Eaton Transmission RTLO-11118A-MT, RTLO-9118A MT Service Manual

Troubleshooting Guide

Fuller Heavy-Duty Transmissions
TRTS0011 EN-US

October 2007

RTLO-11118A-MT
RTLO-9118A-MT

For parts or service call us

Pro Gear & Transmission, Inc.

1 [phone]

[phone]

[e-mail]

906 W. Gore St.

Orlando, FL 32805

Introduction

WARNING................................................................................................................2

Complaint Isolation, Verification & Remedy Procedure.............................................3

How to Use this Troubleshooting Guide...................................................................4

Complaint Diagnosis

Fault Code Diagnosis..............................................................................................6

Symptom Driven Diagnosis.....................................................................................7

Pre-Test

Transmission Electrical Test....................................................................................8

Performance Evaluation

Performance Evaluation Test.................................................................................10

Testing Procedures

Power Relay Coil Test..............................................................................................12

System Voltage Test................................................................................................13

Inertia Brake Solenoid Coil Test...............................................................................15

Inertia Brake Test....................................................................................................17

Inertia Brake Switch Test.........................................................................................18

Inertia Brake Air Supply Test...................................................................................19

Transmission Converter Open Lamp Test................................................................20

Engine Speed Sensor Test......................................................................................21

Bypass/Lockup Solenoid Coil Test..........................................................................23

Interrupt Clutch Solenoid Coil Test..........................................................................25

Hydraulic System Test............................................................................................27

Input Shaft Speed Sensor Test...............................................................................29

Output Shaft Speed Sensor Test.............................................................................31

Table of Contents

Appendix I

System Overview....................................................................................................33

Electrical Schematic................................................................................................34

Wiring Diagram (fold-out page)

1

Introduction

• Before starting a vehicle always be seated in the driver’s seat,
move the shift lever to neutral, and set the parking brakes.

• If engine cranks in any other gear than neutral, service your vehi­cle neutral safety start circuit and start enable relay circuit imme­diately.

• Before working on a vehicle or leaving the cab with engine run­ning, place the transmission in neutral, set the parking brakes,
AND block the wheels.

• Do not release the parking brake or attempt to select a gear until
the air pressure is at the correct level.

• For safety reasons, always engage the service brakes when mov­ing the shift lever from neutral to one of the other gear positions.

• When parking the vehicle or leaving the cab, always place the shift
lever in neutral and set the parking brakes.

• TOWING: To avoid damage to the transmission during towing,
place the transmission in neutral and lift the drive wheels off the
ground or disconnect the driveline.

Every effort has been made to ensure the accuracy of all information in this manual. However, Eaton
Transmission Division makes no expressed or implied warranty or representation based on the

enclosed information. Any errors or omissions may be reported to Training and Publications, Eaton
Transmission Division, P.O. Box 4013, Kalamazoo, MI 49003

2

Complaint Isolation, Verification & Remedy Procedure

Complaint

Identify System Error via Fault Codes

Using: Service Transmission Light

Service Transmission LIght

Able to Identify Fault Codes Observe and Record

Symptoms

Introduction

Utilize Trouble Shooting Guide

Fault Code Diagnosis

Isolate System or Component Failure

Follow Trouble Shooting Guide Test Sequences

PASS

Follow Trouble Shooting Guide
Remedy Sequence Instructions

Next Step in Trouble Shooting Guide

as Required for Further Diagnosis or Repair

Utilize Trouble Shooting guide

Symptom Driven Diagnosis

FAIL

Proceed to

Re-Test

3

Introduction

For all questions
concerning
inspection,
removal,
replacement,
or adjustment
procedures,
refer to Eaton or
OEM Service and
Parts Literature.

How To Use this Troubleshooting Guide

The purpose of this manual is to assist in the diagnosis and verification of your
electronically managed heavy-duty transmission system. It should be used in
conjunction with Eaton Driver Instructions, Illustrated Parts List, Installation
Guide, and Service Manual -- as well as OEM service related material.

This guide provides three functions:

1. Service Transmission Light Diagnostics: designed to lead the service techni-

cian to the source of a problem through flashing error codes.

2. Performance Evaluation: designed to lead the service technician to the source
of a problem through a performance evaluation.

3. Test and remedy Sequences: detailed component testing designed to isolate
and resolve system failures.

Service Transmission Light Diagnostics

The Service Transmission indicator light, which is also the torque converter
open lamp, assists the mechanic in problem diagnosis via flashing signals equal
to Fault Code numbers as listed in the Fault Codes Diagnosis section of this
manual.

