the connector itself

and not the wires extending from the connector.

• Resistance tests involving wiring between the TCM connector and other components adds about

one Ohm of resistance to the component resistance shown.

• Inspect all connector terminals for damage. Terminals may have been 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

NoFlash Electro Contact Cleaner

or LPS

3000 AND 4000 PRODUCT FAMILIES TROUBLESHOOTING MANUAL—ALLISON 4th GENERATION CONTROLS

BASIC KNOWLEDGE

The cleaning solvent must not be:

• Chlorine based

• Contain petroleum distillates

CAUTION:

• Conduct electricity.

The cleaning solvent should evaporate quickly to prevent the 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, latest revision, for detailed information on the recommended cleaners.

CAUTION:

• DTCs displayed after system power is turned on with a harness connector disconnected, can be

Care should be taken when welding on a vehicle equipped with electronic controls. Refer to Appendix G, Paragraph 1–1.

ignored and cleared from memory. Refer to Section 6, Diagnostic Trouble Codes, for the code clearing procedure.

NOTE: Turn off the vehicle HIGH IDLE switch, if present, before shifting from N (Neutral) to D (Drive).

D (Drive) or R (Reverse) will not be attained unless the shift is made with the engine at idle. Also, be aware of other interlocks that would prevent attaining D (Drive) or R (Reverse). Examples are “wheelchair lift not stored” and “service brakes not applied” (service brake interlock present).

B. Cold Weather Starts

All Highway Series transmissions are programmed to restrict full operation until specific fluid temperatures are reached. Refer to the Table 3–1 for temperature restrictions.

Table 3–1. Minimum Fluid Operating Temperatures

Sump Fluid Temperature

CHECK TRANS

Light

Operation

–32ºC to –7ºC (–25ºF to 19ºF) OFF Neutral, Reverse, Second

–7ºC (19ºF) OFF Full operation in all ranges

NOTE: When sump temperature is below 10ºC (50ºF) and transmission fluid is C4 (not DEXRON

TranSynd™), follow these procedures when making directional shift changes:

• To shift from forward to reverse, select N (Neutral) and then R (Reverse).

• To shift from reverse to forward, select N (Neutral) and then D (Drive) or other forward range.

Failure to follow these procedures may cause illumination of the CHECK TRANS light and the transmission will be restricted to N (Neutral).

Transmission operation at cold ambient temperatures may require preheating or the use of a lower viscosity transmission fluid.

3000 AND 4000 PRODUCT FAMILIES TROUBLESHOOTING MANUAL—ALLISON 4th GENERATION CONTROLS

BASIC KNOWLEDGE

C. High Fluid Temperature

The transmission is considered to be overheated when any of the temperatures in Table 3–2 are exceeded:.

Table 3–2. Maximum Allowable Transmission Fluid Temperature

Location of Fluid Temperature

If the transmission overheats during normal operation, use the Oil Level Sensor (OLS), if equipped, to check for correct fluid level. Refer to Section 5-2 for this procedure.

CAUTION:

If the engine temperature gauge indicates a high temperature, the transmission is probably overheated. Stop the vehicle and inspect the cooling system. If it appears to functioning p[roperly , run the engine at 1200 transmission and engine temperature to normal operating levels in two to three minutes. If temperatures do not decrease, reduce the engine rpm.

If the engine temperature indicates a high temperature, an engine or radiator problem is indicated. If high temperature in either the engine or transmission persists, stop the engine and have the overheating condition investigated by maintenance personnel.

Sump fluid 121

Fluid to cooler 149

Retarder out fluid 165

The engine should never be operated for more than ten (10) seconds at full throttle with the transmission in range and the output stalled. Prolonged operation of this type will cause the transmission fluid temperature to become excessively high and will cause severe overheat damage to the transmission.

ºC (250ºF) ºC (300ºF) ºC (330ºF)

–1500 rpm with the transmission in N (Neutral). This should reduce the

3–5. BEGINNING THE TROUBLESHOOTING PROCESS

NOTE:

• Whenever a transmission is overhauled, exchanged, or has undergone internal repairs, the TCM MUST

BE RESET TO FACTORY VALUES by selecting “Reset To Unadapted Shifts” (all), and “Reset Autodetect Information” in Allison DOC

• Be sure the transmission model matches the calibration in the TCM.

1. Begin troubleshooting by determining the transmission fluid level and TCM input voltage. Remember that some problems may be temperature related. Do troubleshooting at the temperature level where the problem occurs. Determine if DTCs have set by:

• Using the shift selector display (see Paragraph 6–2 for code reading).

• Using the Allison DOC For PC–Service Tool.

2. When a problem exists but a DTC is not indicated, refer to the Performance Complaint Section (Section

8) 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 code information and clear the active indicator. Refer to Section 6.

 For PC–Service Tool.

3000 AND 4000 PRODUCT FAMILIES TROUBLESHOOTING MANUAL—ALLISON 4th GENERATION CONTROLS

BASIC KNOWLEDGE

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

• If the code reappears, refer to Section 6, Diagnostic Trouble Code, and the appropriate code chart.

The Diagnostic Trouble Code section lists DTCs and their description. Locate the appropriate troubleshooting chart and follow the instructions.

• If the code does not reappear, it may be an intermittent problem. Use the Allison DOC For PC–

Service Tool and the code display procedure described in Section 6. The code display procedure will indicate the number of times the DTC has occurred. Refer to the troubleshooting chart for the possible cause(s) of the problem.

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

circuit problem is suspected.

5. If difficulties arise, you have unanswered questions, or if you are unable to quickly identify the root cause during troubleshooting, please contact the Technical Assistance Center (TAC):

Technical Assistance Center PO Box 894, Mail Code A01 Indianapolis, IN 46206-0894 Phone: 1-800-252-5283

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

• Use the Allison DOC For PC–Service T ool to 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 connector for damaged or bent pins.

• Replace the TCM with a known, good TCM from a similar vehicle.

NOTE: If using a TCM from another vehicle is unavoidable, the TCM MUST BE set to factory values and the

vehicle MUST BE driven carefully to adapt the shifts to the test vehicle. Refer to SIL 16-WT-96 for the correct procedure. Be sure to reset the Adaptive Shift parameters and Autodetect information when it is installed in the original vehicle.

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

complaint returns. If the complaint is confirmed. install a new TCM.

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

TCM can often correct faulty wiring harness connections that may have been present.

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

NOTE: All Allison 4

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

Generation Controls TCMs are designed to be isolated from the vehicle chassis ground.

3000 AND 4000 PRODUCT FAMILIES TROUBLESHOOTING MANUAL—ALLISON 4th GENERATION CONTROLS

BASIC KNOWLEDGE

3–7. RESETTING A 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 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 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 engine current SEM status.

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

Paragraph 3–8).

3–8. RESETTING TCM AUTOSELECT

Verify a new engine rating by checking the engine data tag. The engine must be compatible with the transmission rating. If 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

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

 for PC–Service Tool is used to reset Autoselect function as follows:

• Display the Action Request menu.

• On the drop down menu, select Reset SEM Autodetect.

• Click on the OK button.

vehicle to allow shift to converge.

3–9. HYDRAULIC OPERAT ION DURING ELECTRICAL INTERRUPTION

NOTE: The terms left, right, up, and down are directions on the figures and hydraulic schematics referenced

by the descriptions in this section.

The solenoid regulator valves are controlled by solenoids that control transmission clutch application. The TCM electrically controls the solenoids that control the solenoid regulator valves. Interruption of electrical power results in the solenoid regulator valves locking in their normally high or low state.

The system that enables the transmission to default to totally hydraulic operation has been incorporated to minimize the impact of an electrical interruption. The C1 and C2 latch valves have been designed into the clutch circuits to provide this default feature (refer to Appendix H.).

When a clutch is applied, clutch feed pressure is routed through the latch valves to the clutch piston. Clutch-apply pressure against the lands of the latch valves hold the latch valves in place or in a normally closed valve allows the fluid to simply flow through the valves. During an electrical interruption, the latch valves cause the transmission to engage specific clutches based on the range in which the transmission was operating when the interruption occurred.

3000 AND 4000 PRODUCT FAMILIES TROUBLESHOOTING MANUAL—ALLISON 4th GENERATION CONTROLS

BASIC KNOWLEDGE

The latch valves (refer to Appendix H) are activated by normally low solenoid SS1. When SS1 is energized, control main pressure flows to the top of C1 and C2 latch valves. This pressure forces the valves down to connect the necessary flow passages for clutch engagement. The exception is when C5 clutch is applied. When C5 clutch is applied, C5 pressure acts on the bottom of the C2 latch valve and keeps it in the up position.

During an electrical interruption, the latch valves and two normally high, PCS1 and PCS2, enable the transmission to operate in a “limp mode”, allowing the operator to drive the vehicle to a location where it can be serviced.

On 7-speed models, SS2 latch valve takes the place of C5 on the bottom of the C2 latch valve. When SS2 is on, the valve is kept up by SS2.

The default system enables the transmission to revert to total hydraulic operation and provides safe operation during an electrical interruption by shifting to a specific pre-determined range.

T able 3–3 lists the operating range and pre-determined default range the transmission will shift to in the event of an electrical interruption.

Table 3–3.

Initial Operating Range

Reverse

Neutral

Hydraulic Default Range*

(Power Off; All Solenoids OFF)

Neutral

(C3 Clutch Applied)

Neutral

(C3 Clutch Applied)

Low (7-speed only) 3

3 (during shift to 2

4 (following shift) 34 44 54

* Some transmissions used in oil field service default to neutral

when power is OFF.

4 (during shift to 6

5 (following shift)

)

3000 AND 4000 PRODUCT FAMILIES TROUBLESHOOTING MANUAL—ALLISON 4th GENERATION CONTROLS

BASIC KNOWLEDGE

NOTES

3000 AND 4000 PRODUCT FAMILIES TROUBLESHOOTING MANUAL—ALLISON 4th GENERATION CONTROLS

SECTION 4—WIRE TEST PROCEDURES

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

(Use Digital Volt/Ohmmeter J 34520-A and Jumper Wire Set J 39197 or 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-test the circuit.

2. Disconnect and inspect all connectors.

Observe the following assembly precautions when mating TCM 80-way Cam-Assist connectors (used in GM truck applications):

• Bring the connector to the TCM “squared up”, not at an angle.

• Keep hands away from the handle, squarely press the connector onto the

CAUTION:

Failure to do so could cause damage to the internal latching mechanism.

TCM until the cam lever handle moves of its own accord approximately

⁄4 inch.

• Gently complete mating the connector to the TCM by moving the cam lever

handle to the locked position.

• Slide the CPA into the secondary lock.

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

• Conduct electricity.

CAUTION:

4. Review the Allison 4

Generation Controls wire numbering system described in Paragraph 3–4.

5. If all connectors are clean and connected correctly, determine which wires in the chassis harness are indicated by the DTC. For example, Code P0960, indicates an open in the pressure control solenoid circuit, wires 111 and 174.

a. Test continuity of wires 111 and 174 by performing the following (Figure 4–1):

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

main connector. At one end of the harness, us ing jumper wire kit J 39197 or J 39197-A, connect wires 111 and 174 to each other, being careful not to distort the terminals. Jumpering the wires together creates a circuit between wires 111 and 174.

CAUTION:

Do not insert test probes larger than 0.81 mm into the TCM 80-way and transmission 20-way connectors. Use the gray-colored 150 Series Metripack Flexible Male Connector probe contained in Jumper W ire Kit J 39197 or 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.

3000 AND 4000 PRODUCT FAMILIES TROUBLESHOOTING MANUAL—ALLISON 4th GENERATION CONTROLS

WIRE TEST PROCEDURES

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

jumpered pair circuit (infinite resistance reading) indicates an open in the wire being tested. Locate and repair the damaged portion of the wire.

b. If the continuity test is good (0–2 Ohms resistance), remove the jumpers. Test the ha rness for

shorts between wires and shorts-to-ground by performing the following (Figure 4–2): (1) At the TCM end of the harness, touch one probe of a digital volt/ohmmeter (DVOM) 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.

BULKHEAD CONNECTOR

WIRING HARNESS

FEEDTHROUGH

HARNESS

CONNECTOR

DIGITAL

VOLT/OHM-METER

(DVOM)

JUMPER

–

WIRING HARNESS

–

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.

0 OHMS OHMS

Circuit has continuity.

Jumper between wires produces

a complete circuit.

DVOM reading is near zero Ohms.

