Allison 3000-4000 Series Troubleshooting
Allison 3000-4000 Series Troubleshooting
Allison 3000-4000 Series Troubleshooting
AND 4000
PRODUCT
FAMILIES TROUBLESHOOTING
CONTROLS
3000 AND3000
4000 PRODUCT
FAMILIES
TROUBLESHOOTING
MANUALALLISON 4MANUAL
GENERATION
PREFACE
Welcome to the TS3989EN Troubleshooting 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
Troubleshooting
Manual
2008 OCTOBER
TS3989EN
Allison Transmission
VOCATIONAL MODELS
3000 VOCATIONAL MODELS
3000 HS
3000 RDS
3000 EVS
3000 MH
3000 PTS
3000 TRV
3200 SP
3200 TRV
3500 RDS
3500 EVS
3500 SP
B 300(P)(R)
B 400(P)(R)
T 200
T 300
3700 SP
4500 EVS
4500 HS
4500 RDS
4500 SP
4500 TRV
4700 EVS
4700 RDS
4700 OFS
4800 EVS
Printed in USA
B 500
B 500P
B 500R
B 500PR
T 425
T 450
3000 AND 4000 PRODUCT FAMILIES TROUBLESHOOTING MANUALALLISON 4th GENERATION CONTROLS
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.
Take time to review the Table of Contents and the manual. Reviewing the Table of Contents will aid you in quickly
locating information.
NOTE:
Allison Transmission is providing 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
ii
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.
WARNING!
Is used when an operating procedure, practice, etc., which, if not correctly followed,
could result in injury or loss of life.
CAUTION:
Is used when an operating procedure, practice, etc., which, if not strictly observed,
could result in damage to or destruction of equipment.
NOTE:
iii
3000 AND 4000 PRODUCT FAMILIES TROUBLESHOOTING MANUALALLISON 4th GENERATION CONTROLS
iv
3000 AND 4000 PRODUCT FAMILIES TROUBLESHOOTING MANUALALLISON 4th GENERATION CONTROLS
TABLE OF CONTENTS
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
11. TRANSMISSION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
12. TRANSMISSION CONTROL MODULE (TCM) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
13. SHIFT SELECTOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
A. Pushbutton Shift Selector . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
B. Lever Shift Selector . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
14. THROTTLE POSITION SENSOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
15. SPEED SENSORS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
16. CONTROL MODULE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
17. WIRING HARNESSES. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 112
A. External Wiring Harness. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 112
B. Internal Wiring Harness . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 114
18. VEHICLE INTERFACE MODULE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 116
19. AUTODETECT FEATURE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 116
A. Retarder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 117
B. Oil Level Sensor (OLS) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 117
C. Throttle Source . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 117
D. Engine Coolant Temperature . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 118
110. TRANSID (TID) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 118
111. SPECIAL ELECTRONIC/ELECTRICAL TOOLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 119
3000 AND 4000 PRODUCT FAMILIES TROUBLESHOOTING MANUALALLISON 4th GENERATION CONTROLS
31
31
32
32
34
35
36
36
36
vi
51
53
53
55
55
56
56
56
57
57
58
58
58
3000 AND 4000 PRODUCT FAMILIES TROUBLESHOOTING MANUALALLISON 4th GENERATION CONTROLS
APPENDICES
A. IDENTIFICATION OF POTENTIAL CIRCUIT PROBLEMS . . . . . . . . . . . . . . . . . . . . . . . . . . . A1
B. MEASURING CLUTCH AND RETARDER PRESSURES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B1
C. SOLENOID AND CLUTCH CHART. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C1
D. WIRE/CONNECTOR CHART . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D1
E. CONNECTOR PART NUMBERS, TERMINAL PART NUMBERS, . . . . . . . . . . . . . . . . . . . . . . .E1
TOOL PART NUMBERS, AND REPAIR INSTRUCTIONS
F. THROTTLE POSITION SENSOR ADJUSTMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .F1
G. WELDING ON VEHICLE/VEHICLE INTERFACE MODULE . . . . . . . . . . . . . . . . . . . . . . . . . . G1
H. HYDRAULIC SCHEMATICS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . H1
J. 3000 AND 4000 PRODUCT FAMILIES WIRING SCHEMATIC. . . . . . . . . . . . . . . . . . . . . . . . . . J1
K. SOLENOID RESISTANCE CHARTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . K1
L. EXTERNALLY-GENERATED ELECTRONIC INTERFERENCE. . . . . . . . . . . . . . . . . . . . . . . . .L1
M. DIAGNOSTIC TREE3000 AND 4000 PRODUCT FAMILIES HYDRAULIC SYSTEM . . . . M1
N. ALLISON DOC FOR PCSERVICE TOOL. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . N1
P. INPUT/OUTPUT FUNCTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .P1
Q. THERMISTOR TROUBLESHOOTING INFORMATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Q1
R. SAE J1939 COMMUNICATION LINK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . R1
vii
3000 AND 4000 PRODUCT FAMILIES TROUBLESHOOTING MANUALALLISON 4th GENERATION CONTROLS
NOTES
viii
3000 AND 4000 PRODUCT FAMILIES TROUBLESHOOTING MANUALALLISON 4th GENERATION CONTROLS
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 11 is a block diagram of the basic system inputs and outputs.
SHIFT SELECTOR
RANGE AND
MODE SWITCH
DISPLAY
SPEED SENSORS
THROTTLE POSITION SENSOR
TCM
RETARDER MODULATION
SOLENOIDS
DIAGNOSTIC PRESSURE SWITCH
VEHICLE/ENGINE
COMMUNICATION LINKS
TEMPERATURE SENSOR
(SUMP/RETARDER)
VIM
INPUTS
FILTER LIFE
SWITCH (PS2)
OUTPUTS
V09074.00.00
NOTE:
11
3000 AND 4000 PRODUCT FAMILIES TROUBLESHOOTING MANUALALLISON 4th GENERATION CONTROLS
GENERAL DESCRIPTION
TRANSMISSION
CONTROL
MODULE
(TCM)
ALLISON DOC
FOR PC - SERVICE TOOL
J1939
CONNECTOR
DIAGNOSTIC
TOOL
CONNECTOR
VIW
CONNECTOR
(OPTIONAL)
DEUTSCH 9-PIN
DIAGNOSTIC TOOL
CONNECTOR
VIM
CONNECTOR
SCI (J1587)
CONNECTOR
(OPTIONAL)
COMPACT
PUSHBUTTON
SELECTOR
RE TARDER ACCUMULATOR
CONNECTOR
RE TARDER
MODULATION
REQUEST (RMR)
CONNECTOR
SENSOR HARNESS
CONNECTOR (OPTIONAL)
REMOTE LEVER
SELEC TOR
OUTPUT
SPEED SENSOR
CONNECTOR
SHIFT
SELEC TOR
CONNECTOR
RE TARDER TEMP.