If a driver reports a degraded mode of operation, advise that the capabilities of
the truck should be assessed and then taken to a service site. The transmission

temperature should be monitored during the trip to the service site.

Examples of potential problem conditions under which a vehicle with a Con­verter Enhanced Mechanical Transmission can be driven include:

• Transmission fails to lock torque converter, but vehicle can still proceed although
speed and/or power is limited.

• Transmission is not able to select all ratios and limits the gears available.

1. Using the Service Transmission Light for Diagnostics: To activate the retrieval
of fault codes via the Service Transmission light perform the following steps:

• Active Codes: Place the Shift Lever in Neutral. Set the parking brakes. Begin
with the key in the off position. Turn the key off and back on two (2) times within
5 seconds (OFF/ON/OFF/ON). It is OK if the engine stops, or continues running,
however do not re-energize the starter when retrieving Fault Codes as you may
cause codes to clear.

• If there are no active fault codes, then retrieve the intermittent codes.

• Intermittent codes: Follow instructions for Active Codes, but turn key OFF and
ON four (4) times.

• To clear fault codes: Follow instructions for Active Codes, but turn key OFF and
ON six (6) times. Fault codes should be cleared each time the transmission is
serviced.

4

1a. After activating the retrieval of codes, to read transmission errors via the Service Transmission

light, observe the sequence of flashes exhibited by the light. The Service Transmission light will
flash in coded sequences equal to Fault Codes identified in this manual. A long pause (5 sec­onds) follows each code before it is repeated, or the next codes sequence is given.
Examples:

• Flash / Pause / Flash = Fault Code 11 System Controller

• Flash - Flash / Pause / Flash - Flash - Flash = Fault Code 23 Engine Speed Sensor

• Flash / Pause / Flash - Long Pause - Flash - Flash / Pause / Flash - Flash - Flash = Fault Codes 11
& 23.

1b. To identify fault codes and applicable tests signalled by the Service Transmission light refer to

the Fault code Diagnosis section of this manual.

Symptom Diagnosis

1. Refer to the Performance Evaluation test in this manual.

2. Locate and perform appropriate Test Sequence as indicated by the Performance Evaluation Test.

Before Beginning Diagnostic Procedures

It is possible to “clear” or “reset” the Converter Enhanced Mechanical Electronic Control Unit
(ECU) for some transmission errors. If the transmission is not functioning properly try these
steps before beginning diagnostic procedures:

1. Stop the vehicle.

2. Place the shift lever in neutral.

3. Set the parking brakes.

4. Turn off the engine/ignition and wait for one minute.

5. Restart the engine.

6. Resume operation.

Introduction

For all questions
concerning
inspection,
removal,
replacement,
or adjustment
procedures,
refer to Eaton or
OEM Service and
Parts Literature.

Test Sequence and Remedy Sequence

1. Locate the correct Test Sequence.

2. Always perform pre-test procedures found at the top of each Test Sequence page before begin-

ning test procedure.

3. Follow test steps in sequence.

4. Go to Remedy Sequence when required.

5. Perform appropriate removal, replacement or adjustment procedures.

5

Fault

Code

Diagnosis

For all questions
concerning
inspection,
removal,
replacement,
or adjustment
procedures,
refer to Eaton or
OEM Service and
Parts Literature.

Fault
Code

Test Procedure Page

13 Power Relay Coil Test 12
15 Inertial Brake Solenoid Coil Test 15
22 Bypass/Lockup Solenoid Coil Test 23
23 Engine Speed Sensor Test 21
33 System Voltage Test 13
56 Input Shaft Speed Sensor Test 29
57 Output Shaft Speed Sensor Test 31

6

Symptom

If no fault codes exist perform the Performance Evaluation Test. Locate and perform appropriate
test sequence as indicated by the evaluation.

Driven

Diagnosis

For all questions
concerning
inspection,
removal,
replacement,
or adjustment
procedures,
refer to Eaton or
OEM Service and
Parts Literature.

7

Transmission

Electrical

For all questions
concerning
inspection,
removal,
replacement,
or adjustment
procedures,
refer to Eaton or
OEM Service and
Parts Literature.

Test

Measure voltage across vehicle battery
terminals [voltage = 12.6 volts].

Is voltage correct?

YES

Refer to Figure A below. Disconnect
vehicle interface harness connector J1
from ECU.

Refer to Figure B below. Measure resis­tance between pins A3, B3, C3, and bat­tery negative terminal [resistance = 0.0-

0.4 ohms].