TRANSMISSION CONNECTOR

TCM 80-WAY CONNECTOR

DIGITAL VOLT/OHM-METER (DVOM)

Figure 4–2. Shor t Between Wires and to Ground

Figure 4–1. Open Circuit

Wires shorted together

–

shorted-to-ground. DVOM continuity beeper will sound,

or reading will go to zero Ohms when meter is probing

–

Circuit does not have continuity due

to a broken wire (open circuit).

DVOM reading is very high

(infinite Ohms or OL – overlimit).

Shorted to ground on metal frame rail

Ground to metal frame rail

0 OHMS0 OHMS

Harness has been chafed and one or more wires are

between this wire and chassis ground.

V03374.02.00

V03375.01.00

3000 AND 4000 PRODUCT FAMILIES TROUBLESHOOTING MANUAL—ALLISON 4th GENERATION CONTROLS

WIRE TEST PROCEDURES

4–2. TESTING AT TRANSMISSION FEEDTHROUGH CONNECTOR FOR INTERNAL

HARNESS 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

CAUTION:

3. If the connectors are clean and connected correctly, determine which wires in the harness to test. Use the DTC system schematic to locate the wire terminals. For this example, Code P0960 indicates an open in the Main Mod solenoid circuit, wires 111 and 174 (Figures 4–3 and 4–4).

• Conduct electricity.

a. At the transmission connector, test the resistance of Main Mod solenoid circuit. Resistance of a

solenoid circuit should be 4.0 to 7.8 Ohms, covering a temperature range of –20°C to 140°C (–4°F to 284°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. Locate and repair the open in the internal harness or replace the internal harness, replace the feedthrough connector, or the solenoid.

FEEDTHROUGH HARNESS CONNECTOR

DIGITAL VOLT/OHM-METER (DVOM)

AT NORMAL OPERATING

5.0

–

2–5 OHMS

TEMPERATURE*

Circuit has continuity.

* Refer to Appendix J

LOCATED IN INTERNAL WIRING HARNESS

SOLENOID

–

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.

SOLENOID

V03376.01.00

Figure 4–3. Checking Continuity

3000 AND 4000 PRODUCT FAMILIES TROUBLESHOOTING MANUAL—ALLISON 4th GENERATION CONTROLS

WIRE TEST PROCEDURES

b. If the resistance test is good, test the harness for shorts between wires and to ground by performing

the following (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 tested. Review the wiring diagram in Appendix J for splice locations. If the short is not a splice, then isolate and repair the short.

FEEDTHROUGH

HARNESS

CONNECTOR

–

VOLT/OHM-METER

DIGITAL

(DVOM)

LOCATED IN INTERNAL

WIRING HARNESS

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 4–4. Shor t Between Wires and to Ground

Bare wires touching each other

SOLENOIDS

–

Shorted to metal

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.

SOLENOID

V03377.01.00

NOTE: When conducting circuit tests that include the external harness, add one (1) Ohm to the values shown.

Speed sensor resistance is 270–330 Ohms. PS1 diagnostic pressure switch resistance is two (2) Ohms maximum when switch is closed and 20,000 Ohms minimum when switch is open.

3000 AND 4000 PRODUCT FAMILIES TROUBLESHOOTING MANUAL—ALLISON 4th GENERATION CONTROLS

SECTION 5—FLUID CHECK PROCEDURES

5–1. OIL LEVEL SENSOR (OLS) INTRODUCTION

The oil level sensor (refer to Figure 5–1) provides a means to electronically determine the transmission fluid level from:

• The shift selector display

• Allison DOC™ For PC–Service T ool

• A customer-supplied remote display.

V07087.01.00

Figure 5–1. Oil Level Sensor

The Allison 4th Generation Controls oil level sensor (OLS) is a one-piece unit with a molded 3-terminal connector built into the sensor housing (refer to Figure 5–1 and SIL 19-WT-99 for more details). The internal wiring harnesses have been designed to include the 3-terminal connector for the OLS.

NOTE: The OLS is standard on all 3000 and 4000 Product Families transmissions except 3000 Product

Family 7-speed transmissions.

Figure 5–2 shows the position and orientation of the OLS on the control modules of the 3000 and 4000 Product Families transmissions. The OLS must be correctly positioned so the internal harness connector reaches the connector on the sensor. The control module must fit onto the transmission main case without interference. The one piece design reduces the complexity of the manufacturing and installation of the sensor. The current OLS uses

shoulder bolts and Viton

ferrules to provide vibration dampening in the mounting.

3000 AND 4000 PRODUCT FAMILIES TROUBLESHOOTING MANUAL—ALLISON 4th GENERATION CONTROLS

FLUID CHECK PROCEDURES

OIL LEVEL SENSOR

6-SPEED

3000 PRODUCT FAMILY

CONTROL MODULE

OIL LEVEL SENSOR

6-SPEED

4000 PRODUCT FAMILY

CONTROL MODULE

OIL LEVEL SENSOR

7-SPEED

4000 PRODUCT FAMILY

CONTROL MODULE

V09271.00.00

Figure 5–2. Current Oil Level Sensor Orientation

3000 AND 4000 PRODUCT FAMILIES TROUBLESHOOTING MANUAL—ALLISON 4th GENERATION CONTROLS

FLUID CHECK PROCEDURES

5–2. ELECTRONIC FLUID LEVEL READING (SHIFT SELECTOR)

CAUTION:

NOTE: The pushbutton and lever shift selectors can display two characters at a time. The strip pushbutton

shift selector does not have diagnostic or display capability. Allison DOC™ For PC–Service Tool or a customer-supplied remote display must be used to obtain fluid level information when using the strip pushbutton shift selector.

A. Fluid Level Reading Procedure

1. Park the vehicle on a level surface and shift to N (Neutral). Apply the parking brake.

2. On the Pushbutton shift selector, simultaneously press the ↑ (Up) and ↓(Down) arrow buttons once.

3. On the Lever shift selector, press the “display mode” button once.

4. For a strip pushbutton shift selector , refer to Allison publication GN3433EN, User Guide for

Allison DOC

NOTE: The TCM may delay the fluid level reading until the following conditions are met:

• The fluid temperature is between 60°C (140°F) and 104°C (220°F).

• The transmission is in N (Neutral).

• The vehicle has been stationary for approximately two minutes to allow the fluid to settle.

A low or high fluid level causes overheating and irregular shift patterns. An incorrect fluid level can damage the transmission.

™ For PC–Service Tool.

• The engine is at idle (below 1000 rpm—not “fast” idle).

Refer to “Invalid for Display” information in Steps (8) and (9).

5. Correct fluid level is reported when oL is displayed (oL indicates the Oil Level Check Mode),

followed by oK. The oK display indicates the fluid level is within the proper fluid level zone. The sensor display and the transmission dipstick may not agree exactly because the oil level sensor compensates for fluid temperature.

Example: oL; oK—Indicates correct fluid level.

6. Low fluid level is reported when oL is displayed, followed by Lo and a number. Lo indicates a

low fluid level and the number is the number of quarts of fluid the transmission requires. Example: oL; Lo; 2—Indicates two (2) additional quarts of fluid will bring the fluid level within

the proper fluid level.

3000 AND 4000 PRODUCT FAMILIES TROUBLESHOOTING MANUAL—ALLISON 4th GENERATION CONTROLS

FLUID CHECK PROCEDURES

7. High fluid level is reported when oL is displayed, followed by HI and a number. HI indicates high

fluid level and the number shows how many quarts the transmission is overfilled. Example: oL, HI, 1—Indicates one quart of fluid above the full level.

8. An Invalid for Display condition is reported when oL is displayed, followed by “–” and a number

display . The displayed number is a fault code and indicates improper conditions or a system malfunction.

Example: oL, –, 7 0—Indicates an Invalid for Display condition and fault code 70.

9. Invalid for Display is activated when conditions do not allow the fluid level to be checked electronically . Review the following codes and conditions, and correct as necessary.

Table 5–1. Invalid for Display Codes

Display (Old)

Display (MY08e,

Cal/Sfw or newer)

Cause of Code

oL, - -,0X oL, - -,0X* Settling time too short* oL, - -,50 oL, - -,EL Engine speed (rpm) too low oL, - -,59 oL, - -,EH Engine speed (rpm) too high oL, - -,65 oL, - -,SN Neutral must be selected oL, - -,70 oL, - -,TL Sump fluid temperature too low oL, - -,79 oL, - -,TH Sump fluid temperature too high oL, - -,89 oL, - -,SH Output shaft rotation oL, - -,95 oL, - -,FL Sensor failure**

* A number between 8 and 1 that flashes during the countdown period. ** Speed sensor, throttle sensor, temperature sensor, or oil level sensor.

10. To exit the fluid level display mode:

• Pushbutton shift selector—press the N (Neutral) pushbutton or press ↑ (Up) and ↓ (Down)

arrow pushbuttons simultaneously two times.

• Lever shift selector—press the “DISPLAY MODE” button two times or move the lever.

3000 AND 4000 PRODUCT FAMILIES TROUBLESHOOTING MANUAL—ALLISON 4th GENERATION CONTROLS

FLUID CHECK PROCEDURES

5–3. ELECTRONIC FLUID LEVEL READING (ALLISON DOC™ FOR PC–SERVICE

TOOL)

Allison DOC™ For PC–Service Tool can also be used to electronically read the transmission’s fluid level (refer to Allison publication GN3433EN, User Guide for Allison DOC

™ For PC–Service Tool for further information).

CAUTION:

A. Fluid Level Check Procedure

1. Connect the Allison DOC

2. Select Diagnostic button.

3. Scroll down the Diagnostic Data List to “Custom Data Monitor” display.

4. Select “oil level deviation.”

5. Read the fluid level deviation, repeat the reading to confirm the first reading.

NOTE: The TCM may delay the fluid level reading until the following conditions are met:

• The fluid temperature is between 60°C (140°F) and 104°C (220°F).

• The transmission is in N (Neutral).

• The vehicle has been stationary for approximately two minutes to allow the fluid to settle.

• The engine is at idle.

The reason for a delayed fluid level reading is indicated on the Allison DOC following diagnostic messages.

A low or high fluid level causes overheating and irregular shift patterns and, if not corrected, can damage the transmission.

™ For PC–Service Tool to the diagnostic tool connector (Figure 1–2).

™ For PC–Service Tool by one of the

Table 5–2. Diagnostic Message

O L — SETTLING TIME (8 down to 1) O L — ENGINE SPEED LO O L — ENGINE SPEED HI O L — SELECT N (NEUTRAL) O L — SUMP TEMP LO O L — SUMP TEMP HI O L — OUTPUT SPEED HI O L — CHECK CODES

3000 AND 4000 PRODUCT FAMILIES TROUBLESHOOTING MANUAL—ALLISON 4th GENERATION CONTROLS

FLUID CHECK PROCEDURES

5–4. COLD CHECK (Figure 5–3)

A. Purpose

The purpose of the cold check is to determine if the transmission has enough fluid to be operated safely until a hot check can be made.

The fluid level rises as fluid temperature rises. DO NOT fill above “COLD

CAUTION:

B. Cold Check Procedure

1. Park the vehicle on a level surface, chock the wheels, and apply the parking brake.

2. Run the engine at idle (500–800 rpm) for about one minute. Shift to D (Drive) and then to R (Reverse) to clear the hydraulic system of air. Then shift to N (Neutral) and allow the engine to remain at idle (500–800 rpm).

3. With the engine running, remove the dipstick from the tube and wipe clean.

CHECK” band if the transmission fluid is below normal operating temperatures. During operation an overfull transmission can become overheated, leading to transmission damage.

4. Insert the dipstick into the tube until it stops and remove. Check the fluid level. Repeat the check procedure to verify the reading.

5. If the fluid level is within the “COLD CHECK” band, the transmission can be operated until the fluid is hot enough to perform a “HOT RUN” check. If the fluid level is not within the “COLD CHECK” band, add or drain as necessary to bring the fluid level to the middle of the “COLD CHECK” band.

6. Perform a hot check at the first opportunity after normal operating temperature is reached—71– 93°C (160–200°F).

3000 AND 4000 PRODUCT FAMILIES TROUBLESHOOTING MANUAL—ALLISON 4th GENERATION CONTROLS

FLUID CHECK PROCEDURES

5–5. HOT CHECK (Figure 5–3)

When performing the Hot Check procedure, the fluid must be at operating

CAUTION:

temperature to be sure of an accurate check and help prevent transmission damage. The fluid level rises as temperature increases. During operation, an overfull transmission can become overheated leading to transmission damage.