SENSOR CONNECTOR
THROTTLE POSITION
SENSOR (TPS)
CONNECTOR
REMOTE
PUSHBUTTON
SELEC TOR
D
THROTTLE
POSITION
SENSOR (TPS)
M
O
VEHICLE
INTERFACE
MODULE
(VIM)
TURBINE
SPEED SENSOR
CONNECTOR
(4000 PRODUCT
FAMILY)
ENGINE
SPEED
SENSOR
CONNECTOR
RE TARDER PCS5
SOLENOID
CONNECTOR
STRI P PUSHBUTTON
SHIFT SELEC TORS
(EUROPEAN
OEM)
1
2
R
N
D
3
D
N
R
20-WAY
TRANSMISSION
FEEDTHROUGH
HARNESS
CONNECTOR
V09274.01.00A
12
3000 AND 4000 PRODUCT FAMILIES TROUBLESHOOTING MANUALALLISON 4th GENERATION CONTROLS
GENERAL DESCRIPTION
12.
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 13) 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.
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
13
3000 AND 4000 PRODUCT FAMILIES TROUBLESHOOTING MANUALALLISON 4th GENERATION CONTROLS
GENERAL DESCRIPTION
13.
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.
14
3000 AND 4000 PRODUCT FAMILIES TROUBLESHOOTING MANUALALLISON 4th GENERATION CONTROLS
GENERAL DESCRIPTION
B. Lever Shift Selector (Figure 14)
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
HOLD OVERRIDE
BUTTON
HOLD OVERRIDE
BUTTON
MODE ID
MODE
INDICATOR
(LED)
MODE
INDICATOR
(LED)
R
N
D
6
5
4
3
2
1
MODE BUTTON
DIGITAL DISPLAY
DISPLAY MODE
DIAGNOSTIC
BUTTON
SIX-SPEED,
LEFT-HAND
LEVER SELECTOR
MODE BUTTON
MODE ID
DIGITAL
DISPLAY
DISPLAY MODE
DIAGNOSTIC
BUTTON
SEVEN-SPEED,
RIGHT-HAND
LEVER SELECTOR
CONTOURED
BEZEL
DIGITAL DISPLAY*
MODE ID
R
N
D
MODE
MODE
MODE
N
D
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
SERVICE ICON
V11058.00.00
15
3000 AND 4000 PRODUCT FAMILIES TROUBLESHOOTING MANUALALLISON 4th GENERATION CONTROLS
GENERAL DESCRIPTION
14.
The Throttle Position Sensor (TPS) can be mounted to the engine, chassis, or transmission. The TPS contains a pull
actuation cable and a potentiometer. One end of the cable is attached to the engine fuel lever and the other, inside a
protective housing, to the TPS potentiometer. Output voltage from the TPS is directed to the TCM through the
external harness. The voltage signal indicates the throttle position and, in combination with other input data,
determines shift timing.
A
B
C
V00628
16
3000 AND 4000 PRODUCT FAMILIES TROUBLESHOOTING MANUALALLISON 4th GENERATION CONTROLS
GENERAL DESCRIPTION
15.
Three speed sensorsengine speed, turbine speed, and output speedprovide 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 ranges speed sensor information stored in the TCM
memory.
FORMER (BEFORE JANUARY, 2006)
4000
PRODUCT FAMILY
TURBINE
(EXTERNAL)
3000
PRODUCT FAMILY
TURBINE
(INTERNAL)
3000
PRODUCT FAMILY
(EXCEPT 7-SPEED)
RETARDER OUTPUT
(EXTERNAL)
3000
PRODUCT FAMILY
7-SPEED OUTPUT
(INTERNAL)
3000
PRODUCT FAMILY
7-SPEED OUTPUT
(INTERNAL)
3000/4000
PRODUCT FAMILIES
ENGINE
(EXTERNAL)
4000
PRODUCT FAMILY
TURBINE
(EXTERNAL)
3000
PRODUCT FAMILY
TURBINE
(INTERNAL)
3000
PRODUCT FAMILY
(EXCEPT 7-SPEED)
RETARDER OUTPUT
(EXTERNAL)
V09819.00.00
17
3000 AND 4000 PRODUCT FAMILIES TROUBLESHOOTING MANUALALLISON 4th GENERATION CONTROLS
GENERAL DESCRIPTION
16.
The Allison 4th Generation Series transmission control module contains a main body assembly and solenoid valve
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).
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
V09276.00.00
18
3000 AND 4000 PRODUCT FAMILIES TROUBLESHOOTING MANUALALLISON 4th GENERATION CONTROLS
GENERAL DESCRIPTION
6-SPEED W/PROGNOSTICS
3000 PRODUCT FAMILY
CONTROL MODULE
6-SPEED W/PROGNOSTICS
4000 PRODUCT FAMILY
CONTROL MODULE
V09276.00.00.A
19
3000 AND 4000 PRODUCT FAMILIES TROUBLESHOOTING MANUALALLISON 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 low valve body assembly (in 3000 and 4000 Product Families 7-speed models) contains solenoid PCS6 (C6)
and one ON/OFF solenoid SS2 (C6 enable). Refer to the appropriate service manual for valve locations.
The Allison 4th Generation controls system includes a main modulation solenoid. Modulated main pressure results
in improved cooler flow and reduced pump losses when throttle position and output speed is low. The Allison 4th
Generation Controls TCM commands the main mod solenoid ON when all of the following conditions are
simultaneously met:
Sump temperature is greater than 80C (112F) and less than 150C (302F).
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
110
3000 AND 4000 PRODUCT FAMILIES TROUBLESHOOTING MANUALALLISON 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
Use the Allison DOC For PCService 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.
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.
Copyright 2008 Allison Transmission, Inc.
111
3000 AND 4000 PRODUCT FAMILIES TROUBLESHOOTING MANUALALLISON 4th GENERATION CONTROLS
GENERAL DESCRIPTION
17.
WIRING HARNESSES
A.
TPS
Vehicle interface module (VIM)
Retarder control module
Shift selector
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
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 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 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
112
3000 AND 4000 PRODUCT FAMILIES TROUBLESHOOTING MANUALALLISON 4th GENERATION CONTROLS
GENERAL DESCRIPTION
TRANSMISSION
CONTROL
MODULE
(TCM)
ALLISON DOC
FOR PC - SERVICE TOOL
J1939
CONNECTOR
DIAGNOSTIC
TOOL
CONNECTOR
VIW
CONNECTOR
(OPTIONAL)
DEUTSCH 9-PIN
DIAGNOSTIC TOOL
CONNECTOR
VIM
CONNECTOR
SCI (J1587)
CONNECTOR
(OPTIONAL)
COMPACT
PUSHBUTTON
SELECTOR
RE TARDER ACCUMULATOR
CONNECTOR
RE TARDER
MODULATION
REQUEST (RMR)
CONNECTOR
SENSOR HARNESS
CONNECTOR (OPTIONAL)
REMOTE LEVER
SELEC TOR
OUTPUT
SPEED SENSOR
CONNECTOR
SHIFT
SELEC TOR
CONNECTOR
RE TARDER TEMP.