Is resistance correct?

YES NO

Refer to Figure B on
page 9.
Measure voltage
between harness
connector pins A3
and G2 [voltage =
battery voltage].

Is voltage correct?

A problem exists
with transmis­sion electrical
grounds.
Contact OEM for
service informa­tion.

NO

Repair low voltage problem. Contact OEM
for service information.

YES

Refer to Figure B
below. Measure
voltage between
harness connector
pins A3 and G1
[voltage = 0 volts.]

Is voltage correct?

YES NO

CONTINUE

NO

A problem exists
in vehicle inter­face harness or
batter supply cir­cuit breaker. Con­tact service
information.

A problem exists
in vehicle interface
harness or ignition
voltage supply cir­cuit breaker. Con­tact OEM for
service informa­tion.

8

Continuation

Turn the ignition key “ON”.

Refer to Figure B on page 12.
Measure the voltage between
the harness connector pins A3
and G1 [voltage = battery volt­age]. Is voltage correct?

YES NO

Turn ignition key “OFF”. A problem exists in vehicle interface har-

ness or ignition voltage supply circuit
breaker. Contact OEM for service informa­tion.

Transmission

Electrical

Test

For all questions
concerning
inspection,
removal,
replacement,
or adjustment
procedures,
refer to Eaton or
OEM Service and
Parts Literature.

Refer to Figure B below. Place
jumper wire across vehicle
interface harness connector
pins F1 and A3.

Refer to Figure B below. Mea­sure voltage between harness
connector pins B3 and E1 [volt­age = battery voltage]. Is volt-

age correct?

YES

Refer to Figure A on page 8.
Disconnect vehicle interface
harness J2 connector from
ECU.

Refer to Figure C on page 12. Measure
voltage between J1 connector pin B3
and J2 connector pin A3 [voltage = bat­tery voltage]. Is voltage correct?

YES

NO

A problem exists in transmis­sion power relay or vehicle
interface harness. contact
OEM for service information.

NO

Test complete

Repair/replace vehicle interface har­ness according to OEM service
information.

9

Performance

Evaluation

For all questions
concerning
inspection,
removal,
replacement,
or adjustment
procedures,
refer to Eaton or
OEM Service and
Parts Literature.

Test

Before beginning test procedure:

1. Set parking brakes.

2. Perform Transmission Electrical Test.

3. Turn ignition key “OFF”.

Turn ignition key “ON”.

Does converter open lamp turn “ON”?

YES

Perform fault code retrieval as outlined
in the introduction section of this man­ual. Are fault codes present?

YES

Perform
diagnostics for
fault codes as
outlined in the
fault code diag­nostic section of
this manual.

NO

Start the vehicle
and allow the air
system to reach
governor cut off
[90-120 psi].

NO

Perform Transmission Electrical Test,
then torque Converter Open Lamp Test.

Continue

Allow the transmission temperature to
reach operating temperature [180-

°F].

220

Fully depress the clutch pedal and place
the shift lever in gear. Does the trans-

mission engage gears without harsh
grinding?

YES

Does the vehicle
move?

NO

Perform Inertia
Break Test.

YES NO

Perform the Inter­rupt Clutch Sole­noid Test and the
Hydraulic System
Test.

10

t

Continuation

Performance
Evaluation Tes

Drive the vehicle and increase engine
rpm to 1600 rpm. Does the torque con-
verter open lamp turn “OFF”?

YES

Perform range
shift. Does range

shift complete
properly?

YES

Perform splitter
shift. Does the

splitter shift com­plete properly?

YES

NO

Perform Hydrau­lic System Test.

NO

Perform range sys­tem evaluation
according to Eaton
Fuller Air System
Troubleshooting
and Operation
Guide.

NO

For all questions
concerning
inspection,
removal,
replacement,
or adjustment
procedures,
refer to Eaton or
OEM Service and
Parts Literature.

Does engine flare
after clutch pedal
release?

YES

Perform Hydraulic
System Test.

Perform Hydraulic
System Test

Perform splitter
system evaluation
according to Eaton
Fuller Air System
Troubleshooting
and Operation
Guide.

NO

Does vehicle have
trouble pul ling
light loads?

YES NO

Test complete

11

Power

Relay

Coil

Test

For all questions
concerning
inspection,
removal,
replacement,
or adjustment
procedures,
refer to Eaton or
OEM Service and
Parts Literature.

Before beginning test procedure:

1. Set parking brakes.

2. Perform Transmission Electrical Test.

3. Turn ignition key “OFF”.

Refer to Figure A below. Disconnect
vehicle interface harness J1 connector
from the transmission ECU.