CALIBRATION WITH RESPECT TO

SPLITLINE AND FILL TUBE

SCALE: NONE

BLADE WIDTH WHEN

CHARACTERS ARE STAMPED

BLADE WIDTH WHEN

CHARACTERS ARE DOT-MATRIX

6.35 mm REF

(0.250

in.)

4.76 mm REF (0.187

in.)

FILL TUBE

DIMENSION

(SEE CHART BELOW)

OIL

SUMP

4 INCH DEEP SUMP

2 INCH SHALLOW SUMP

7 INCH STANDARD**

Reference only dimension. Actual dimension determined by installation.*

3700 SP have 7.00 in. oil sump. **

DIMENSION

(SEE CHART BELOW)

DIMENSION

(SEE CHART BELOW)

TRANSMISSION CONTROL MODULE SPLITLINE

TRANSMISSION SUMP

DESCRIPTION

5.9 mm REF (0.23

DIMENSION

101.6 mm (4.00 in.)

LLUF

TOH

DDA

DLOC

LLUF

DLOC

DDA

in.)

DIMENSION

HOT RUN

BAND

COLD

CHECK

BAND

63.5 mm (2.50 in.)

73.7 mm (2.90 in.)

63.5 mm (2.50 in.)

86.6 mm (3.41

DIMENSION

(DETERMINED BY

INSTALLATION)

DIMENSION

45.7 mm (1.80 in.)

50.8 mm (2.00 in.)

45.7 mm (1.80 in.)

V01832.01.00

in.)

Figure 5–3. Fluid Dipstick Markings

A. Hot Check Procedure

1. Operate the transmission in D (Drive) range until normal operating temperature is reached:

• Sump temperature—71–93°C (160–200°F)

• Converter-out temperature—82–104°C (180–220°F)

If a transmission temperature gauge is not present, check fluid level when the engine water temperature gauge has stabilized and the transmission has been operated under load for at least one hour.

3000 AND 4000 PRODUCT FAMILIES TROUBLESHOOTING MANUAL—ALLISON 4th GENERATION CONTROLS

FLUID CHECK PROCEDURES

2. Park the vehicle on a level surface and shift to N (Neutral). Apply the parking brake and block the

wheels. Allow the engine to idle (500–800 rpm).

3. With the engine running, remove the dipstick from the tube and wipe clean.

4. Insert the dipstick into the tube until it stops and remove. Check fluid level. Repeat the check procedure to verify the reading.

If the fluid level is not within the “HOT RUN” band, add or drain as necessary to bring the fluid level to within the band. Safe operating level is within the “HOT RUN” band on the dipstick (refer to Figure 2–1).

5–6. KEEPING FLUID CLEAN

Containers or fillers that have been used for antifreeze or engine coolant solution

CAUTION:

must NEVER be used for transmission fluid. Antifreeze and coolant solutions contain ethylene glycol which, if put into the transmission, can cause clutch plate failure.

A. Foreign Material

Prevent foreign material from entering the transmission by using clean containers, fillers, etc. Lay th e dipstick in a clean place while filling the transmission.

5–7. FLUID RECOMMENDATIONS

NOTE: Effective January 1, 2007, General Motors no longer licenses DEXRON–III® fluids. Fluid specification TES

389 replaces DEXRON–III®. TES 389 fluids have the same fluid and filter change intervals as the former DEXRON–III®.

The seal material in transmissions beginning with transmission S/N 6510717075 has

CAUTION:

1. The hydraulic fluids (oils) used in Allison transmissions directly affect transmission performance, reliability, and durability. Use a Allison approved TES 295 fluid, DEXRON ular duty, on-highway applications.

been changed to be compatible with DEXRON–VI® fluids. DO NOT use DEXRON–VI® in transmission with earlier serial numbers.

-VI, or TES 389 for reg-

2. To be sure your fluid is qualified for use in Allison transmissions, check for an Allison approved TES 295 label, a DEXRON®-VI, or a TES 389 fluid license, or approval number on the fluid container, or consult the lubricant manufacturer . Consu lt your Allison Tr ansmission dealer or distributor before using any fluid types except those fluids qualified for use in Allison transmissions.

3000 AND 4000 PRODUCT FAMILIES TROUBLESHOOTING MANUAL—ALLISON 4th GENERATION CONTROLS

FLUID CHECK PROCEDURES

CAUTION:

3. When choosing the optimum viscosity grade of fluid to use, duty cycle, preheat capabilities, and/or

Disregarding minimum fluid temperature limits can result in transmission malfunction or reduced transmission life.

geographical location must be taken into consideration. Table 2–4 lists the minimum fluid temperatures at which the transmission may be safely operated. Preheat with auxiliary heating equipment or by running the equipment or vehicle with the transmission in neutral for a minimum of 20 minutes before attempting range operation.

Table 5–3. Transmission Fluid Operating

Temperature Requirements

Viscosity Grade Celsius Fahrenheit

0W-20 or TES 295* –30 –22

DEXRON TES 389

-VI or –27 –17

SAE 10W –20 –4 SAE 15W-40 –15 5 SAE 30 0 32 SAE 40 10 50

* “Arctic” as defined by MIL-L-46167B

(Ambient Temperature Below Which Preheat Is Required)

3000 AND 4000 PRODUCT FAMILIES TROUBLESHOOTING MANUAL—ALLISON 4th GENERATION CONTROLS

FLUID CHECK PROCEDURES

NOTES

3000 AND 4000 PRODUCT FAMILIES TROUBLESHOOTING MANUAL—ALLISON 4th GENERATION CONTROLS

SECTION 6—DIAGNOSTIC TROUBLE CODES (DTCS)

6–1. DIAGNOSTIC TROUBLE CODE MEMORY

Diagnostic Trouble Codes are logged in a list in memory (sometimes referred to as the queue), listing the most recently occurring code first and logging all active and inactive codes. The codes contained in the list have information recorded as shown in the table below (codes are examples). Access to the code list position, DTC, and active indicator is through the shift selector display. The shift selector displays only five codes, beginning with the most recent active followed by the most recent inactive DTCs.

Allison DOC™ for PC–Service Tool displays the data as shown in Table 6-1, except Code List Position, which is indicated by row number. Further details on the use of the Allison DOC™ For PC–Service Tool are presented in GN3433EN User Guide provided with each tool.

Table 6–1. Code List

Code List

Position*

DTC Active** Historic

Check

Trans

Failure

Record

Description

d1 P0880 Y Y N Y TCM Power Input Signal d2 P2723 Y Y Y Y Pressure Control Solenoid 1 Stuck Off d3 P0727 N Y N Y Engine Speed Input Circuit No Signal d4 P0610 N Y N Y TCM Vehicle Options (TID) Error d5 — — — — — —

* Displayed on shift selector only, d = diagnostic ** On shift selector, Y = Mode indicator (LED) illuminated

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

A. Code List Position (shift selector only). The position which a code occupies in the code list.

Positions are displayed as d1 through d5 (Code List Position 1 through Code List Position 5).

B. DTC. The diagnostic trouble code number referring to the general condition or area of fault detected

by the TCM. Double click on the numerical code in the DTC column to link to the specific troubleshooting instructions for the DTC.

C. Active Indicator. Indicates when a DTC is active. The MODE indicator LED on the shift selector is

illuminated or the diagnostic tool displays Y when DTC is active.

D. Historic Indicator. Indicates when the DTC has met sufficient criteria to be stored in long term

memory . Suf ficient criteria may mean the DTC occurred over a specific span of time or over multiple test cycles.

E. Check Trans Indicator. Indicates when the TCM is requesting the CHECK TRANS light as a result

of the DTC.

F. Failure Records Indicator. Indicates when Failure Records are present. Double click on Y in the

Failure Records column to display failure record information.

G. Description. Provides a brief description of the DTC. Double click on the DTC description to link to

the specific troubleshooting instructions for the DTC.

3000 AND 4000 PRODUCT FAMILIES TROUBLESHOOTING MANUAL—ALLISON 4th GENERATION CONTROLS

DIAGNOSTIC TROUBLE CODES (DTCs)

6–2. CODE READING AND CODE CLEARING

DTCs can be read and cleared by the following methods:

• Allison DOC™ For PC–Service Tool.

• Diagnostic display mode on the shift selector.

Using Allison DOC™ For PC–Service Tool is described in GN3433EN, User Guide, supplied with each tool. The method of reading and clearing codes described in this section refers to entering th e diagnosti c display mode of the shift selector.

The diagnostic display mode may be entered for viewing of codes at any speed. Active codes can only be cleared when the output speed = 0 and no output speed sensor failure is active.

NOTE: If a do not shift condition is present (CHECK TRANS light illuminated), the shift selector may or may

not respond to requested range changes.

NOTE: If an oil level sensor is present, the fluid level is displayed first. DTC display is achieved by

simultaneously pressing the a second time.

↑ (Up)

and

↓ (

Down) arrow buttons a second time or the MODE button

A. Reading Codes

1. Pushbutton Shift Selector—If the transmission contains an oil level sensor, enter the diagnostic display mode by pressing the ↑ (UP) and ↓ (DOWN) arrow buttons simultaneously twice (preMY09). If the transmission also contains MY09 Prognostics, enter the diagnostic display mode by pressing the ↑ (UP) and ↓ (DOWN) arrow buttons simultaneously five times.

2. Lever Shift Selector—If the transmission contains an oil level sensor, enter the diagnostic display mode by pressing the DISPLAY MODE/DIAGNOSTICS button twice (pre-MY09). If the transmission also contains MY09 Prognostics, ente r the diagn ostic d isp lay mo de by pressing the DISPLAY MODE/DIAGNOSTICS button five times.

The code list or queue position is the first item displayed, followed by the DTC. Each item is displayed for about one second. The display cycles continuously until the next code list position is accessed by pressing the MODE button. The following example shows how DTC C1312 is displayed on the pushbutton and lever shift selectors:

SELECT MONITOR

C 13 12

Any code position that does not have a DTC logged displays – for the DTC. No DTCs are logged after an empty code position.

B. Clearing Active Indicators. A DTC’s active indicator can be cleared, which allows the code inhibit

to be cleared but remains in the queue as inactive. The active indicator clearing methods are:

1. Power down—All active indicators are cleared at TCM power down.

3000 AND 4000 PRODUCT FAMILIES TROUBLESHOOTING MANUAL—ALLISON 4th GENERATION CONTROLS

DIAGNOSTIC TROUBLE CODES (DTCs)

2. Self-clearing—Some codes will clear their active indicator when the condition causing the code is no longer detected by the TCM.

3. Manual—Some active indicators can be cleared manually, while in the diagnostic display mode, after the condition causing the code is corrected.

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

CAUTION:

C. Manually Clearing Codes and Active Indicators from the Code List. To clear active indicators or

all codes:

1. Enter the diagnostic display mode.

2. Press and hold the MODE button for approximately ten seconds until the LED indicator flashes. All active and inactive indicators are cleared. All active indicators will be cleared at TCM power down.

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

3. Codes that cannot be manually cleared will remain.

D. Exiting the diagnostic display mode. Exit the diagnostic display mode using one of the following

procedures:

1. On a pushbutton shift selector, press the ↑ (Up) and ↓ (Down) arrow buttons at the same time or press any range button, D, N, or R. The shift (D, N, or R) is commanded if not inhibited by an active code.

2. On a lever shift selector, momentarily press the MODE button or move the shift lever to any shift position other than the one it was in when the diagnostic display mode was activated. If the shift is inhibited, the TCM will continue to command the current transmission range attained and the lever should be returned to its original position.

3. W ait until timeout (approximately 10 minutes) and the system will automatically return to the normal operating mode.

4. Turn off power to the TCM (turn off the vehicle engine at the ignition switch).

6–3. DIAGNOSTIC TROUBLE CODE RESPONSE

The following TCM responses to a fault provide for safe transmission operation:

• Do Not Shift (DNS) Response — Release lockup clutch and inhibit lockup operation. — Inhibit all shifts. — Turn on the CHECK TRANS light. — Display the range attained. — Ignore any range selection inputs from the pushbutton or lever shift selector.

• Do Not Adapt (DNA) Response — The TCM stops adaptive shift control while the code is active. Do not adapt shifts when a code with

the DNA response is active.

3000 AND 4000 PRODUCT FAMILIES TROUBLESHOOTING MANUAL—ALLISON 4th GENERATION CONTROLS

DIAGNOSTIC TROUBLE CODES (DTCs)

• SOLenoid OFF (SOL OFF) Response

— All solenoids are commanded off (turning solenoids PCS1 and PCS2 off electrically causes them to

be on hydraulically).

• Return to Previous Range (RPR) Response — When the speed sensor ratio or PS1 pressure switch tests associated with a shift are not successful,

the TCM commands the same range as commanded before the shift.