SENSOR CONNECTOR
THROTTLE POSITION
SENSOR (TPS)
CONNECTOR
REMOTE
PUSHBUTTON
SELEC TOR
D
THROTTLE
POSITION
SENSOR (TPS)
M
O
VEHICLE
INTERFACE
MODULE
(VIM)
TURBINE
SPEED SENSOR
CONNECTOR
(4000 PRODUCT
FAMILY)
ENGINE
SPEED
SENSOR
CONNECTOR
RE TARDER PCS5
SOLENOID
CONNECTOR
STRI P PUSHBUTTON
SHIFT SELEC TORS
(EUROPEAN
OEM)
1
2
R
N
D
3
D
N
R
20-WAY
TRANSMISSION
FEEDTHROUGH
HARNESS
CONNECTOR
V09274.01.00A
Figure 19. Typical 4th Generation Electronic Controls External Wiring Harnesses
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3000 AND 4000 PRODUCT FAMILIES TROUBLESHOOTING MANUALALLISON 4th GENERATION CONTROLS
GENERAL DESCRIPTION
B. Internal Wiring Harness (Figure 110)
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.
TCC (LOCKUP)
PCS1 (C1)
PCS2 (C2/C3)
PS1 DIAGNOSTIC
PRESSURE SWITCH
NT1 TURBINE
SPEED SENSOR
(3000 ONLY)
MAIN MOD
PCS6
(C6, 7-SPEED)
SS1
ON/OFF
OIL LEVEL SENSOR
(4000 ONLY)
PCS4 (C4)
OIL
TEMPERATURE
SENSOR
PCS3 (C3\C5)
SS2
(3000 AND 4000 PRODUCT
FAMILIES 7-SPEED C6 ENABLE)
114
3000 AND 4000 PRODUCT FAMILIES TROUBLESHOOTING MANUALALLISON 4th GENERATION CONTROLS
GENERAL DESCRIPTION
TCC (LOCKUP)
PCS1 (C1)
PCS2 (C2/C3)
PS1 DIAGNOSTIC
PRESSURE SWITCH
NT1 TURBINE
SPEED SENSOR
(3000 ONLY)
MAIN MOD
PS2
FILTER LIFE
SS1
ON/OFF
OIL LEVEL SENSOR
(4000 ONLY)
PCS4 (C4)
OIL
TEMPERATURE
SENSOR
PCS3 (C3\C5)
SS2
(3000 AND 4000 PRODUCT
FAMILIES 7-SPEED C6 ENABLE)
Figure 111. Allison 4th Generation Internal Wiring Harness with Prognostics
115
3000 AND 4000 PRODUCT FAMILIES TROUBLESHOOTING MANUALALLISON 4th GENERATION CONTROLS
GENERAL DESCRIPTION
18.
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 D15 and
D16 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 112.
V00631.02
19.
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 PCService Tool. To use the
Allison DOC For PCService 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 PCService 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 DOCTM Users Guide, GN3433EN, for, detailed instructions
related to Allison 4th Generation Controls CMC. Additional details for each of the four autodetectable features are
given below.
116
3000 AND 4000 PRODUCT FAMILIES TROUBLESHOOTING MANUALALLISON 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 retarder
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.
WARNING:
If a retarder is present but is not detected by autodetect, the retarder will not
function. Be sure to determine that the retarder is functioning properly
immediately after the 35th engine start. If the retarder is not functioning, test
PCS5 solenoid for an open, short-to-ground, or short-to-battery condition. Use
the Allison DOC For PCService Tool to reset retarder autodetect or to
manually select the presence of the retarder after the PCS5 circuit is repaired.
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 PCService 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.
Copyright 2008 Allison Transmission, Inc.
117
3000 AND 4000 PRODUCT FAMILIES TROUBLESHOOTING MANUALALLISON 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.
118
3000 AND 4000 PRODUCT FAMILIES TROUBLESHOOTING MANUALALLISON 4th GENERATION CONTROLS
GENERAL DESCRIPTION
111. 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 11. Essential Tools
3 4 of 9
500
50
DIGITA
40
MULTIM
200
300
400
600
2
5
7
200
500
300
600
400
500
500
600
700
COM
abcde
xyz ab
J 47275
TCM Breakout
Harness Adapter
J 34520-A
Digital
Volt/Ohmmeter
ETER
100
300
900
A
10 A
abcde
xyz ab
multimete
J 47276
T Breakout and TCM
Reflashing Harness
J 39700
Univeral Breakout Box
J 47276
J 39700
J 47277
Terminal Probe
J 42455-A
Load Box
J 42455-A
J 44950
Allison DOC For
PCService Tool
J 47279
3000 and 4000 Product
Families Breakout Harness
*
*
NOTE: J 44950 is
superseded for each new
release of Allison DOC
For PCService Tool
V09224.01.00
J 44950
119
3000 AND 4000 PRODUCT FAMILIES TROUBLESHOOTING MANUALALLISON 4th GENERATION CONTROLS
GENERAL DESCRIPTION
Table 11. Essential Tools (contd)
J 47943-A
or
J 47943
DPA4 (Plus) USB
Translator Device Kit
J 47943
J 47949-A
or
J 47949
GMLAN Cable
J 47949
J 39197
or
J 39197-A
Jumper Kit
NOTE: J 47277 Terminal
Probe is now included in
the J 39197-A Kit.
J 39197-A
J 38125-12A
Terminal Remover
(80-way connector)
GM P/N: 12094429
J 38125-12A
120
J 47139 (Former)
63811-6000 (Current)
Crimper
J 47139
3000 AND 4000 PRODUCT FAMILIES TROUBLESHOOTING MANUALALLISON 4th GENERATION CONTROLS
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.
NOTE:
Prognostic information can only be reset in the higher of two shift schedules, if applicable.
The SERVICE TRANS indicator illuminates briefly following a reset to acknowledge the reset was
successful.
Copyright 2008 Allison Transmission, Inc.
21
3000 AND 4000 PRODUCT FAMILIES TROUBLESHOOTING MANUALALLISON 4th GENERATION CONTROLS
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.
NOTE:
22
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.
The Filter Life Monitor triggers the SERVICE TRANS icon following a reset if the Filter Life
indicator switch reopens.
Copyright 2008 Allison Transmission, Inc.