Refer to Figure B below. Measure resis­tance between J1 connector pins F1 and
G2 [resistance = 40-90 ohms]. Mea­sure voltage between G2 and vehicle
ground, F1 and vehicle electrical ground
[should = battery voltage].

YES

Replace transmission ECU. Locate power relay assembly and

NO

disconnect vehicle interface harness
from relay assembly.

Refer to Figure C below. Measure
resistance between pins 85 and 86 of
each power relay [resistance = 40-90
ohms]. Is resistance correct?

YES

Replace vehicle
interface harness
according to OEM
service informa­tion.

NO

Replace power
relay assembly
according to
OEM service
information.

Test complete

12

Before beginning test procedure:

1. Set parking brakes.

2. Perform Transmission Electrical Test.

3. Turn ignition key “OFF”.

System

Voltage

Measure voltage across vehicle battery
terminals [voltage = 12.6 volts].

Is voltage correct?

YES NO

Refer to Figure A below. Disconnect
vehicle interface harness connector J1
from ECU.

Refer to Figure B below. Measure
resistance between pins A3, B3, C3,
and battery negative terminal [resis­tance = 0.0-0.4 ohms].

Is resistance correct?

YES NO

Refer to Figure B
below. Measure
voltage between
harness connec­tor pins A3 and
G2 [voltage =
battery voltage].

Is voltage cor­rect?

YES NO

A problem exists
with transmis­sion electrical
grounds.
Contact OEM for
service informa­tion.

Repair low voltage problem. Contact
OEM for service information.

Test

For all questions
concerning
inspection,
removal,
replacement,
or adjustment
procedures,
refer to Eaton or
OEM Service and
Parts Literature.

Refer to Figure B
below. Measure
voltage between
harness connec­tor pins A3 and
G1 [voltage = 0
volts]. Is voltage

correct?

YES NO

Continue

A problem exists
in vehicle inter­face harness or
battery supply cir­cuit breaker. Con­tact OEM for
service informa­tion.

A problem exists
in vehicle inter­face harness or
ignition voltage
supply circuit
breaker. Contact
OEM for service
information.

13

System

Voltage

Test

For all questions
concerning
inspection,
removal,
replacement,
or adjustment
procedures,
refer to Eaton or
OEM Service and
Parts Literature.

Continuation

Turn the ignition key “ON”.

Refer to Figure B below. Measure the
voltage between the harness connector
pins A3 and G1 [voltage = battery volt­age. Is voltage correct?

YES

Turn ignition key “OFF”. A problem exists in vehicle interface

Refer to Figure B below. Place jumper
wire across vehicle interface harness
connector pins F1 and A3.

NO

harness or ignition voltage supply cir­cuit breaker. Contact OEM for service
information.

Refer to Figure B below. Measure volt­age between harness connector pins B3
and E1 [voltage = batter voltage]. Is volt-
age correct?

YES NO

Refer to Figure A at left.
Disconnect vehicle interface
harness J2 connector from
ECU.

Refer to Figure C at left. Measure
voltage between J1 connector pin B3
and J2 connector pin A3 [voltage =
battery voltage]. Is voltage correct?

YES

Test Complete Repair/replace vehicle interface

A problem exists in transmission
power relay or vehicle interface
harness. Contact OEM for ser­vice information.

NO

harness according to OEM service
information

14

t

Before beginning test procedure:

1. Set parking brakes.

2. Perform Transmission Electrical Test.

3. Turn ignition key “OFF”.

Refer to Figure A below. Disconnect
inertia brake solenoid from the trans­mission electrical harness.

Measure resistance between inertia
brake solenoid connector pins [resis­tance = 11-18 ohms]. Measure resis­tance between inertia brake solenoid
and vehicle electrical ground [resis­tance = infinity]. Is resistance correct?

YES

Connect inertia brake solenoid to
transmission harness.

NO

Replace inertia brake solenoid.

I n e r t i a B r ak e
Solenoid
Coil Tes

For all questions
concerning
inspection,
removal,
replacement,
or adjustment
procedures,
refer to Eaton or
OEM Service and
Parts Literature.

Disconnect transmission harness
from vehicle interface harness.

Refer to Figure B below. Measure
resistance between transmission
harness pins G and H [resistance
= 11-18 ohms]. Measure resis­tance between transmission har­ness pin H and vehicle electrical
ground [resistance = infinity]. Is

resistance correct?