• Neutral No Clutches (NNC) Response — When certain speed sensor ratio or PS1 pressure switch tests are not successful, the TCM commands

a neutral condition with no clutches applied.

6–4. SHIFT SELECTOR DISPLAYS RELATED TO ACTIVE CODES

• Cateye—The forward slash segment and the middle horizontal segments (-/-) may be on under the

following conditions:

— Lost communication between the TCM and shift selector (U0103 or U0291) — J1939 Controller Area Network (CAN) problems — Invalid data from shift selector (U0592 or U0404)

• All Segments Displayed—All display segments will be illuminated during shift selector initialization.

Low supply voltage can cause the shift selector to fail to complete initialization.

• Blank select digit with monitor digit showing range

6–5. DIAGNOSTIC TROUBLE CODE LIST AND DESCRIPTION

Table 6–2. Diagnostic Trouble Codes (DTC) and Descriptions

CHECK TRANS

DTC Description

Light

C1312 Retarder Request Sensor Failed Low No May inhibit retarder operation if not

using J1939 data link

C1313 Retarder Request Sensor Failed High No May inhibit retarder operation if not

using J1939 data link

P0122 Pedal Position Sensor Low Voltage No Use default throttle values. Freezes

shift adapts.

P0123 Pedal Position Sensor High Voltage No Use default throttle values. Freezes

shift adapts.

P0218 Transmission Fluid Over Temperature No Use hot mode shift schedule. Holds

fourth range. TCC is inhibited.

Freezes shift adapts. P0562 System Voltage - Low No Inhibit TCC Operation, DNA P0602 TCM Not Programmed Yes Lock in Neutral P0610 TCM Vehicle Options (TID) Error Yes Use TID A calibration P0613 TCM Processor No All solenoids off P0614 Torque Control Data Mismatch—ECM/TCM Yes Allows operation only in reverse

and second range.

Inhibited Operation

Description

3000 AND 4000 PRODUCT FAMILIES TROUBLESHOOTING MANUAL—ALLISON 4th GENERATION CONTROLS

DIAGNOSTIC TROUBLE CODES (DTCs)

Table 6–2. Diagnostic Trouble Codes (DTC) and Descriptions (cont’d)

CHECK

TRANS

DTC Description

Light

P0634 TCM Internal Temperature Too High Yes SOL OFF (hydraulic default) P063E Auto Configuration Throttle Input Not Present Yes Use default throttle values P063F Auto Configuration Engine Coolant Temp Input Not

No None

Present

P0657 Actuator Supply Voltage 1 (HSD1) Open Yes SOL OFF, DNA, Inhibit TCC

operation, Inhibit main modulation P0658 Actuator Supply Voltage 1 (HSD1) Low Yes DNS, SOL OFF (hydraulic default) P0659 Actuator Supply Voltage 1 (HSD1) High Yes DNS, SOL OFF (hydraulic default) P0702 Transmission Control System Electrical (TID) Yes Uses TID A calibration P0703 Brake Switch Circuit Malfunction No No Neutral to Drive shifts for refuse

packer. TCM inhibits retarder

operation if a TPS code is also

active. P0708 Transmission Range Sensor Circuit High Input Yes Ignore defective strip selector inputs P070C Transmission Fluid Level Sensor Circuit—Low Input No None P070D Transmission Fluid Level Sensor Circuit—High Input No None P0711 Transmission Fluid Temperature Sensor Circuit

Yes Use default sump temp

Performance

P0712 Transmission Fluid Temperature Sensor Circuit

Yes Use default sump temp

Low Input

P0713 Transmission Fluid Temperature Sensor Circuit

Yes Use default sump temp

High Input P0716 Turbine Speed Sensor Circuit Performance Yes DNS, Lock in current range P0717 Turbine Speed Sensor Circuit No Signal Yes DNS, Lock in current range P0719 Brake Switch ABS Input Low No TCM assumes ABS is OFF P071A RELS Input Failed On Yes Inhibit RELS operation P071D General Purpose Input Fault Yes None P0721 Output Speed Sensor Circuit Performance Yes DNS, Lock in current range P0722 Output Speed Sensor Circuit No Signal Yes DNS, Lock in current range P0726 Engine Speed Sensor Circuit Performance No Default to turbine speed P0727 Engine Speed Sensor Circuit No Signal No Default to turbine speed P0729 Incorrect 6th Gear Ratio Yes DNS, Attempt 5th, then 3rd P0731 Incorrect 1st Gear Ratio Yes DNS, Attempt 2nd, then 5th P0732 Incorrect 2nd Gear Ratio Yes DNS, Attempt 3rd, then 5th P0733 Incorrect 3rd Gear Ratio Yes DNS, Attempt 4th, then 6th P0734 Incorrect 4th Gear Ratio Yes DNS, Attempt 5th, then 3rd P0735 Incorrect 5th Gear Ratio Yes DNS, Attempt 6th, then 3rd,

then 2nd

Inhibited Operation

Description

3000 AND 4000 PRODUCT FAMILIES TROUBLESHOOTING MANUAL—ALLISON 4th GENERATION CONTROLS

DIAGNOSTIC TROUBLE CODES (DTCs)

Table 6–2. Diagnostic Trouble Codes (DTC) and Descriptions (cont’d)

CHECK TRANS

DTC Description

Light

P0736 Incorrect Reverse Gear Ratio Yes DNS, Lock in Neutral P0741 Torque Converter Clutch System Stuck Off Yes None P0752 Shift Solenoid 1 (SS1) Valve Performance—Stuck On Yes DNS P0776 Pressure Control Solenoid 2 Stuck Off Yes DNS, RPR P0777 Pressure Control Solenoid 2 Stuck On Yes DNS, RPR P0796 Pressure Control Solenoid 3 Stuck Off Yes DNS, RPR P0797 Pressure Control Solenoid 3 Stuck On Yes DNS, RPR P0842 Transmission Pressure Switch 1 Circuit Low Yes DNS, Lock in current range P0843 Transmission Pressure Switch 1 Circuit High Yes DNS, Lock in current range P0847 Pressure Switch 2 (PS2) Circuit Low Yes None P0848 Pressure Switch 2 (PS2) Circuit High Yes None P0880 TCM Power Input Signal No None P0881 TCM Power Input Signal Performance No None P0882 TCM Power Input Signal Low Yes DNS, SOL OFF (hydraulic default) P0883 TCM Power Input Signal High No None P088A Transmission Fluid Filter Deteriorated No None P088B Transmisison Fluid Filter Very Deteriorated (Expired) No None P0894 Transmission Component Slipping Yes DNS, Lock in first P0897 Transmission Fluid Deteriorated Yes None P0960 Pressure Control Solenoid Main Mod Control

Yes None

Circuit Open

P0962 Pressure Control Solenoid Main Mod Control

Yes DNS, SOL OFF (hydraulic default)

Circuit Low

P0963 Pressure Control Solenoid Main Mod Control

Yes None

Circuit High

P0964 Pressure Control Solenoid 2 (PCS2) Control

Yes DNS, SOL OFF (hydraulic default)

Circuit Open P0966 Pressure Control Solenoid 2 (PCS2) Control Circuit Low Y es DNS, SOL OFF (hydraulic default) P0967 Pressure Control Solenoid 2 (PCS2) Control

Yes DNS, SOL OFF (hydraulic default)

Circuit High P0968 Pressure Control Solenoid 3 (PCS3) Control

Yes DNS, SOL OFF (hydraulic default)

Circuit Open P0970 Pressure Control Solenoid 3 (PCS3) Control Circuit Low Y es DNS, SOL OFF (hydraulic default) P0971 Pressure Control Solenoid 3 (PCS3) Control

Yes DNS, SOL OFF (hydraulic default)

Circuit High P0973 Shift Solenoid 1 (SS1) Control Circuit Low Yes DNS, SOL OFF (hydraulic default) P0974 Shift Solenoid 1 (SS1) Control Circuit High Yes DNS, SOL OFF (hydraulic default)

Inhibited Operation

Description

3000 AND 4000 PRODUCT FAMILIES TROUBLESHOOTING MANUAL—ALLISON 4th GENERATION CONTROLS

DIAGNOSTIC TROUBLE CODES (DTCs)

Table 6–2. Diagnostic Trouble Codes (DTC) and Descriptions (cont’d)

CHECK

TRANS

DTC Description

Light

P0975 Shift Solenoid 2 (SS2) Control Circuit Open Yes 7-speed: Allow 2 through 6, N, R P0976 Shift Solenoid 2 (SS2) Control Circuit Low Yes 7-speed: Allow 2 through 6, N, R.

Inhibit TCC operation P0977 Shift Solenoid 2 (SS2) Control Circuit High Yes 7-speed: Allow 2 through 6, N, R P0989 Retarder Pressure Sensor Failed Low No None P0990 Retarder Pressure Sensor Failed High No None P1739 Incorrect Low Gear Ratio Yes Command 2nd and allow shifts 2

through 6, N, R P1891 Throttle Position Sensor PWM Signal Low Input No Use default throttle values P1892 Throttle Position Sensor PWM Signal High Input No Use default throttle values P2184 Engine Coolant Temperature Sensor Circuit Low Input No Use default engine coolant values P2185 Engine Coolant Temperature Sensor Circuit

No Use default engine coolant values

High Input P2637 Torque Management Feedback Signal (SEM) Yes Inhibit SEM P2641 Torque Management Feedback Signal (LRTP) Ye s Inhibit LRTP P2669 Actuator Supply Voltage 2 (HSD2) Open Yes SOL OFF, Inhibit TCC operation,

Inhibit main modulation, DNA P2670 Actuator Supply Voltage 2 (HSD2) Low Yes DNS, SOL OFF (hydraulic default) P2671 Actuator Supply Voltage 2 (HSD2) High Yes DNS, SOL OFF (hydraulic default) P2684 Actuator Supply Voltage 3 (HSD3) Open Yes SOL OFF, Inhibit TCC operation,

Inhibit main modulation, DNA P2685 Actuator Supply Voltage 3 (HSD3) Low Yes DNS, SOL OFF (hydraulic default) P2686 Actuator Supply Voltage 3 (HSD3) High Yes DNS, SOL OFF (hydraulic default) P2714 Pressure Control Solenoid 4 (PCS4) Stuck Off Yes DNS, RPR P2715 Pressure Control Solenoid 4 (PCS4) Stuck On Yes DNS, SOL OFF (hydraulic default) P2718 Pressure Control Solenoid 4 (PCS4) Control

Yes DNS, SOL OFF (hydraulic default)

Circuit Open P2720 Pressure Control Solenoid 4 (PCS4) Control Circuit Low Yes DNS, SOL OFF (hydraulic default) P2721 Pressure Control Solenoid 4 (PCS4) Control

Yes DNS, SOL OFF (hydraulic default)

Circuit High P2723 Pressure Control Solenoid 1 (PCS1) Stuck Off Yes DNS, RPR P2724 Pressure Control Solenoid 1 (PCS1) Stuck On Yes DNS, RPR P2727 Pressure Control Solenoid 1 (PCS1) Control

Yes DNS, SOL OFF (hydraulic default)

Circuit Open P2729 Pressure Control Solenoid 1 (PCS1) Control Circuit Low Yes DNS, SOL OFF (hydraulic default) P2730 Pressure Control Solenoid 1 (PCS1) Control

Yes DNS, SOL OFF (hydraulic default)

Circuit High P2736 Pressure Control Solenoid 5 (PCS5) Control

Yes Inhibit retarder operation

Circuit Open

Inhibited Operation

Description

3000 AND 4000 PRODUCT FAMILIES TROUBLESHOOTING MANUAL—ALLISON 4th GENERATION CONTROLS

DIAGNOSTIC TROUBLE CODES (DTCs)

Table 6–2. Diagnostic Trouble Codes (DTC) and Descriptions (cont’d)

CHECK TRANS

DTC Description

Light

P2738 Pressure Control Solenoid 5 (PCS5) Control Circuit Low Yes Allow 2 through 6, N, R. Inhibit

retarder and TCC operation

P2739 Pressure Control Solenoid 5 (PCS5) Control

Yes Inhibit retarder operation

Circuit High P2740 Retarder Oil Temperature Hot No None P2742 Retarder Oil Temperature Sensor Circuit—Low Input No Use default retarder temp values P2743 Retarder Oil Temperature Sensor Circuit—High Input No Use default retarder temp values P2761 TCC PCS Control Circuit Open Yes Inhibit TCC operation P2763 TCC PCS Control Circuit High Yes Inhibit TCC operation P2764 TCC PCS Control Circuit Low Yes 7-speed: allow 2 through 6, N, R.