3000 AND 4000 PRODUCT FAMILIES TROUBLESHOOTING MANUALALLISON 4th GENERATION CONTROLS
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.
23
3000 AND 4000 PRODUCT FAMILIES TROUBLESHOOTING MANUALALLISON 4th GENERATION CONTROLS
MAIN PRESSURE
(BEFORE FILTER)
EX
FILTERED
MAIN
PS 2
CONTROL MAIN
TCC FLOW
PUMP
FILTERED
MAIN
SUCTION FILTER
EX
SUMP
LUBE
MAIN
FLOW
V11111.00.00
D.
24
3000 AND 4000 PRODUCT FAMILIES TROUBLESHOOTING MANUALALLISON 4th GENERATION CONTROLS
22.
Allison DOC (Diagnostic Optimized Connection) For PCService Tool is a PC-based diagnostic tool for use
with 3000 and 4000 Product Families transmissions. The Allison DOC For PCService Tool is a full-feature
diagnostic software application supporting the Allison 4th Generation Control System. When installed on the users
own PC, it will allow the technician to acquire data from the transmissions control system and through the use of
embedded troubleshooting manuals, conduct systematic troubleshooting of transmission complaints.
Basic Features
Allison DOC For PCService Tool uses a Windows style graphical user interface (GUI) and includes:
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 4th Generation Control System Troubleshooting Manuals
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, Video-based training materials, Allison
25
3000 AND 4000 PRODUCT FAMILIES TROUBLESHOOTING MANUALALLISON 4th GENERATION CONTROLS
In order to install and run Allison DOC for PCService 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 portUSB 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 PCService
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:
26
3000 AND 4000 PRODUCT FAMILIES TROUBLESHOOTING MANUALALLISON 4th GENERATION CONTROLS
ABBREVIATIONS
A/N
Assembly Number
ABS
Amp
API
AT
Allison Transmission
C1...C6
Clutch 1....Clutch 6
CAN
Controller Area NetworkA network for all SAE J1939 communications in a vehicle
(engine, transmission, ABS, etc.)
CIN
CMC
CPA
CT
Closed Throttle
DCE
DMM
Digital Multimeter
DNA
DNS
DO NOT SHIFTRefers 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
DPA
DTC
DVOM
Digital Volt/Ohmmeter
ECM
EMI
ElectroMagnetic Interference
FBO
FCC
FM
GPI
General Purpose InputInput signal to the TCM to request a special operating mode or
condition
GPO
General Purpose OutputOutput signal from the TCM to control vehicle components
(such as PTOs, backup lights, etc.) or allow a special operating mode or condition
GUI
HSD
J1587
J1939
27
3000 AND 4000 PRODUCT FAMILIES TROUBLESHOOTING MANUALALLISON 4th GENERATION CONTROLS
ABBREVIATIONS (contd)
LED
LRTP
LSD
MB
Mega Byte
NNC
NVL
Neutral Very LowThe 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
Ohm
OL
Over Limit or Oil LevelFor Over Limit see . Indicates Oil Level is being displayed
on a shift selector
OLS
OM
PC
Personal Computer
PCCS
PCS
PLR
P/N
Part Number
PROM
PSS
PTO
Power Takeoff
PWM
RELS
RFI
RMR
RPR
RTDR
Retarder
SCI
SCTI
SEM
28
3000 AND 4000 PRODUCT FAMILIES TROUBLESHOOTING MANUALALLISON 4th GENERATION CONTROLS
ABBREVIATIONS (contd)
S/N
Serial Number
SOH
State Of Health
SOL OFF
SPI
SS
Shift Solenoid
SSS
TCC
TCM
TFT
TID
TransIDA feature which allows the TCM to know the transmission configuration and
provide the corresponding calibration required
TM
TPA
TPS
Throttle Position SensorPotentiometer for signaling the position of the engine fuel
control lever
VDC
VF
Vacuum Fluorescent
VIM
Vehicle Interface ModuleA watertight box containing relays and fusesinterfaces the
transmission electronic control system with components on the vehicle
VIW
Vehicle Interface WiringInterfaces TCM programmed input and output functions with
the vehicle wiring
Volt
WOT
29
3000 AND 4000 PRODUCT FAMILIES TROUBLESHOOTING MANUALALLISON 4th GENERATION CONTROLS
210
3000 AND 4000 PRODUCT FAMILIES TROUBLESHOOTING MANUALALLISON 4th GENERATION CONTROLS
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 BDetermining 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 4th 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 4th 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 Tech 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
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 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 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
32.
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.
Copyright 2008 Allison Transmission, Inc.
31
3000 AND 4000 PRODUCT FAMILIES TROUBLESHOOTING MANUALALLISON 4th GENERATION CONTROLS
BASIC KNOWLEDGE
33.
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.
34.
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
non-residue, non-lubricating, cleaning solvent such as LPS Electro Contact Cleaner or LPS
NoFlash Electro Contact Cleaner.
32
3000 AND 4000 PRODUCT FAMILIES TROUBLESHOOTING MANUALALLISON 4th GENERATION CONTROLS
BASIC KNOWLEDGE
The cleaning solvent must not be:
Chlorine based
Contain petroleum distillates
CAUTION:
CAUTION:
Conduct electricity.
Care should be taken when welding on a vehicle equipped with electronic controls.
Refer to Appendix G, Paragraph 11.
DTCs displayed after system power is turned on with a harness connector disconnected, can be
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.
NOTE:
CHECK TRANS
Light
Operation
OFF
7C (19F)
OFF
When sump temperature is below 10C (50F) and transmission fluid is C4 (not DEXRON or
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.
Copyright 2008 Allison Transmission, Inc.
33
3000 AND 4000 PRODUCT FAMILIES TROUBLESHOOTING MANUALALLISON 4th GENERATION CONTROLS
BASIC KNOWLEDGE
C.
Temperature
Sump fluid
121C (250F)
Fluid to cooler
149C (300F)
165C (330F)
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:
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.
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 12001500 rpm with the transmission in N (Neutral). This should reduce the
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.
35.
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 For PCService Tool.
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 62 for code reading).
Using the Allison DOC For PCService Tool.
34
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.
Copyright 2008 Allison Transmission, Inc.
3000 AND 4000 PRODUCT FAMILIES TROUBLESHOOTING MANUALALLISON 4th GENERATION CONTROLS
BASIC KNOWLEDGE
4.
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
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:
36.
Information concerning specific items is contained in the appendices located in the back of this
manual. The appendices are referred to throughout the manual.
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
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 4th Generation Controls TCMs are designed to be isolated from the vehicle chassis ground.
Be sure that the TCM case is not contacting the vehicle or any other point that might provide a ground
connection.
Copyright 2008 Allison Transmission, Inc.