YES

Connect trans­mission har­ness to vehicle
interface har­ness.

NO

Replace trans­mission har­ness.

Continue

15

Inertia

Brake

Solenoid

Coil Test

For all questions
concerning
inspection,
removal,
replacement,
or adjustment
procedures,
refer to Eaton or
OEM Service and
Parts Literature.

Continuation

Refer to Figure C below. Disconnect
vehicle interface harness J1 connector
from transmission ECU.

YES

Refer to Figure D below. Measure resis­tance between vehicle interface harness
connector pins E1 and H1 [resistance =
11-18 ohms]. Measure resistance
between pin H1 and vehicle electrical
ground [resistance = infinity]. Is resis-

tance correct?

NO

YES NO

Replace transmission ECU. Replace vehicle interface harness

according to OEM service information.

Test complete

16

t

Before beginning test procedure:

1. Set parking brakes.

2. Perform Transmission Electrical Test.

3. Turn ignition key “OFF”.

Refer to Figure A below. Install 0-100 psi
air gauge in inertia brake air line. Gauge
should be installed in “T” fashion.

Inertia
Brake Tes

Start vehicle and allow air pressure to
reach governor cut off [90-125 psi].

With the vehicle at idle fully depress clutch
pedal and monitor air pressure gauge.

Does the inertia brake air pressure cycle
on and off?

Replace inertia brake according to
service manual.

For all questions
concerning
inspection,
removal,
replacement,
or adjustment
procedures,
refer to Eaton or
OEM Service and
Parts Literature.

NOYES

Refer to Figure B below. Disconnect vehi­cle interface harness connector J1 from
transmission ECU.

Refer to Figure C below. Place jumper wire
between pins G2 and E1.

Refer to Figure C below. Place jumper wire
between pins H1 and A3. Monitor pressure
gauge. Does the inertia brake air pressure
read 85-95 psi?

YES

Go to Inertia
Brake Switch
Test

NO

Remove air gauge
from inertia brake
air line.

Go to Inertia Brake
Air Supply Test

17

Inertia

Brake

S w i t c h

Test

Before beginning test procedure:

1. Set parking brakes.

2. Perform Transmission Electrical Test.

3. Turn ignition key “OFF”.

Refer to Figure A below. Disconnect vehi­cle interface harness connector J2 from the
transmission ECU.

For all questions
concerning
inspection,
removal,
replacement,
or adjustment
procedures,
refer to Eaton or
OEM Service and
Parts Literature.

Refer to Figure B below. Measure the resis­tance between pin F3 and vehicle electrical
ground [resistance = infinity]. Is resistance

correct?

YES NO

Fully depress the clutch pedal. Repair inertia brake switch according to

OEM service information.

Refer to Figure A below. Measure the
resistance between pin F3 and vehicle
electrical ground [resistance = 0-5
ohms]. Is resistance correct?

YES NO

Replce transmis­sion ECU accord­ing to
transmission ser­vice manual.

Repair inertia
brake switch cir­cuit according to
OEM service
information.

18

Before beginning test procedure:

1. Set parking brakes.

2. Perform Transmission Electrical Test.

3. Turn ignition key “OFF”.

Refer to Figure A below. Install 0-100 psi
air gauge in inertia brake solenoid air
regulator port.

I n e r t i a
Brake
A i r
S u pp l y
Test

Start the vehicle and allow air system to
reach governor cut-off [90-120 psi].
Monitor air pressure gauge. Does air
pressure equal 73-83 psi?

YES NO

Replace inertia brake solenoid
according to transmission service
manual.

Replace air filter regulator according
to transmission service manual.

For all questions
concerning
inspection,
removal,
replacement,
or adjustment
procedures,
refer to Eaton or
OEM Service and
Parts Literature.

19

Transmission

Converter

Open

Lamp

Test

Before beginning test procedure:

1. Set parking brakes.

2. Perform Transmission Electrical Test.

3. Turn ignition key “OFF”.

Refer to Figure A below. Disconnect vehicle
interface harness connector J1 from the
transmission ECU.

For all questions
concerning
inspection,
removal,
replacement,
or adjustment
procedures,
refer to Eaton or
OEM Service and
Parts Literature.

Refer to Figure B below. Place jumper wire
between pins G2 and E1. Place jumper wire
between pins C2 and A3. Does Converter

open lamp turn “ON”?

YES NO

Replace transmission ECU according
to OEM service information.

Replace converter open lamp and
inspect the vehicle interface harness.

Does condition still exist?