Inhibit TCC operation P2789 Clutch Adaptive Learning At Limit Yes None P278A Kickdown Input Failed ON No Inhibit kickdown operation P2793 Gear Shift Direction Circuit Yes Ignores PWM input from shift

selector P2808 Pressure Control Solenoid 6 (PCS6) Stuck Off Yes DNS, RPR P2809 Pressure Control Solenoid 6 (PCS6) Stuck On Yes DNS, RPR P2812 Pressure Control Solenoid 6 (PCS6) Control

Yes DNS, SOL OFF (hydraulic default)

Circuit Open P2814 Pressure Control Solenoid 6 (PCS6) Control Circuit Low Y es DNS, SOL OFF (hydraulic default) P2815 Pressure Control Solenoid 6 (PCS6) Control

Yes DNS, SOL OFF (hydraulic default)

Circuit High U0001 Hi Speed CAN Bus Reset Counter Overrun (IESCAN) No Use default values, inhibit SEM U0010 CAN BUS Reset Counter Overrun No Use default values, inhibit SEM U0100 L ost Communications with ECM/PCM (J1587) Yes Use default values U0103 Lost Communication Wit h Gear Shift Module

(Shift Selector) 1

Yes Maintain range selected, observe

gear shift direction circuit U0115 L ost Communication With ECM Yes Use default values U0291 Lost Communication W it h Gear Shift Module

(Shift Selector) 2

Yes Maintain range selected, observe

gear shift direction circuit U0304 Incompatible Gear Shift Module 1 (Shift Selector) ID Yes Ignore shift selector inputs U0333 Incompatible Gear Shift Module 2 (Shift Selector) ID Yes Ignore shift selector inputs U0400 Invalid J1939 Communications Yes None U0404 Invalid Data Received From Gear Shift Module

(Shift Selector) 1

U0442 Invalid Data Received from ECM/PCM B

Yes Maintain range selected, observe

gear shift direction circuit

No None

(CAN1/J1939)

U0592 Invalid Data Received From Gear Shift Module

(Shift Selector) 2

Yes Maintain range selected, observe

gear shift direction circuit

Inhibited Operation

Description

3000 AND 4000 PRODUCT FAMILIES TROUBLESHOOTING MANUAL—ALLISON 4th GENERATION CONTROLS

DIAGNOSTIC TROUBLE CODES (DTCs)

TRANSMISSION

COMPONENT

WIRING DIAGRAMS

AND

DIAGNOSTICS

3000 AND 4000 PRODUCT FAMILIES TROUBLESHOOTING MANUAL—ALLISON 4th GENERATION CONTROLS

DIAGNOSTIC TROUBLE CODES (DTC)

NOTES

3000 AND 4000 PRODUCT FAMILIES TROUBLESHOOTING MANUAL—ALLISON 4th GENERATION CONTROLS

DIAGNOSTIC TROUBLE CODES (DTCs)

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 6–1. J 39700 Breakout Box and J 47275 TCM Breakout Harness Adapter

To Vehicle

V09225.01.00

3000 AND 4000 PRODUCT FAMILIES TROUBLESHOOTING MANUAL—ALLISON 4th GENERATION CONTROLS

DIAGNOSTIC TROUBLE CODES (DTCs)

J 39700 BREAKOUT BOX

J 47279-1

ENGINE SPEED

WT RETARDER AIR SOLENOID

SENSOR

18765432

916151413121110

17 201918

SENSOR

RETARDER TEMP

TURBINE SPEED

Detail of

Magnetic Overlay

for use with

J 47279

Transmission

Breakout Harness

To Engine

Speed Sensor

OUTPUT SPEED

SENSOR

RETARDER FEED

THRU VALVE BODY

To Existing

Harness

To Existing

Harness

To Retarder

Solenoid

To Existing

Harness

To Retarder

Air Solenoid

To Existing Harness

To Retarder Temperature Sensor

Figure 6–2. J 39700 Breakout Box and J 47279 Transmission Breakout Harness

To Transmission

Connector

To Existing

Harness

To Turbine

Speed Sensor

To Existing

Harness

To Output

Speed Sensor

To Existing

Harness

NOTE: 4000 Product Family

V09224.00.00

3000 AND 4000 PRODUCT FAMILIES TROUBLESHOOTING MANUAL—ALLISON 4th GENERATION CONTROLS

DIAGNOSTIC TROUBLE CODES (DTCs)

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 6–3. J 47276 T Breakout and TCM Reflashing Harness

3000 AND 4000 PRODUCT FAMILIES TROUBLESHOOTING MANUAL—ALLISON 4th GENERATION CONTROLS

DIAGNOSTIC TROUBLE CODES (DTCs)

6–6. DIAGNOSTIC TROUBLE CODE TROUBLESHOOTING

A. Beginning The Trou bleshooting Process

1. Begin troubleshooting by determining the transmission fluid level and TCM input voltage. Access DTCs by using:

• The shift selector display.

• Allison DOC™ For PC–Service Tool.

2. When a problem exists but a DTC is not indicated, refer to Section 8, Gen eral Troubleshooting of Performance Complaints 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 code information and clear the active indicator . Read TCM fre eze frame da ta using Allison DOC™ For PC–Service Tool. Refer to Section 6–2.

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

• If the code reappears, refer to Section 6–5, Table 6–2. Table 6–2 lists DTCs and their

description.

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

Service Tool or the code display procedure described in Section 6–2.

• The code display procedure will indicate the number of times the DTC has occurred. Refer to

Section 8, General Troubleshooting of Performance Complaints, for the possible cause(s) of the problem.

• Use pressure gauges as necessary to evaluate hydraulic conditions.

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

circuit problem is suspected.

5. If difficulties arise, you have unanswered questions, or if you are unable to quickly identify the root cause during troubleshooting, please contact the Technical Assistance Center (TAC):

Technical Assistance Center PO Box 894, Mail Code A01 Indianapolis, IN 46206-0894 Phone: 1-800-252-5283

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.

B. Solenoid Locations

Solenoid locations in the control module are as illustrated in Figure 6–4. Refer to Figure 6–4 as necessary when using the DTC schematics.

C. Diagnostic Trouble Code Schematics

The diagnostic trouble code schematics in this section show wiring for the optional oil level sensor, Prognostic Filter Life Switch, and retarder , as applicable. If your transmission is not equipped with an oil level sensor, retarder, or Prognostic Filter Life Switch, disregard the portions of the schematic pertaining to those optional pieces of equipment. Refer to the appropriate transmission service manual for solenoid replacement procedures.

3000 AND 4000 PRODUCT FAMILIES TROUBLESHOOTING MANUAL—ALLISON 4th GENERATION CONTROLS

DIAGNOSTIC TROUBLE CODES (DTCs)

LEFT RIGHT

PCS6 (C6) (3000 AND 4000 PRODUCT FAMILIES – 7-SPEED MODELS ONLY)

MAIN MOD

PCS4 (C4)

PCS3 (C3/C5)

SS2 (C6 ENABLE) (3000 AND 4000 PRODUCT FAMILIES 7-SPEED MODELS ONLY)

FRONT

NT (TURBINE SPEED SENSOR 3000 PRODUCT FAMILIES ONLY)

PS1 PRESSURE SWITCH

BACK

TCC LOCKUP

PCS1 (C1)

PCS2 (C2/C3)

SS1 (FORWARD–ON MAIN VALVE BODY)

V09250.00.00

Figure 6–4. Control Module Solenoid Location

LEFT RIGHT

PCS6 (C6) (3000 AND 4000 PRODUCT FAMILIES – 7-SPEED MODELS ONLY)

MAIN MOD

PCS4 (C4)

PS2

PCS3 (C3/C5)

FRONT

NT (TURBINE SPEED SENSOR 3000 PRODUCT FAMILIES ONLY)

PS1 PRESSURE SWITCH

TCC LOCKUP

PCS1 (C1)

PCS2 (C2/C3)

SS1 (FORWARD–ON MAIN VALVE BODY)

BACK

Figure 6–5. Control Module Solenoid Location With Prognostics

V09250.00.00.A

3000 AND 4000 PRODUCT FAMILIES TROUBLESHOOTING MANUAL—ALLISON 4th GENERATION CONTROLS

DIAGNOSTIC TROUBLE CODES (DTCs)

DTC C1312 Retarder Request Sensor Failed Low

END VIEW OF

20-WAY CONNECTOR

PWM

THROTTLE

SOURCE

END VIEW OF

80-WAY CONNECTOR

TO RETARDER

CONTROL DEVICES

RETARDER

REQUEST SENSOR

(RESISTANCE

MODULE)

CBA

THROTTLE

POSITION

SENSOR (TPS)

ELECTRONIC

BRAKING (EBS)

RTDR PRESSURE

SENSOR

TRANSMISSION

ANALOG RETURN

OIL LEVEL

HALL

EFFECT

SUMP TEMP

PS1

PS2

* NORMALLY CLOSED

TCM

WIRE 156

C12

B44

A58

RETARDER TEMP

ENGINE TEMP

WIRE 158

WIRE 112

15 16

18 54

377

17 18 PS2 FILTER LIFE SWITCH

WIRE 116

WIRE 154

WIRE 177

WIRE 118

WIRE 112

WIRE 144

WIRE 158

WIRE 175

WIRE 135

RETARDER REQUEST SIGNAL

5V SENSOR VOLTAGE

THROTTLE POSITION OR RTDR PRESSURE SIGNAL

ANALOG RETURN

7535RETARDER TEMP

ENGINE WATER TEMP

OIL LEVEL SENSOR

SUMP TEMP

PS1 DIAGNOSTIC PRESSURE SWITCH

3000 AND 4000 PRODUCT FAMILIES TROUBLESHOOTING MANUAL—ALLISON 4th GENERATION CONTROLS

DIAGNOSTIC TROUBLE CODES (DTCs)

DTC C1312 Retarder Request Sensor Failed Low

Circuit Description

The Transmission Control Module (TCM) can be calibrated to receive a retarder request signal from a retarder request sensor, sometimes called a resistance module. The TCM is connected to the retarder request sensor by:

• a reference voltage wire,

• retarder request signal wire, and

• analog ground wire. The TCM provides a 5V reference voltage to the retarder request sensor. A voltage divider network in the sensor

produces a retarder request signal in response to inputs from the retarder control device(s). The TCM interprets this signal as a percent retarder requested.

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 9V and less than 32V (24V TCM).

• The components are powered and engine speed is greater than 200 rpm and less than 7500 rpm.

Conditions for Setting the DTC

DTC C1312 sets if the TCM is calibrated to receive the retarder request signal, and the signal voltage is less than

0.3V for five seconds.

Actions Taken When the DTC Sets

When DTC C1312 is active, the following conditions occur:

• The TCM does not illuminate the CHECK TRANS light.

• DTC is stored in TCM history.

• TCM may inhibit retarder operation, if not using the J1939 data link for retarder request signal.

Conditions for Clearing DTC/CHECK TRANS Light

Use Allison DOC™ For PC–Service Tool 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

• DTC C1312 indicates the TCM has detected a voltage signal from the retarder request sensor in the low error zone. The code can be caused by:

— Faulty wiring. — Faulty connections to the retarder request sensor or retarder control device. — A faulty retarder request sensor (resistance module). — A faulty retarder control device. — A faulty TCM.

• DTC C1312 can be caused by an open or short-to-ground in either the 5V reference wire 112 or retarder request signal wire 156. The retarder request sensor shares a common 5V reference voltage with the transmission oil level sensor (OLS) and throttle position sensor (TPS) on wire 112. An open or short-to-ground in the common 5V reference causes a sensor failed low code for the other devices as well. An open or short-toground on wire 156 will cause a DTC C1312 only.

3000 AND 4000 PRODUCT FAMILIES TROUBLESHOOTING MANUAL—ALLISON 4th GENERATION CONTROLS

DIAGNOSTIC TROUBLE CODES (DTCs)

• 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

Test Description

This DTC requires the use of the J 47275 TCM Breakout. The numbers below refer to step numbers on the diagnostic table.

2. Tests for an active DTC.

3. Tests for damaged wiring in external harness.

5. Tests for retarder request sensor functionality.

6. Tests for proper 5V reference voltage at the TCM with OEM harness disconnected.

DTC C1312 Retarder Request Sensor Failed Low

Step Action Value(s) Yes No

1 Was Section 3–5, Beginning The Troubleshooting

Process, performed?

2 1. Install the Allison DOC™ For PC–Service Tool.