35
3000 AND 4000 PRODUCT FAMILIES TROUBLESHOOTING MANUALALLISON 4th GENERATION CONTROLS
BASIC KNOWLEDGE
37.
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:
38.
Once TCM Autoselect locks, the only way to reactivate is to perform a reset procedure (refer to
Paragraph 38).
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 for PCService 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.
The TCM is now reset to Autoselect and will start looking for supporting engine software. Drive the vehicle;
confirm DTCs have not returned.
NOTE:
39.
NOTE:
Transmission shifts will now be in the unadaptive (base) state, so it will be necessary to drive the
vehicle to allow shift to converge.
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.
36
3000 AND 4000 PRODUCT FAMILIES TROUBLESHOOTING MANUALALLISON 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.
Table 33 lists the operating range and pre-determined default range the transmission will shift to in the event of an
electrical interruption.
Table 33.
Initial Operating Range
Reverse
Neutral
(C3 Clutch Applied)
Neutral
Neutral
(C3 Clutch Applied)
37
3000 AND 4000 PRODUCT FAMILIES TROUBLESHOOTING MANUALALLISON 4th GENERATION CONTROLS
BASIC KNOWLEDGE
NOTES
38
3000 AND 4000 PRODUCT FAMILIES TROUBLESHOOTING MANUALALLISON 4th GENERATION CONTROLS
NOTE:
Make sure all connectors are tightly connected and re-test the circuit.
2.
CAUTION:
3.
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
TCM until the cam lever handle moves of its own accord approximately
34 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.
Failure to do so could cause damage to the internal latching mechanism.
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).
CAUTION:
4.
Review the Allison 4th Generation Controls wire numbering system described in Paragraph 34.
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 41):
(1) Disconnect the 80-way connector from the TCM and disconnect the harness from the transmission
main connector. At one end of the harness, using 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 Wire 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.
Copyright 2008 Allison Transmission, Inc.
41
3000 AND 4000 PRODUCT FAMILIES TROUBLESHOOTING MANUALALLISON 4th GENERATION CONTROLS
FEEDTHROUGH
HARNESS
CONNECTOR
DIGITAL
VOLT/OHM-METER
(DVOM)
0 OHMS
OHMS
V03374.02.00
Wires shorted
together
Shorted to
ground on
metal frame
rail
TCM
80-WAY
CONNECTOR
Ground
to metal
frame rail
DIGITAL VOLT/OHM-METER
(DVOM)
0 OHMS
0 OHMS
42
3000 AND 4000 PRODUCT FAMILIES TROUBLESHOOTING MANUALALLISON 4th GENERATION CONTROLS
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 43 and 44).
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 20C to 140C
(4F to 284F). 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
LOCATED IN
INTERNAL
WIRING HARNESS
5.0
OL
DIGITAL
VOLT/OHM-METER
(DVOM)
SOLENOID
SOLENOID
25 OHMS
AT NORMAL OPERATING
TEMPERATURE*
Circuit has continuity.
* Refer to Appendix J
INFINITE (
) OHMS
V03376.01.00
43
3000 AND 4000 PRODUCT FAMILIES TROUBLESHOOTING MANUALALLISON 4th GENERATION CONTROLS
LOCATED IN INTERNAL
WIRING HARNESS
FEEDTHROUGH
HARNESS
CONNECTOR
Shorted
to metal
Bare wires
touching
each other
SOLENOID
DIGITAL
VOLT/OHM-METER
(DVOM)
0 OHMS
0 OHMS
NOTE:
44
When conducting circuit tests that include the external harness, add one (1) Ohm to the values shown.
Speed sensor resistance is 270330 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 MANUALALLISON 4th GENERATION CONTROLS
The oil level sensor (refer to Figure 51) provides a means to electronically determine the transmission fluid level
from:
The shift selector display
Allison DOC For PCService Tool
A customer-supplied remote display.
V07087.01.00
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 51 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 52 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.
51
3000 AND 4000 PRODUCT FAMILIES TROUBLESHOOTING MANUALALLISON 4th GENERATION CONTROLS
6-SPEED
3000 PRODUCT FAMILY
CONTROL MODULE
6-SPEED
4000 PRODUCT FAMILY
CONTROL MODULE
7-SPEED
4000 PRODUCT FAMILY
CONTROL MODULE
V09271.00.00
52
3000 AND 4000 PRODUCT FAMILIES TROUBLESHOOTING MANUALALLISON 4th GENERATION CONTROLS
CAUTION:
NOTE:
A low or high fluid level causes overheating and irregular shift patterns. An
incorrect fluid level can damage the transmission.
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 PCService Tool or a
customer-supplied remote display must be used to obtain fluid level information when using the strip
pushbutton shift selector.
A.
NOTE:
The TCM may delay the fluid level reading until the following conditions are met:
The fluid temperature is between 60C (140F) and 104C (220F).
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 (below 1000 rpmnot fast idle).
53
3000 AND 4000 PRODUCT FAMILIES TROUBLESHOOTING MANUALALLISON 4th GENERATION CONTROLS
Display (MY08e,
Cal/Sfw or newer)
Cause of Code
oL, - -,0X
oL, - -,0X*
oL, - -,50
oL, - -,EL
oL, - -,59
oL, - -,EH
oL, - -,65
oL, - -,SN
oL, - -,70
oL, - -,TL
oL, - -,79
oL, - -,TH
oL, - -,89
oL, - -,SH
oL, - -,95
oL, - -,FL
Sensor failure**
54
3000 AND 4000 PRODUCT FAMILIES TROUBLESHOOTING MANUALALLISON 4th GENERATION CONTROLS
Allison DOC For PCService Tool can also be used to electronically read the transmissions fluid level (refer to
Allison publication GN3433EN, User Guide for Allison DOC For PCService Tool for further information).
CAUTION:
A.
A low or high fluid level causes overheating and irregular shift patterns and, if not
corrected, can damage the transmission.
NOTE:
The TCM may delay the fluid level reading until the following conditions are met:
The fluid temperature is between 60C (140F) and 104C (220F).
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 For PCService Tool by one of the
following diagnostic messages.
Table 52. Diagnostic Message
OL
OL
ENGINE SPEED LO
OL
ENGINE SPEED HI
OL
SELECT N (NEUTRAL)
OL
SUMP TEMP LO
OL
SUMP TEMP HI
OL
OUTPUT SPEED HI
OL
CHECK CODES
55
3000 AND 4000 PRODUCT FAMILIES TROUBLESHOOTING MANUALALLISON 4th GENERATION CONTROLS
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.
CAUTION:
B.
The fluid level rises as fluid temperature rises. DO NOT fill above COLD
CHECK band if the transmission fluid is below normal operating temperatures.
During operation an overfull transmission can become overheated, leading to
transmission damage.