YES

Perform Tr an s­mission Electri­cal Test.

NO

Test Complete

20

Before beginning test procedure:

1. Set parking brakes.

2. Perform Transmission Electrical Test.

3. Turn ignition key “OFF”.

Refer to Figure A below. Disconnect engine
speed sensor from transmission electrical
harness.

Measure resistance between engine speed
sensor connector pins [resistance = 3k-4k
ohms]. Measure resistance between
engine speed sensor pin A and vehicle elec­trical ground [resistance = infinity]. Is

resistance correct?

Connect engine speed sensor to
transmission harness.

YES NO

Replace engine speed sensor.

Engine
Speed
Sensor
Test

For all questions
concerning
inspection,
removal,
replacement,
or adjustment
procedures,
refer to Eaton or
OEM Service and
Parts Literature.

Refer to Figure B below. Disconnect
transmission harness from the vehi­cle interface harness.

Measure resistance between trans­mission harness pins N and P [resis­tance = 3k-4k ohms]. Measure
resistance between transmission
harness pin P and vehicle electrical
ground [resistance = infinity]. Is

resistance correct?

YES NO

Connect trans­mission har­ness to vehicle
interface har­ness.

Replace trans­mission har­ness.

Continue

21

Engine

Speed

Sensor

For all questions
concerning
inspection,
removal,
replacement,
or adjustment
procedures,
refer to Eaton or
OEM Service and
Parts Literature.

Test

Continuation

Refer to Figure C below. Disconnect
vehicle interface harness J1 connector
from transmission ECU.

Refer to Figure D below. Measure resis­tance between vehicle interface harness
connector pins J3 and K3 [resistance =
3k-4k ohms]. Measure resistance
between pin K3 and vehicle electrical
ground [resistance = infinity]. Is resis-

tance correct?

YES NO

Replace transmission ECU. Replace vehicle interface harness accord-

ing to OEM service information.

Test complete

22

Before beginning test procedure:

1. Set parking brakes.

2. Perform Transmission Electrical Test.

3. Turn ignition key “OFF”.

Refer to Figure A below. Disconnect
torque converter harness from trans­mission electrical harness.

Bypass/
Lockup
S o l e n o i d
Coil
Test

Measure resistance between torque
converter harness pins A and B [resis­tance = 2.5-4 ohms]. Measure resis­tance between torque converter
harness pin A and vehicle electrical
ground [resistance = infinity]. Is resis-

tance correct?

YES NO

Connect torque converter harness to
transmission harness.

Refer to Figure B below. Disconnect
transmission harness from the vehi­cle interface harness.

Measure resistance between trans­mission harness pins A and B [resis­tance = 2.5-4 ohms]. Measure
resistance between transmission
harness pin B and vehicle electrical
ground [resistance = infinity]. Is

resistance correct?

For all questions
concerning
inspection,
removal,
replacement,
or adjustment
procedures,
refer to Eaton or
OEM Service and
Parts Literature.

Replace torque converter harness.

YES

Connect trans­mission har­ness to vehicle
interface har­ness.

Continue

NO

Replace trans­mission har­ness.

23

Bypass/

Lockup

Solenoid

Coil

Before beginning test procedure:

1. Set parking brakes.

2. Perform Transmission Electrical Test.

3. Turn ignition key “OFF”.

For all questions
concerning
inspection,
removal,
replacement,
or adjustment
procedures,
refer to Eaton or
OEM Service and
Parts Literature.

Test

Continuation

Refer to Figure C below. Disconnect
vehicle interface harness J1 connector
from transmission ECU.

Refer to Figure D below. Measure resis­tance between vehicle interface harness
connector pins E1 and K2 [resistance =

2.5-4 ohms]. Measure resistance
between vehicle electrical ground pins E1
and C1 [resistance = 2.5-4 ohms]. Mea­sure resistance between pin C1 and vehi­cle electrical ground [resistance infinity].

Is resistance correct?

YES

Replace transmission ECU. Replace vehicle interface harness

NO

according to OEM service information.

Test complete

24

Before beginning test procedure:

1. Set parking brakes.

2. Perform Transmission Electrical Test.

3. Turn ignition key “OFF”.

Disconnect torque converter harness
from transmission harness.

Refer to Figure A below. Measure resis­tance between torque converter harness
pins C and D [resistance = 2.5-4 ohms].
Is resistance correct?

YES NO

Refer to Figure A below. Measure
resistance between torque converter
harness pin C and vehicle electrical
ground [resistance = infinity]. Is
resistance correct?

Replace torque converter harness.