2. Start the engine.

3. Record the failure records.

4. Clear the DTC and drive the vehicle. Attempt to duplicate same operating conditions observed in failure records.

NOTE: This DTC indicates that the retarder

request sensor voltage is below a set voltage for a set period of time. It may also indicate an open or short-to-ground in either the 5V reference wire 112 or retarder request signal wire 156.

Did DTC C1312 return?

3 1. Turn ignition OFF.

2. Inspect the routing of 5V reference wire 112, retarder request signal wire 156, and analog return (ground) wire 158 between the TCM and the retarder request sensor.

3. Disconnect the 80-way connector from the TCM.

4. Install the OEM-side of the 80-way connector to J 47275 TCM Breakout. Leave the TCM disconnected.

5. Disconnect the transmission 20-way connector, RMR connector, and TPS connector, if installed.

6. Test for opens or shorts-to-ground on wires 112 and 156.

Was chafing or wire damage found?

Go to Step 3 Go to

Go to Step 2 Go to Section 3–5,

Beginning the

Troubleshooting

Process

Diagnostic Aids

Go to Step 4 Go to Step 5

3000 AND 4000 PRODUCT FAMILIES TROUBLESHOOTING MANUAL—ALLISON 4th GENERATION CONTROLS

DIAGNOSTIC TROUBLE CODES (DTCs)

DTC C1312 Retarder Request Sensor Failed Low (cont’d)

Step Action Value(s) Yes No

4 NOTE: The vehicle OEM has responsibility for all

external wiring harness repairs. 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 vehicle wiring.

Is the repair complete?

5 1. Turn ignition OFF.

2. Reconnect the TCM to J 47275 TCM Breakout.

3. Reconnect the RMR connector, transmission 20-way connector, and TPS connector, if installed.

4. Turn ignition ON.

5. At J 47 275 -1 TCM overlay, connect a DVOM and measure voltage between pins 56 and 58 for each position of each retarder control device used on the vehicle.

If two resistance modules are used, disconnect one of them when measuring voltage signals from the other.

Are the voltages within the specified values?

6 1. Turn ignition OFF.

2. Disconnect the 16-pin bypass connector on J 47275 TCM Breakout.

3. Turn ignition ON.

4. At J 47 275-1 TCM Overlay, connect a DVOM and measure voltage between pins 12 and 58.

Is the voltage within the specified value?

7 Replace the retarder request sensor (resistance

module). Is replacement complete?

8 After replacing the retarder request sensor, perform

the following:

1. Turn ignition ON.

2. Reconnect the 16-pin bypass connector on J 47275 TCM Breakout.

3. At J 47 275 -1 TCM overlay, connect a DVOM and measure voltage between pins 56 and 58 for each position of each retarder control device used on the vehicle.

If two resistance modules are used, disconnect one of them when measuring voltage signals from the other.

Are voltages within specified values?

9 Replace the retarder control device.

Is 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?

Refer to

Table 6–3

4.75–5.0V Go to Step 7 Go to Step 10

Refer to

Table 6–3

Go to Step 11 Go to Step 5

Go to Step 10 Go to Step 6

Go to Step 8 Go to Step 7

Go to Step 11 Go to Step 9

Go to Step 11 Go to Step 1

3000 AND 4000 PRODUCT FAMILIES TROUBLESHOOTING MANUAL—ALLISON 4th GENERATION CONTROLS

DIAGNOSTIC TROUBLE CODES (DTCs)

DTC C1312 Retarder Request Sensor Failed Low (cont’d)

Step Action Value(s) Yes No

11 To verify the repair:

1. Clear the DTC.

2. Use Allison DOC™ For PC–Service Tool to monitor retarder request signal.

3. Drive the vehicle under conditions noted in failure records.

4. Confirm with the service tool in the test passed section that the diagnostic test was run.

Did the DTC return?

Table 6–3. Voltage/Resistance

Begin the

diagnosis again.

Go to Step 1

System OK

Resistance Test in

Resistance Module*

Resistance

KΩ +/

Description Terminals

Auto Full On A to C 12 100 3.6 No connections Pressure Switch

Full On

High 3-Step E-10R Bendix Pedal

6-Step Hand Lever A to C 32

OFF 0 1.1 +

Position 1 14 1.5 1

Position 2 28 1.9 2

Position 3 45 2.3 3

Position 4 65 2.8 4

Position 5 82 3.2 5

Position 6 100 3.6 6 Auto 1/2 ON A to C 12 50 2.4 No connections 3 Pressure Switches A to C 32 0 1.1

Low 32 1.9 A and B

Medium 68 2.8 A and B

High 100 3.6 A and B Auto 1/2 ON A to C 21.4 2 Pressure Switches

Auto 32 1.9 A

Medium 68 2.8 B

High 100 3.6 A and B Dedicated Pedal No Check Interface not a

* Resistance module must be disconnected from the wiring harness and retarder control devices. ** These voltages may be measured between TCM pins 56 and 58 using J 47275 TCM Breakout.

A to C 32

A to C 32 0 1.1 A

resistance module

− 5%

Voltage Signal**

% Retarder

Application

0 1.1 A

100 3.6 B

32 1.9 B 58 2.8 C

100 3.6 D

100

Voltage

− 0.2V

0.7–1.2

3.4–3.5

Wiring to Control

Device

Device Terminal

A B C

3000 AND 4000 PRODUCT FAMILIES TROUBLESHOOTING MANUAL—ALLISON 4th GENERATION CONTROLS

DIAGNOSTIC TROUBLE CODES (DTCs)

DTC C1313 Retarder Request Sensor Failed High

END VIEW OF

20-WAY CONNECTOR

PWM

THROTTLE

SOURCE

END VIEW OF

80-WAY CONNECTOR

TO RETARDER

CONTROL DEVICES

RETARDER

REQUEST SENSOR

(RESISTANCE

MODULE)

CBA

THROTTLE

POSITION

SENSOR (TPS)

ELECTRONIC

BRAKING (EBS)

RTDR PRESSURE

SENSOR

TRANSMISSION

ANALOG RETURN

OIL LEVEL

HALL

EFFECT

SUMP TEMP

PS1

PS2

* NORMALLY CLOSED

TCM

WIRE 156

C12

B44

A58

RETARDER TEMP

ENGINE TEMP

WIRE 158

WIRE 112

15 16

18 54

377

17 18 PS2 FILTER LIFE SWITCH

WIRE 116

WIRE 154

WIRE 177

WIRE 118

WIRE 112

WIRE 144

WIRE 158

WIRE 175

WIRE 135

RETARDER REQUEST SIGNAL

5V SENSOR VOLTAGE

THROTTLE POSITION OR RTDR PRESSURE SIGNAL

ANALOG RETURN

7535RETARDER TEMP

ENGINE WATER TEMP

OIL LEVEL SENSOR

SUMP TEMP

PS1 DIAGNOSTIC PRESSURE SWITCH

3000 AND 4000 PRODUCT FAMILIES TROUBLESHOOTING MANUAL—ALLISON 4th GENERATION CONTROLS

DIAGNOSTIC TROUBLE CODES (DTCs)

DTC C1313 Retarder Request Sensor Failed High

Circuit Description

• a reference voltage wire,

• retarder request signal wire, and

• analog ground wire. The TCM provides a 5V reference voltage to the retarder request sensor. A voltage divider network in the sensor

produces a retarder request signal in response to inputs from the retarder control device(s). The TCM interprets this signal as a percent retarder requested.

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 9V and less than 32V (24V TCM).

• The components are powered and engine speed is greater than 200 rpm and less than 7500 rpm.

Conditions for Setting the DTC

DTC C1313 sets if the TCM is calibrated to receive the retarder request signal, and the signal voltage is greater than 4.7V for 5 seconds.

Actions Taken When the DTC Sets

When DTC C1313 is active, the following conditions occur:

• The TCM does not illuminate the CHECK TRANS light.

• DTC is stored in TCM history.

• TCM may inhibit retarder operation, if not using the J1939 data link for retarder request signal.

Conditions for Clearing 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

• DTC C1313 indicates the TCM has detected a voltage signal from the retarder request sensor in the high error zone. The code can be caused by:

• DTC C1313 can be caused by a short-to-battery in the 5V reference wire 112 or retarder request signal wire 156. DTC C1313 can also be caused by an open in analog return wire 158. The retarder request sensor shares a common 5V reference voltage with the transmission oil level sensor (OLS) and throttle position sensor (TPS) on wire 112. A short-to-battery in the 5V reference wire 112 or open in analog return wire 158 causes a sensor failed high code for the other devices as well. A short-to-battery in retarder request signal wire 156 will produce a DTC C1313 only.

3000 AND 4000 PRODUCT FAMILIES TROUBLESHOOTING MANUAL—ALLISON 4th GENERATION CONTROLS

DIAGNOSTIC TROUBLE CODES (DTCs)

• 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

Test Description

This DTC requires the use of the J 47275 TCM Breakout. The numbers below refer to step numbers on the diagnostic table.

2. Tests for an active DTC.

3. Tests for damaged wiring in external harness.

5. Tests for retarder request sensor functionality.

6. Tests for proper 5V reference voltage at the TCM with OEM harness disconnected.

DTC C1313 Retarder Request Sensor Failed High

Step Action Value(s) Yes No

1 Was Section 3–5, Beginning The Troubleshooting

Process, performed?

2 1. Install the Allison DOC™ For PC–Service Tool.

2. Start the engine.

3. Record the failure records.

4. Clear the DTC and drive the vehicle. Attempt to duplicate same operating conditions observed in failure records.

NOTE: This DTC indicates that the retarder

request sensor voltage is above a set voltage for a set period of time. It may also indicate a short-to-battery on 5V reference wire 112 or an open on analog return wire 158.

Did DTC C1313 return?

3 1. Turn ignition OFF.

2. Inspect the routing of 5V reference wire 112, retarder request signal wire 156, and analog return (ground) wire 158 between the TCM and the retarder request sensor.

3. Disconnect the 80-way connector from the TCM.

4. Install the OEM-side of the 80-way connector to the J 47275 TCM Breakout. Leave the TCM disconnected.

5. Disconnect the transmission 20-way connector, RMR connector, and TPS connector, if installed.

6. Test for shorts-to-battery on wires 112 and 156, and opens on wire 158.

Was chafing or wire damage found?

Go to Step 2 Go to Section 3–5,

Beginning the

Troubleshooting

Process

Go to Step 3 Go to

Diagnostic Aids

Go to Step 4 Go to Step 5

3000 AND 4000 PRODUCT FAMILIES TROUBLESHOOTING MANUAL—ALLISON 4th GENERATION CONTROLS

DIAGNOSTIC TROUBLE CODES (DTCs)

DTC C1313 Retarder Request Sensor Failed High (cont’d)

Step Action Value(s) Yes No

4 NOTE: The vehicle OEM has responsibility for all

external wiring harness repairs. 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 vehicle wiring.

Is the repair complete?

5 1. Turn ignition OFF.

2. Reconnect the TCM to J 47275 TCM Breakout.

3. Reconnect the RMR connector, transmission 20-way connector, and TPS connector, if installed.

4. Turn ignition ON.

5. At J 47 275-1 TCM Overlay, connect a DVOM and measure voltage between pins 56 and 58 for each position of each retarder control device used on the vehicle.

If two resistance modules are used, disconnect one of them when measuring voltage signals from the other.

Are the voltages within the specified values?

6 1. Turn ignition OFF.

2. Disconnect the 16-pin bypass connector on J 47275 TCM Breakout.

3. Turn ignition ON.

4. At J 47 275-1 TCM Overlay, connect a DVOM and measure voltage between pins 12 and 58.

Is the voltage within the specified value?

7 Replace the retarder request sensor (resistance

module). Is replacement complete?

8 After replacing the retarder request sensor, perform

the following:

1. Turn ignition ON.

2. Reconnect the 16-pin bypass connector on J 47275 TCM Breakout.

3. At J 47 275-1 TCM Overlay, connect a DVOM and measure voltage between pins 56 and 58 for each position of each retarder control device used on the vehicle.

If two resistance modules are used, disconnect one of them when measuring voltage signals from the other.

Are voltages within specified values?

9 Replace the retarder control device.

Is replacement complete?