56
3000 AND 4000 PRODUCT FAMILIES TROUBLESHOOTING MANUALALLISON 4th GENERATION CONTROLS
CAUTION:
When performing the Hot Check procedure, the fluid must be at operating
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.
4.76 mm REF
(0.187 in.)
HOT
FULL
FILL TUBE
6.35 mm REF
(0.250 in.)
HOT
RUN
BAND
DIMENSION A
COLD
FULL
HOT
ADD
DIMENSION B
COLD
CHECK
BAND
86.6 mm
(3.41 in.)
DIMENSION C
(SEE CHART BELOW)
TRANSMISSION
CONTROL MODULE
SPLITLINE
COLD
ADD
55.
5.9 mm REF
(0.23 in.)
DIMENSION D
(DETERMINED BY
INSTALLATION)
DEEP SUMP
2 INCH
SHALLOW SUMP
7 INCH
STANDARD**
101.6 mm
(4.00 in.)
101.6 mm
(4.00 in.)
101.6 mm
(4.00 in.)
63.5 mm
(2.50 in.)
73.7 mm
(2.90 in.)
63.5 mm
(2.50 in.)
45.7 mm
(1.80 in.)
50.8 mm
(2.00 in.)
45.7 mm
(1.80 in.)
V01832.01.00
A.
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.
Copyright 2008 Allison Transmission, Inc.
57
3000 AND 4000 PRODUCT FAMILIES TROUBLESHOOTING MANUALALLISON 4th GENERATION CONTROLS
56.
CAUTION:
A.
Containers or fillers that have been used for antifreeze or engine coolant solution
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.
Foreign Material
Prevent foreign material from entering the transmission by using clean containers, fillers, etc. Lay the
dipstick in a clean place while filling the transmission.
57.
FLUID RECOMMENDATIONS
NOTE:
Effective January 1, 2007, General Motors no longer licenses DEXRONIII fluids. Fluid specification TES
389 replaces DEXRONIII. TES 389 fluids have the same fluid and filter change intervals as the former
DEXRONIII.
CAUTION:
The seal material in transmissions beginning with transmission S/N 6510717075 has
been changed to be compatible with DEXRONVI fluids. DO NOT use
DEXRONVI in transmission with earlier serial numbers.
1. The hydraulic fluids (oils) used in Allison transmissions directly affect transmission performance,
reliability, and durability. Use a Allison approved TES 295 fluid, DEXRON-VI, or TES 389 for regular duty, on-highway applications.
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. Consult your Allison Transmission dealer or distributor
before using any fluid types except those fluids qualified for use in Allison transmissions.
58
3000 AND 4000 PRODUCT FAMILIES TROUBLESHOOTING MANUALALLISON 4th GENERATION CONTROLS
CAUTION:
3. When choosing the optimum viscosity grade of fluid to use, duty cycle, preheat capabilities, and/or
geographical location must be taken into consideration. Table 24 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 53. Transmission Fluid Operating
Temperature Requirements
Viscosity Grade
0W-20 or TES 295*
DEXRON-VI or
TES 389
SAE 10W
SAE 15W-40
SAE 30
SAE 40
Celsius
30
Fahrenheit
22
27
17
20
15
0
10
4
5
32
50
59
3000 AND 4000 PRODUCT FAMILIES TROUBLESHOOTING MANUALALLISON 4th GENERATION CONTROLS
510
3000 AND 4000 PRODUCT FAMILIES TROUBLESHOOTING MANUALALLISON 4th GENERATION CONTROLS
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 PCService 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 PCService Tool are presented in
GN3433EN User Guide provided with each tool.
Table 61. Code List
Code List
Position*
DTC
Active**
Historic
Check
Trans
Failure
Record
Description
d1
d2
d3
d4
d5
P0880
P2723
P0727
P0610
Y
Y
N
N
Y
Y
Y
Y
N
Y
N
N
Y
Y
Y
Y
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. Sufficient 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.
Copyright 2008 Allison Transmission, Inc.
61
3000 AND 4000 PRODUCT FAMILIES TROUBLESHOOTING MANUALALLISON 4th GENERATION CONTROLS
Using Allison DOC For PCService 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 the diagnostic 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 (Up) and (Down) arrow buttons a second time or the MODE button
a second time.
A.
Reading Codes
1. Pushbutton Shift SelectorIf 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 SelectorIf 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, enter the diagnostic display mode 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
1
C
3
2
1
1
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 DTCs 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 downAll active indicators are cleared at TCM power down.
62
3000 AND 4000 PRODUCT FAMILIES TROUBLESHOOTING MANUALALLISON 4th GENERATION CONTROLS
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.
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. Wait 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).
63.
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.
63
3000 AND 4000 PRODUCT FAMILIES TROUBLESHOOTING MANUALALLISON 4th GENERATION CONTROLS
be on hydraulically).
the TCM commands the same range as commanded before the shift.
64.
CateyeThe 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)
65.
All Segments DisplayedAll display segments will be illuminated during shift selector initialization.
Low supply voltage can cause the shift selector to fail to complete initialization.
DTC
Description
CHECK
TRANS
Light
No
No
No
No
No
P0562
P0602
P0610
P0613
P0614
No
Yes
Yes
No
Yes
64
Inhibited Operation
Description
3000 AND 4000 PRODUCT FAMILIES TROUBLESHOOTING MANUALALLISON 4th GENERATION CONTROLS
DTC
Description
CHECK
TRANS
Light
Inhibited Operation
Description
Yes
Yes
No
Yes
P0658
P0659
P0702
P0703
Yes
Yes
Yes
No
P0708
P070C
P070D
P0711
Yes
No
No
Yes
Yes
Yes
Yes
Yes
No
Yes
Yes
Yes
Yes
No
No
Yes
Yes
Yes
Yes
Yes
Yes
P0712
P0713
P0716
P0717
P0719
P071A
P071D
P0721
P0722
P0726
P0727
P0729
P0731
P0732
P0733
P0734
P0735
65
3000 AND 4000 PRODUCT FAMILIES TROUBLESHOOTING MANUALALLISON 4th GENERATION CONTROLS
DTC
Description
P0736
P0741
P0752
P0776
P0777
P0796
P0797
P0842
P0843
P0847
P0848
P0880
P0881
P0882
P0883
P088A
P088B
P0894
P0897
P0960
P0962
P0963
P0964
P0966
P0967
P0968
P0970
P0971
P0973
P0974
66
CHECK
TRANS
Light
Inhibited Operation
Description
Yes
Yes
Yes
Yes
Yes
Yes
Yes
Yes
Yes
Yes
Yes
No
No
Yes
No
No
No
Yes
Yes
Yes
Yes
Yes
None
Yes
Yes
Yes
Yes
Yes
Yes
Yes
Yes
3000 AND 4000 PRODUCT FAMILIES TROUBLESHOOTING MANUALALLISON 4th GENERATION CONTROLS
DTC
Description
CHECK
TRANS
Light
Yes
Yes
P0977
P0989
P0990
P1739
Yes
No
No
Yes
P1891
P1892
P2184
P2185
Yes
Yes
Yes
Yes
Yes
Yes
P2685
P2686
P2714
P2715
P2718
Yes
Yes
Yes
Yes
Yes
Inhibit SEM
Inhibit LRTP
SOL OFF, Inhibit TCC operation,
Inhibit main modulation, DNA
DNS, SOL OFF (hydraulic default)
DNS, SOL OFF (hydraulic default)
SOL OFF, Inhibit TCC operation,
Inhibit main modulation, DNA
DNS, SOL OFF (hydraulic default)
DNS, SOL OFF (hydraulic default)
DNS, RPR
DNS, SOL OFF (hydraulic default)
DNS, SOL OFF (hydraulic default)
Yes
Yes
Yes
Yes
Yes
DNS, RPR
DNS, RPR
DNS, SOL OFF (hydraulic default)
Yes
Yes
Yes
P2720
P2721
P2723
P2724
P2727
P2729
P2730
P2736
No
No
No
No
Inhibited Operation
Description
67
3000 AND 4000 PRODUCT FAMILIES TROUBLESHOOTING MANUALALLISON 4th GENERATION CONTROLS
DTC
Description
CHECK
TRANS
Light
Inhibited Operation
Description
Yes
Yes
Yes
No
Yes
Yes
Yes
Yes
None
Use default retarder temp values
Use default retarder temp values
Inhibit TCC operation
Inhibit TCC operation
7-speed: allow 2 through 6, N, R.