Interrupt
Clutch
So len oid
Coil
Test

For all questions
concerning
inspection,
removal,
replacement,
or adjustment
procedures,
refer to Eaton or
OEM Service and
Parts Literature.

YES

Turn ignition key
“ON”.

Refer to Figure A
at right. Measure
voltage between
transmission har­ness pins C and
D [voltage = bat­tery voltage]. Is
voltage correct?

YESNO

Depress clutch
pedal.

NO

Replace torque
converter har­ness.

Continue Continue

25

Interrupt

Clutch

Solenoid

Coil

Test

Continuation Continuation

For all questions
concerning
inspection,
removal,
replacement,
or adjustment
procedures,
refer to Eaton or
OEM Service and
Parts Literature.

Refer to Figure A below. Measure volt­age between transmission harness pins
C and D [voltage = 0 volts]. Is voltage
correct?

YES NO

Test Complete Release clutch

pedal.

Connect torque converter harness to
transmission harness. Disconnect
transmission harness from vehicle
interface harness.

Refer to Figure B below. Measure volt­age between vehicle interface harness
pins C and D [voltage = battery volt­age]. Is voltage correct?

YES NO

26

Depress clutch
pedal.

Refer to Figure B
at left. Measure
voltage between
vehicle interface
harness pins C
and D [voltage = 0
volts].

correct

YES NO

Replace trans­mission harness

Is voltage

?

A problem exists in the vehicle interface
harness, clutch switch or power
connect relay. Contact OEM for service
information.

Before beginning test procedure:

1. Set parking brakes.

2. Perform Transmission Electrical Test.

3. Turn ignition key “OFF”.

Set Parking brake and place shift lever in
neutral position.

Refer to Figure A below. Connect 0-300
psi gauges to main interrupt and bypass/
lockup torque converter ports.

Refer to Figure A below. Connect 0-100
psi gauge to torque converter lube port.

Start vehicle and allow transmission tem­perature to reach 180-220

Depress clutch pedal.

°F.

H y d r a u l i c
S y s t e m
Test

For all questions
concerning
inspection,
removal,
replacement,
or adjustment
procedures,
refer to Eaton or
OEM Service and
Parts Literature.

Monitor pressure gauges.

Main pressure: 225-255 psi

Interrupt pressure: 0 psi
Bypass/lockup pressure: 0 psi
Lube pressure: 20-35 psi

Are the pressures correct?

YES NO

Release clutch pedal. Inspect/clean oil strainer in oil pan.

Replace hydraulic valve. If conflict still
exists, a failure has occurred in the
hydraulic system.

Monitor pressure gauges.

Main pressure: 225-255 psi
Interrupt pressure:
Bypass/lockup pressure: 0 psi

Lube pressure: 15-20 psi

Are the pressures correct?

±5 psi of main

Continue

27

Hydraulic

System

Test

Continuation

For all questions
concerning
inspection,
removal,
replacement,
or adjustment
procedures,
refer to Eaton or
OEM Service and
Parts Literature.

YES NO

Increase engine rpm to 1600 rpm to
lock up the torque converter. Torque
converter open light turns “OFF”.
Note: Light should come back on at
1400 rpm.

Monitor pressure gauges.

Main pressure: 225-255 psi
Interrupt pressure:
Bypass/lockup pressure:

Lube pressure: 15-20 psi

Are the pressures correct?

Test complete Replace hydrau-

±5 psi of main

±5 psi of

main

lic valve. If con­flict still exists, a
failure has
occurred in the
hydraulic sys­tem.

Replace hydraulic valve. If conflict
still exists, a failure has occurred in
the hydraulic system.

28

Before beginning test procedure:

1. Set parking brakes.

2. Perform Transmission Electrical Test.

3. Turn ignition key “OFF”.

Refer to Figure A below. Disconnect
input shaft speed sensor from the trans­mission electrical harness.

Measure resistance between input shaft
speed sensor connector pins [resistance
= 3k-4k ohms]. Measure resistance
between input shaft speed sensor pin A
and vehicle electrical ground [resistance
= infinity].

Is resistance correct?

YES

NO

Input
Shaft
Speed
Sensor
Test

For all questions
concerning
inspection,
removal,
replacement,
or adjustment
procedures,
refer to Eaton or
OEM Service and
Parts Literature.

Connect input shaft speed sensor to
transmission harness.

Refer to Figure B below. Disconnect
transmission harness from vehicle
interface harness.