Refer to

Table 6–4

4.7–5.0V Go to Step 7 Go to Step 10

Refer to

Table 6–4

Go to Step 11 Go to Step 5

Go to Step 10 Go to Step 6

Go to Step 8 Go to Step 7

Go to Step 11 Go to Step 9

3000 AND 4000 PRODUCT FAMILIES TROUBLESHOOTING MANUAL—ALLISON 4th GENERATION CONTROLS

DIAGNOSTIC TROUBLE CODES (DTCs)

DTC C1313 Retarder Request Sensor Failed High (cont’d)

Step Action Value(s) Yes No

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 To verify the repair:

1. Clear the DTC.

2. Use Allison DOC™ For PC–Service Tool to monitor retarder request signal.

3. Drive the vehicle under conditions noted in failure records.

4. Confirm with the service tool in the test passed section that the diagnostic test was run.

Did the DTC return?

Table 6–4. Voltage/Resistance

Go to Step 11 Go to Step 10

Begin the

diagnosis again.

Go to Step 1

System OK

Resistance Test in

Resistance Module*

Resistance

KΩ +/

Description Terminals

Auto Full On A to C 12 100 3.6 No connections Pressure Switch

Full On

High 3-Step E-10R Bendix Pedal

6-Step Hand Lever A to C 32

OFF 0 1.1 +

Position 1 14 1.5 1

Position 2 28 1.9 2

Position 3 45 2.3 3

Position 4 65 2.8 4

Position 5 82 3.2 5

Position 6 100 3.6 6 Auto 1/2 ON A to C 12 50 2.4 No conn ections 3 Pressure Switches A to C 32 0 1.1

Low 32 1.9 A and B

Medium 68 2.8 A and B

High 100 3.6 A and B Auto 1/2 ON A to C 21.4 2 Pressure Switches

Auto 32 1.9 A

Medium 68 2.8 B

High 100 3.6 A and B

A to C 32

A to C 32 0 1.1 A

− 5%

Voltage Signal**

% Retarder

Application

0 1.1 A

100 3.6 B

32 1.9 B 58 2.8 C

100 3.6 D

Voltage

− 0.2V

Wiring to Control

Device

Device Terminal

3000 AND 4000 PRODUCT FAMILIES TROUBLESHOOTING MANUAL—ALLISON 4th GENERATION CONTROLS

DIAGNOSTIC TROUBLE CODES (DTCs)

Table 6–4. Voltage/Resistance

Resistance Test in

Resistance Module*

Resistance

KΩ +/

Description Terminals

Dedicated Pedal No Check Interface not a

resistance module

* Resistance module must be disconnected from the wiring harness and retarder control devices. ** These voltages may be measured between TCM pins 56 and 58 using J 47275 TCM Breakout.

− 5%

Voltage Signal**

% Retarder

Application

100

Voltage

0.7–1.2

3.4–3.5

− 0.2V

Wiring to Control

Device

Device Terminal

A B C

3000 AND 4000 PRODUCT FAMILIES TROUBLESHOOTING MANUAL—ALLISON 4th GENERATION CONTROLS

DIAGNOSTIC TROUBLE CODES (DTCs)

DTC P0122 Pedal Position Sensor Low Voltage

END VIEW OF

20-WAY CONNECTOR

PWM

THROTTLE

SOURCE

END VIEW OF

80-WAY CONNECTOR

TO RETARDER

CONTROL DEVICES

RETARDER

REQUEST SENSOR

(RESISTANCE

MODULE)

CBA

THROTTLE

POSITION

SENSOR (TPS)

ELECTRONIC

BRAKING (EBS)

RTDR PRESSURE

SENSOR

TRANSMISSION

ANALOG RETURN

OIL LEVEL

HALL

EFFECT

SUMP TEMP

PS1

PS2

* NORMALLY CLOSED

TCM

WIRE 156

C12

B44

A58

RETARDER TEMP

ENGINE TEMP

WIRE 158

WIRE 112

15 16

18 54

377

17 18 PS2 FILTER LIFE SWITCH

WIRE 116

WIRE 154

WIRE 177

WIRE 118

WIRE 112

WIRE 144

WIRE 158

WIRE 175

WIRE 135

RETARDER REQUEST SIGNAL

5V SENSOR VOLTAGE

THROTTLE POSITION OR RTDR PRESSURE SIGNAL

ANALOG RETURN

7535RETARDER TEMP

ENGINE WATER TEMP

OIL LEVEL SENSOR

SUMP TEMP

PS1 DIAGNOSTIC PRESSURE SWITCH

3000 AND 4000 PRODUCT FAMILIES TROUBLESHOOTING MANUAL—ALLISON 4th GENERATION CONTROLS

DIAGNOSTIC TROUBLE CODES (DTCs)

DTC P0122 Pedal Position Sensor Low Voltage

Circuit Description

The Transmission Control Module (TCM) may receive 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 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 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 0.78 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 9V and less than 32V (24V TCM).

• The components are powered and engine speed is greater than 200 rpm.

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

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

• The TCM does not illuminate the CHECK TRANS light.

• DTC P0122 is stored in the TCM memory.

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

• The TCM freezes shift adapts (DNA).

Conditions for Clearing the DTC/CHECK TRANS LIGHT

Use Allison DOC™ For PC–Service Tool 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, 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.

3000 AND 4000 PRODUCT FAMILIES TROUBLESHOOTING MANUAL—ALLISON 4th GENERATION CONTROLS

DIAGNOSTIC TROUBLE CODES (DTCs)

• DTC P0122 can be caused by an open or short-to-ground in either the 5V reference wire 112 or TPS signal

wire 144. The TPS shares a common 5V reference voltage wire 112 with the optional transmission oil level sensor (OLS) and retarder request sensor. An open or short-to-ground in the common 5V reference causes a sensor failed low code for the other devices as well. An open or short-to-ground on wire 144 will cause a DTC P0122 only.

Test Description

This DTC requires the use of the J 47275 TCM Breakout. The numbers below refer to step numbers on the diagnostic table.

2. Tests for the proper adjustment of TPS.

3. Tests for the proper ignition voltage.

4. Tests for the proper TCM 5V reference voltage.

5. Tests for dead spots in the potentiometer.

6. Tests for abnormal TPS resistance.

7. Tests for proper resistance of the TPS circuit.

8. Tests for an open or short-to-ground in TPS signal wire 144.

9. Tests for proper 5V reference voltage at TCM without OEM harness.

10. Tests for an open or short-to-ground on 5V reference wire 112.

DTC P0122 Pedal Position Sensor Low Voltage

Step Action Value(s) Yes No

1 Was Section 3–5, Beginning The Troubleshooting

Process, performed?

2 Refer to Appendix F to check for proper TPS

adjustment. Is the TPS adjusted properly?

3 1. Install the Allison DOC™ For PC–Service Tool.

2. Start the engine.

3. Record the DTC failure record data.

4. Using the Allison DOC™ For PC–Service Tool, measure ignition voltage.

Is voltage within the specified values?

4 1. Turn ignition OFF.

2. Connect the 80-way connector to the TCM and install the J 47275 TCM Breakout between the TCM and the OEM-side connector.

3. With the engine OFF, turn the ignition to the ON position.

4. Using a DVOM, measure the voltage between pins 12 and 58.

Is the voltage within the specified value?

9−18V (12V TCM) 18−32V (24V TCM)

4.75−5.0V Go to Step 5 Go to Step 9

Go to Step 2 Go to Section 3–5,

Beginning the

Troubleshooting

Process

Go to Step 3 Adjust TPS to

proper setting.

Go to Step 14

Go to Step 4 Resolve voltage

problem (refer to

DTC P0882 and

DTC P0883)

3000 AND 4000 PRODUCT FAMILIES TROUBLESHOOTING MANUAL—ALLISON 4th GENERATION CONTROLS

DIAGNOSTIC TROUBLE CODES (DTCs)

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

Step Action Value(s) Yes No

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

position, monitor TPS percentage with Allison DOC™ For PC–Service Tool.

2. Slowly increase the throttle from idle to full throttle position.

3. Watch for a steady increase in TPS percentage.

Was the throttle percentage steady and without interruptions?

6 1. Turn ignition OFF.

2. Disconnect the TPS connector.

3. Using a DVOM, measure the resistance between TPS pins A and C.

Is resistance within the specified value?

7 1. Reconnect the TPS connector.

2. Disconnect the J 47275 TCM Breakout from the TCM. Leave the OEM 80-way connector mated to the J 47275 TCM Breakout.

3. Using a DVOM, measure resistance between 80-way connector pins 12 and 58.

Is resistance within the specified value?

8 1. Turn ignition OFF.

2. Disconnect the TPS connector.

3. Using a DVOM at J47275-1 TCM Overlay, test for opens, wire-to-wire shorts, and shorts-toground at pin 44.

Were any opens, wire-to-wire shorts or shorts-tobattery found?

9 1. Turn ignition OFF.

2. Disconnect the 16-pin bypass connector on J 47275 TCM breakout.

3. Turn ignition ON.

4. Using a DVOM at J 47275-1 TCM Overlay , measure voltage between pins 12 and 58.

Is the voltage within the specified value?

10 1. Turn ignition OFF.

2. Disconnect the J 47275 TCM Breakout from the TCM. Leave the OEM 80-way connector mated to the J 47275 TCM Breakout.

3. Reconnect the 16-pin bypass connector on J 47275 TCM Breakout.

4. Disconnect the TPS connector, transmission 20-way connector, and RMR device, if installed.

5. Using a DVOM at J 47275-1 TCM Overlay, test for opens, wire-to-wire shorts, and shorts-toground at pin 12.

6. Test for opens at pin 58.

Were any opens, wire-to-wire shorts, or shorts-toground found?

Go to

Diagnostic Aids

9000−15,000

Ohms

9000−15,000

Ohms

4.75–5.0V Go to Step 10 Go to Step 13

Go to Step 7 Go to Step 12

Go to Step 13 Go to Step 8

Go to Step 11 Go to Step 14

Go to Step 11 Go to

Go to Step 6

Diagnostic Aids

3000 AND 4000 PRODUCT FAMILIES TROUBLESHOOTING MANUAL—ALLISON 4th GENERATION CONTROLS

DIAGNOSTIC TROUBLE CODES (DTCs)

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

Step Action Value(s) Yes No

11 NOTE: The vehicle OEM has responsibility for all

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

Repair the vehicle wiring harness. Is the repair complete?

12 Replace the throttle position sensor.

Is the replacement complete?

13 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 the replacement complete?

14 To verify the repair:

1. Clear the DTC.

2. Operate the vehicle under normal driving conditions.

Did the DTC return?

Go to Step 14 Go to Step 11

Go to Step 14 Go to Step 12

Go to Step 14 Go to Step 13

Begin the

diagnosis again.

Go to Step 1

System OK

3000 AND 4000 PRODUCT FAMILIES TROUBLESHOOTING MANUAL—ALLISON 4th GENERATION CONTROLS

DIAGNOSTIC TROUBLE CODES (DTCs)

DTC P0123 Pedal Position Sensor High Voltage

END VIEW OF

20-WAY CONNECTOR

PWM

THROTTLE

SOURCE

END VIEW OF

80-WAY CONNECTOR

TO RETARDER

CONTROL DEVICES

RETARDER

REQUEST SENSOR

(RESISTANCE

MODULE)

CBA

THROTTLE

POSITION

SENSOR (TPS)

ELECTRONIC

BRAKING (EBS)

RTDR PRESSURE

SENSOR

TRANSMISSION

ANALOG RETURN

OIL LEVEL

HALL

EFFECT

SUMP TEMP

PS1

PS2

* NORMALLY CLOSED

TCM

WIRE 156

C12

B44

A58

RETARDER TEMP

ENGINE TEMP

WIRE 158

WIRE 112

15 16

18 54

377

17 18 PS2 FILTER LIFE SWITCH

WIRE 116

WIRE 154

WIRE 177

WIRE 118

WIRE 112

WIRE 144

WIRE 158

WIRE 175

WIRE 135

RETARDER REQUEST SIGNAL

5V SENSOR VOLTAGE

THROTTLE POSITION OR RTDR PRESSURE SIGNAL

ANALOG RETURN

7535RETARDER TEMP

ENGINE WATER TEMP

OIL LEVEL SENSOR

SUMP TEMP

PS1 DIAGNOSTIC PRESSURE SWITCH

3000 AND 4000 PRODUCT FAMILIES TROUBLESHOOTING MANUAL—ALLISON 4th GENERATION CONTROLS

DIAGNOSTIC TROUBLE CODES (DTCs)

DTC P0123 Pedal Position Sensor High Voltage

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 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.

Conditions for Running the DTC

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

• The components are powered and engine speed is greater than 200 rpm.

• DTC P0123 Throttle/Pedal Position Sensor/Switch A Circuit Low Input is not active.

Conditions for Setting the DTC

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

Action Taken When the DTC Sets

• The TCM does not illuminate the CHECK TRANS light.