Inhibit TCC operation
None
Inhibit kickdown operation
Ignores PWM input from shift
selector
DNS, RPR
DNS, RPR
DNS, SOL OFF (hydraulic default)
Yes
Yes
No
No
Yes
Yes
68
No
No
No
Yes
Yes
Yes
Yes
Yes
Yes
Yes
Yes
Yes
No
Yes
3000 AND 4000 PRODUCT FAMILIES TROUBLESHOOTING MANUALALLISON 4th GENERATION CONTROLS
TRANSMISSION
COMPONENT
WIRING DIAGRAMS
AND
DIAGNOSTICS
69
3000 AND 4000 PRODUCT FAMILIES TROUBLESHOOTING MANUALALLISON 4th GENERATION CONTROLS
610
3000 AND 4000 PRODUCT FAMILIES TROUBLESHOOTING MANUALALLISON 4th GENERATION CONTROLS
J 47275-1
1
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
28
29
30
31
32
33
34
35
36
37
38
39
40
41
42
43
44
45
46
47
48
49
50
51
52
53
54
55
56
57
58
59
60
61
62
63
64
65
66
67
68
69
70
71
72
73
74
75
76
77
78
79
80
Detail of
TCM Overlay
for use with
J 47275
TCM Breakout
Harness Adapter
16-Pin Bypass
Connector
80-Way Connector
To Vehicle
80-Way Connector
To TCM
TCM
V09225.01.00
Figure 61. J 39700 Breakout Box and J 47275 TCM Breakout Harness Adapter
611
3000 AND 4000 PRODUCT FAMILIES TROUBLESHOOTING MANUALALLISON 4th GENERATION CONTROLS
J 47279-1
A
10
TURBINE SPEED
SENSOR
ENGINE SPEED
SENSOR
WT RETARDER
AIR SOLENOID
15
16
RETARDER FEED
THRU VALVE BODY
RETARDER TEMP
OUTPUT SPEED
SENSOR
11
12
13
14
17
18
19
20
Detail of
Magnetic Overlay
for use with
J 47279
Transmission
Breakout Harness
To Existing
Harness
To Engine
Speed Sensor
To Existing *
Harness
To Turbine *
Speed Sensor
To Existing
Harness
To Existing
Harness
To Output
Speed Sensor
To Retarder
Solenoid
To Existing
Harness
To Existing
Harness
To Retarder
Air Solenoid
To Existing
Harness
To Retarder
Temperature Sensor
To Transmission
Connector
V09224.00.00
Figure 62. J 39700 Breakout Box and J 47279 Transmission Breakout Harness
612
3000 AND 4000 PRODUCT FAMILIES TROUBLESHOOTING MANUALALLISON 4th GENERATION CONTROLS
J1939-13 9-Pin
Deutsch Connector
J1962 Connector
To GM LAN
(GM Pickup Truck
Application)
24-Way Connector
To Vehicle
80-Way Connector
To TCM
TCM
V09227.00.00
613
3000 AND 4000 PRODUCT FAMILIES TROUBLESHOOTING MANUALALLISON 4th GENERATION CONTROLS
2. When a problem exists but a DTC is not indicated, refer to Section 8, General 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 freeze frame data using Allison DOC For PCService Tool. Refer to Section
62.
4. Test drive the vehicle to confirm a DTC or performance complaint.
If the code reappears, refer to Section 65, Table 62. Table 62 lists DTCs and their
description.
If the code does not reappear, it may be an intermittent problem. Use Allison DOC For PC
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
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 64. Refer to Figure 64 as
necessary when using the DTC schematics.
C.
614
3000 AND 4000 PRODUCT FAMILIES TROUBLESHOOTING MANUALALLISON 4th GENERATION CONTROLS
FRONT
RIGHT
NT (TURBINE SPEED SENSOR
3000 PRODUCT FAMILIES ONLY)
PCS6 (C6)
(3000 AND 4000
PRODUCT FAMILIES
7-SPEED MODELS ONLY)
TCC LOCKUP
PCS1 (C1)
MAIN MOD
PCS4 (C4)
PCS3 (C3/C5)
PCS2 (C2/C3)
SS1 (FORWARDON
MAIN VALVE BODY)
BACK
V09250.00.00
FRONT
RIGHT
NT (TURBINE SPEED SENSOR
3000 PRODUCT FAMILIES ONLY)
PCS6 (C6)
(3000 AND 4000
PRODUCT FAMILIES
7-SPEED MODELS ONLY)
TCC LOCKUP
MAIN MOD
PCS1 (C1)
PCS4 (C4)
PS2
PCS3 (C3/C5)
PCS2 (C2/C3)
SS1 (FORWARDON
MAIN VALVE BODY)
BACK
V09250.00.00.A
615
3000 AND 4000 PRODUCT FAMILIES TROUBLESHOOTING MANUALALLISON 4th GENERATION CONTROLS
END VIEW OF
80-WAY CONNECTOR
10
11
14
15
20
61
80
41
60
21
40
20
TO RETARDER
CONTROL DEVICES
RETARDER
REQUEST SENSOR
(RESISTANCE
MODULE)
A
PWM
THROTTLE
SOURCE
TCM
THROTTLE
POSITION
SENSOR (TPS)
OR
ELECTRONIC
BRAKING (EBS)
RTDR PRESSURE
SENSOR
WIRE 156
WIRE 112
WIRE 144
WIRE 158
A
RETARDER TEMP
ENGINE TEMP
TRANSMISSION
ANALOG RETURN
OIL LEVEL
HALL
A
C
EFFECT
B
SUMP TEMP
19
16
15
18
PS1
PS2 NC*
NC*
* NORMALLY
616
3
17
WIRE 175
WIRE 135
56
12
5V SENSOR VOLTAGE
44
THROTTLE POSITION OR
RTDR PRESSURE SIGNAL
58
ANALOG RETURN
75
RETARDER TEMP
35
16
54
SUMP TEMP
77
WIRE 158
WIRE 112
WIRE 116
WIRE 154
WIRE 177
WIRE 118
18
CLOSED
3000 AND 4000 PRODUCT FAMILIES TROUBLESHOOTING MANUALALLISON 4th GENERATION CONTROLS
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.