Measure resistance between trans­mission harness pins J and K [resis­tance = 3k-4k ohms]. Measure
resistance between transmission har­ness pin K and vehicle electrical
ground [resistance = infinity].

Is resistance correct?

YES NO

Connect transmission harness to
transmission electrical harness.

Replace the input shaft speed sensor.

Replace the transmission harness.

Continue

29

Input

Shaft

Sensor

Test

Continuation

For all questions
concerning
inspection,
removal,
replacement,
or adjustment
procedures,
refer to Eaton or
OEM Service and
Parts Literature.

Refer to Figure C below. Disconnect
vehicle interface harness J1 connector
from transmission ECU.

Refer to Figure D below. Measure resis­tance between vehicle interface harness
connector pin G3 and H3 [resistance = 3k­4k ohms]. Measure resistance between
pin H3 and vehicle electrical ground
[resistance = infinity].

Is resistance correct?

YES

Replace transmission ECU. Replace vehicle interface harness

Test Complete

NO

according to OEM service informa­tion.

30

Before beginning test procedure:

1. Set parking brakes.

2. Perform Transmission Electrical Test.

3. Turn ignition key “OFF”.

Refer to Figure A below. Disconnect out­put shaft speed sensor from the transmis­sion electrical harness.

Output
Shaft
Speed
Sensor
Test

Measure resistance between output shaft
speed sensor connector pins [resistance =
3k-4k ohms]. Measure resistance
between output shaft speed sensor pin A
and vehicle electrical ground [resistance =
infinity].

Is resistance correct?

YES

Connect output shaft speed sensor to
transmission harness.

Refer to Figure B below. Disconnect
transmission harness from vehicle
interface harness.

Measure resistance between transmis­sion harness pins E and F [resistance =
3k-4k ohms]. Measure resistance
between transmission harness pin F
and vehicle electrical ground [resis­tance = infinity].

Is resistance correct?

NO

Replace the output shaft speed sensor.

For all questions
concerning
inspection,
removal,
replacement,
or adjustment
procedures,
refer to Eaton or
OEM Service and
Parts Literature.

YES

Connect transmission harness to
transmission electrical harness.

Continue

NO

Replace the transmission harness.

31

Output

Shaft

Sensor

Test

Continuation

For all questions
concerning
inspection,
removal,
replacement,
or adjustment
procedures,
refer to Eaton or
OEM Service and
Parts Literature.

Refer to Figure C below. Disconnect
vehicle interface harness J1 connector
from transmission ECU.

Refer to Figure D below. Measure resis­tance between vehicle interface harness
connector pins A1 and B1 [resistance =
3k-4k ohms]. Measure resistance
between pin B1 and vehicle electrical
ground [resistance = infinity]. Is resis-

tance correct?

YES NO

Replace transmission ECU. Replace vehicle interface harness

according to OEM service informa­tion.

Test complete

32

System Overview

Appendix I

For all questions
concerning
inspection,
removal,
replacement,
or adjustment
procedures,
refer to Eaton or
OEM Service and
Parts Literature.

33

Appendix I

For all questions
concerning
inspection,
removal,
replacement,
or adjustment
procedures,
refer to Eaton or
OEM Service and
Parts Literature.

Electrical Schematic

34

Copyright Eaton Corporation, 2012.
Eaton hereby grant their customers,
vendors, or distributors permission
to freely copy, reproduce and/or
distribute this document in printed
format. It may be copied only in
its entirety without any changes or
modifications. THIS INFORMATION
IS NOT INTENDED FOR SALE OR
RESALE, AND THIS NOTICE MUST
REMAIN ON ALL COPIES.

Note: Features and specifications
listed in this document are subject to
change without notice and represent
the maximum capabilities of the
software and products with all options
installed. Although every attempt has
been made to ensure the accuracy of
information contained within, Eaton
makes no representation about the
completeness, correctness or accuracy
and assumes no responsibility for
any errors or omissions. Features and
functionality may vary depending on
selected options.

For spec’ing or service assistance,
call 1-800-826-HELP (4357) or visit
www.eaton.com/roadranger.
In Mexico, call 001-800-826-4357.

Roadranger: Eaton and trusted partners
providing the best products and services in the
industry, ensuring more time on the road.

Eaton Corporation

Vehicle Group
P.O. Box 4013
Kalamazoo, MI 49003 USA
800-826-HELP (4357)
www.eaton.com/roadranger

Printed in USA

For parts or service call us

Pro Gear & Transmission, Inc.

1 [phone]

[phone]

[e-mail]

906 W. Gore St.

Orlando, FL 32805