• 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).

Conditions for Clearing the DTC/CHECK TRANS LIGHT

Use the Allison DOC™ For PC–Service Tool 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, 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.

3000 AND 4000 PRODUCT FAMILIES TROUBLESHOOTING MANUAL—ALLISON 4th GENERATION CONTROLS

DIAGNOSTIC TROUBLE CODES (DTCs)

• DTC P0123 can be caused by a short-to-battery in either the 5V reference wire 112 or TPS signal wire 144. DTC P0123 can also be caused by an open in analog return wire 158. The TPS shares a common 5V reference voltage wire 112 with the transmission oil level sensor (OLS) and retarder request sensor. A short-to-battery in 5V reference wire or open in analog return wire 158 causes a sensor failed high code for the other devices as well. A short-to-battery on TPS signal wire 144 will produce a DTC P0123 only.

Test Description

This DTC requires the use of the J 47275 TCM Breakout. The numbers below refer to step numbers on the diagnostic table.

2. Tests for the proper adjustment of TPS.

3. Tests for the proper ignition voltage.

4. Tests for the proper TCM 5V reference voltage.

5. Tests for dead spots in the potentiometer.

6. Tests for abnormal TPS resistance.

7. Tests for proper resistance of the TPS circuit.

8. Tests for a short-to-battery in TPS signal wire 144.

9. Tests for proper 5V reference voltage at TCM without OEM harness.

10. Tests for a short-to-battery in 5V reference wire 112 or open in analog return wire 158.

DTC P0123 Pedal Position Sensor High Voltage

Step Action Value(s) Yes No

1 Was Section 3–5, Beginning The Troubleshooting

Process, performed?

2 Refer to Appendix F to determine proper TPS

adjustment. Is the TPS adjusted properly?

3 1. Install the Allison DOC™ For PC–Service Tool.

2. Start the engine.

3. Record the DTC failure record data.

4. Using the Allison DOC™ For PC–Service Tool, measure ignition voltage.

Is voltage within the specified values?

4 1. Turn ignition OFF.

2. Disconnect the 80-way connector from the TCM and install the J 47275 TCM Breakout between the TCM and the OEM-side connector.

3. With the engine OFF, turn the ignition to the ON position.

4. Using a DVOM, measure the voltage between pins 12 and 58.

Is the voltage within the specified value?

9−18V (12V TCM)

18−32V (24V TCM)

4.75−5.0V Go to Step 5 Go to Step 9

Go to Step 2

Go to Step 3 Adjust TPS to

Go to Step 4 Resolve voltage

Go to Section 3–5,

Beginning the

Troubleshooting

Process

proper setting. Go

to Step 14

problem (refer to

DTC P0882 and

DTC P0883)

3000 AND 4000 PRODUCT FAMILIES TROUBLESHOOTING MANUAL—ALLISON 4th GENERATION CONTROLS

DIAGNOSTIC TROUBLE CODES (DTCs)

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

Step Action Value(s) Yes No

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

position, monitor TPS percentage with Allison DOC™ For PC–Service Tool.

2. Slowly increase the throttle from idle to full throttle position.

3. Watch for a steady increase in TPS percentage.

Was TPS percentage steady and without interruptions?

6 1. Turn ignition OFF.

2. Disconnect the TPS connector.

3. Using a DVOM, measure the resistance between TPS pins A and C.

Is resistance within the specified value?

7 1. Reconnect the TPS connector.

2. Disconnect the J 47275 TCM Breakout from the TCM. Leave the OEM 80-way connector mated to the J 47275 TCM Breakout.

3. Using a DVOM, measure resistance between 80-way connector pins 12 and 58.

Is resistance within the specified value?

8 1. Turn ignition OFF.

2. Disconnect the TPS connector.

3. Using a DVOM at J 47275-1 TCM Overlay, test for wire-to-wire shorts and shorts-to-battery at pin 44.

Were any opens, wire-to-wire shorts or shorts-tobattery found?

9 1. Turn ignition OFF.

2. Disconnect the 16-pin bypass connector on J 47275 TCM breakout.

3. Turn ignition ON.

4. Using a DVOM at J 47275-1 TCM Overlay , measure voltage between pins 12 and 58.

Is the voltage within the specified value?

10 1. Turn ignition OFF.

2. Disconnect the J 47275 TCM Breakout from the TCM. Leave the OEM 80-way connector mated to the J 47275 TCM Breakout.

3. Reconnect the 16-pin bypass connector on J 47275 TCM Breakout.

4. Disconnect the TPS connector, transmission 20-way connector, and RMR connector, if installed.

5. Using a DVOM at J 47275-1 TCM Overlay, test for opens, wire-to-wire shorts, and shorts-toground at pin 12.

6. Test for opens at pin 58.

Were any opens, wire-to-wire shorts, or shorts-toground found?

9000−15,000

Ohms

9000−15,000

Ohms

4.75–5.0V Go to Step 10 Go to Step 13

Go to Step 6 Go to Step 12

Go to Step 7 Go to Step 12

Go to Step 13 Go to Step 8

Go to Step 11 Go to Step 14

Go to Step 11 Go to

Diagnostic Aids

3000 AND 4000 PRODUCT FAMILIES TROUBLESHOOTING MANUAL—ALLISON 4th GENERATION CONTROLS

DIAGNOSTIC TROUBLE CODES (DTCs)

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

Step Action Value(s) Yes No

11 NOTE: The vehicle OEM has responsibility for all

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

Repair the vehicle wiring harness. Is the repair complete?

12 Replace the throttle position sensor.

Is the replacement complete?

13 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 the replacement complete?

14 To verify the repair:

1. Clear the DTC.

2. Operate the vehicle under normal driving conditions.

Did the DTC return?

Go to Step 14 Go to Step 11

Go to Step 14 Go to Step 12

Go to Step 14 Go to Step 13

Begin the

diagnosis again.

Go to Step 1

System OK

3000 AND 4000 PRODUCT FAMILIES TROUBLESHOOTING MANUAL—ALLISON 4th GENERATION CONTROLS

DIAGNOSTIC TROUBLE CODES (DTCs)

DTC P0218 Transmission Fluid Over-Temperature

MAIN

FILTER

PUMP

MAIN

REGULATOR

FILTER

SUCTION

V09282.00.00.eps

SUMP

MAIN

MAIN MOD

Relief

Pressure

FORWARD

KNOCKDOWN

AND

CONTROL

CLUTCHES

TO COOLER

CONVERTER FLOW CIRCUIT

LOCKUP PRESSURE

TCC

SOL

MAIN

CIRCUIT

CONVERTER

REGULATOR

FLOW

FROM LUBE

SUCTION

LEGEND:

COOLER/LUBE

EX. BACKFILL

CONVERTER

MAIN MOD

COOLER/LUBE

EX. BACKFILL

CONVERTER

SUCTION

LOCKUP

CONVERTER OUT

CONVERTER IN

TORQUE

CONVERTER

3000 AND 4000 PRODUCT FAMILIES TROUBLESHOOTING MANUAL—ALLISON 4th GENERATION CONTROLS

DIAGNOSTIC TROUBLE CODES (DTCs)

DTC P0218 Transmission Fluid Over-Temperature

Circuit Description

Transmission fluid flow starts in the transmission sump. Fluid is drawn into the oil pump assembly through the suction filter and internal passages in the main housing and front support. The gerotor gear set in the oil pump assembly turns at engine speed and pressurizes the fluid. The main regulator valve regulates the discharge pressure at the oil pump. Pressurized fluid returns to the hydraulic control module where it is directed to the clutch apply circuits and the control main regulator valve. Control main pressure is used to stroke solenoid regulator valves, which apply and release transmission clutches in response to solenoid commands from the Transmission Control Module (TCM).

The main pump produces substantially more fluid flow than is required by the clutch apply circuit. Surplus oil pressure (overage) at the main regulator valve is relieved into the converter flow circuit. The converter flow circuit routes pressurized fluid to the torque converter via the converter flow valve and the converter regulator valve. Hot fluid leaving the torque converter is routed back through the converter flow valve into cooler lines that run to the transmission oil cooler in the vehicle cooling system. The cooled fluid is returned to the transmission and enters the transmission lubrication circuit. The lube regulator valve regulates the proper lubrication pressure and directs excess fluid back to the sump. The transmission fluid temperature sensor is part of the internal wiring harness and measures the sump temperature.

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 9V and less than 32V (24V TCM).

• The components are powered and engine speed is greater than 200 rpm and less than 7500 rpm for 5 seconds.

• Engine is running. If engine runtime is less than 10 minutes, then engine coolant temperature must be above

°C (68°F) for more than 20 seconds.

Conditions for Setting the DTC

The TCM detects transmission fluid temperature greater than 126.85

Actions Taken When the DTC Sets

When DTC P0218 is active, the following conditions occur:

• The TCM does not illuminate the CHECK TRANS light.

• DTC is stored in TCM history.

• The TCM freezes shift adapts (DNA).

• TCM defaults to hot mode shift schedule where fourth range is held and TCC is inhibited to increase engine speed and improve cooler flow.

Conditions for Clearing the DTC/CHECK TRANS Light

°C (260°F) value for more than 10 seconds.

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

Diagnostic Aids

• Using the Allison DOC™ For PC–Service Tool, monitor the transmission fluid temperature to verify that it rises in 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 table for P0218. Repairing the condition that set DTC P0711 will likely eliminate DTC P0218.

Allison Transmission 3000, 4000 Troubleshooting Manual

Specifications and Main Features

Frequently Asked Questions

User Manual

IMPORTANT SAFETY NOTICE

WARNINGS, CAUTIONS, AND NOTES

TRADEMARKS USED IN THIS MANUAL

SHIFT SELECTOR TERMS AND DISPLAY INDICATIONS

TABLE OF CONTENTS

1–1. TRANSMISSION

1–2. TRANSMISSION CONTROL MODULE (TCM)

1–3. SHIFT SELECTOR

A. Control System Prognostics Operation and Display

B. Filter Life Valve Body

1–7. WIRING HARNESSES

1–9. AUTODETECT FEATURE

A. Retarder

B. Oil Level Sensor (OLS)

C. Throttle Source

D. Engine Coolant Temperature

1–10. TRANSID (TID)

1–11. SPECIAL ELECTRONIC/ELECTRICAL TOOLS

2–1. CHECK TRANS LIGHT

A. Oil Life Monitor (OM)

B. Filter Life Monitor (FM)

C. Operation of Filter Life Valve and Pressure Switch (PS2)

D. Transmission Health Monitor (TM)

2–2. ALLISON TRANSMISSION DIAGNOSTIC TOOL

2–3. ABBREVIATIONS

3–1. BASIC KNOWLEDGE REQUIRED

3–2. USING THE TROUBLESHOOTING MANUAL

3–3. SYSTEM OVERVIEW

3–4. IMPORTANT INFORMATION IN THE TROUBLESHOOTING PROCESS

A. Before Beginning Troubleshooting

B. Cold Weather Starts

C. High Fluid Temperature

3–5. BEGINNING THE TROUBLESHOOTING PROCESS

3–6. TCM DIAGNOSTIC PROCEDURE

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

3–8. RESETTING TCM AUTOSELECT

3–9. HYDRAULIC OPERAT ION DURING ELECTRICAL INTERRUPTION

5–1. OIL LEVEL SENSOR (OLS) INTRODUCTION

5–2. ELECTRONIC FLUID LEVEL READING (SHIFT SELECTOR)

A. Fluid Level Reading Procedure

A. Fluid Level Check Procedure

A. Purpose

B. Cold Check Procedure

A. Hot Check Procedure

5–6. KEEPING FLUID CLEAN

A. Foreign Material

5–7. FLUID RECOMMENDATIONS

6–1. DIAGNOSTIC TROUBLE CODE MEMORY

6–2. CODE READING AND CODE CLEARING

A. Reading Codes

6–3. DIAGNOSTIC TROUBLE CODE RESPONSE

6–4. SHIFT SELECTOR DISPLAYS RELATED TO ACTIVE CODES

6–5. DIAGNOSTIC TROUBLE CODE LIST AND DESCRIPTION

6–6. DIAGNOSTIC TROUBLE CODE TROUBLESHOOTING

A. Beginning The Trou bleshooting Process

B. Solenoid Locations

C. Diagnostic Trouble Code Schematics

DTC C1312 Retarder Request Sensor Failed Low

DTC C1313 Retarder Request Sensor Failed High

DTC P0122 Pedal Position Sensor Low Voltage

DTC P0123 Pedal Position Sensor High Voltage