TCM may inhibit retarder operation, if not using the J1939 data link for retarder request signal.
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.
Copyright 2008 Allison Transmission, Inc.
617
3000 AND 4000 PRODUCT FAMILIES TROUBLESHOOTING MANUALALLISON 4th GENERATION CONTROLS
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.
618
Action
Was Section 35, Beginning The Troubleshooting
Process, performed?
Value(s)
1.
2.
3.
4.
Yes
Go to Step 2
Go to Step 3
Go to Step 4
No
Go to Section 35,
Beginning the
Troubleshooting
Process
Go to
Diagnostic Aids
Go to Step 5
3000 AND 4000 PRODUCT FAMILIES TROUBLESHOOTING MANUALALLISON 4th GENERATION CONTROLS
9
10
Action
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?
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 47275-1 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?
1. Turn ignition OFF.
2. Disconnect the 16-pin bypass connector on
J 47275 TCM Breakout.
3. Turn ignition ON.
4. At J 47275-1 TCM Overlay, connect a DVOM
and measure voltage between pins 12 and 58.
Is the voltage within the specified value?
Replace the retarder request sensor (resistance
module).
Is replacement complete?
After replacing the retarder request sensor, perform
the following:
Value(s)
Yes
Go to Step 11
No
Go to Step 5
Refer to
Table 63
Go to Step 10
Go to Step 6
4.755.0V
Go to Step 7
Go to Step 10
Go to Step 8
Go to Step 7
Go to Step 11
Go to Step 9
Go to Step 11
Go to Step 9
Go to Step 11
Go to Step 1
Refer to
Table 63
619
3000 AND 4000 PRODUCT FAMILIES TROUBLESHOOTING MANUALALLISON 4th GENERATION CONTROLS
Action
Value(s)
Yes
Begin the
diagnosis again.
Go to Step 1
No
System OK
Description
Auto Full On
Pressure Switch
Full On
High
3-Step E-10R
Bendix Pedal
Resistance Test in
Resistance Module*
Resistance
K +/ 5%
Terminals
A to C
12
A to C
32
A to C
32
A to C
32
A to C
A to C
A to C
No Check
12
32
Voltage Signal**
Voltage
% Retarder
+/ 0.2V
Application
100
3.6
Device Terminal
No connections
0
100
0
32
58
100
1.1
3.6
1.1
1.9
2.8
3.6
A
B
A
B
C
D
0
14
28
45
65
82
100
50
0
32
68
100
1.1
1.5
1.9
2.3
2.8
3.2
3.6
2.4
1.1
1.9
2.8
3.6
+
1
2
3
4
5
6
No connections
32
68
100
0
100
1.9
2.8
3.6
0.71.2
3.43.5
A
B
A and B
A
B
C
A and B
A and B
A and B
21.4
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.
620
Wiring to Control
Device
3000 AND 4000 PRODUCT FAMILIES TROUBLESHOOTING MANUALALLISON 4th GENERATION CONTROLS
END VIEW OF
80-WAY CONNECTOR
10
11
14
15
20
61
80
41
60
21
40
20
TO RETARDER
CONTROL DEVICES
RETARDER
REQUEST SENSOR
(RESISTANCE
MODULE)
A
PWM
THROTTLE
SOURCE
TCM
THROTTLE
POSITION
SENSOR (TPS)
OR
ELECTRONIC
BRAKING (EBS)
RTDR PRESSURE
SENSOR
WIRE 156
WIRE 112
WIRE 144
WIRE 158
A
RETARDER TEMP
ENGINE TEMP
TRANSMISSION
ANALOG RETURN
OIL LEVEL
HALL
A
C
EFFECT
B
SUMP TEMP
19
16
15
18
PS1
PS2 NC*
NC*
* NORMALLY
3
17
WIRE 175
WIRE 135
56
12
5V SENSOR VOLTAGE
44
THROTTLE POSITION OR
RTDR PRESSURE SIGNAL
58
ANALOG RETURN
75
RETARDER TEMP
35
16
54
SUMP TEMP
77
WIRE 158
WIRE 112
WIRE 116
WIRE 154
WIRE 177
WIRE 118
18
CLOSED
621
3000 AND 4000 PRODUCT FAMILIES TROUBLESHOOTING MANUALALLISON 4th GENERATION CONTROLS
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.
TCM may inhibit retarder operation, if not using the J1939 data link for retarder request signal.
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.
622
3000 AND 4000 PRODUCT FAMILIES TROUBLESHOOTING MANUALALLISON 4th GENERATION CONTROLS
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.
Action
Value(s)
Yes
No
Go to Step 2
Go to Section 35,
Beginning the
Troubleshooting
Process
1.
2.
3.
4.
Go to Step 3
Go to
Diagnostic Aids
Go to Step 4
Go to Step 5
623
3000 AND 4000 PRODUCT FAMILIES TROUBLESHOOTING MANUALALLISON 4th GENERATION CONTROLS
Action
Value(s)
Yes
No
Go to Step 11
Go to Step 5
Refer to
Table 64
Go to Step 10
Go to Step 6
4.75.0V
Go to Step 7
Go to Step 10
Go to Step 8
Go to Step 7
Go to Step 11
Go to Step 9
Go to Step 11
Go to Step 9
Is replacement complete?
8
Refer to
Table 64
624
3000 AND 4000 PRODUCT FAMILIES TROUBLESHOOTING MANUALALLISON 4th GENERATION CONTROLS
Action
Value(s)
10
11
Yes
No
Go to Step 11
Go to Step 10
Begin the
diagnosis again.
Go to Step 1
System OK
Description
Auto Full On
Pressure Switch
Full On
High
3-Step E-10R
Bendix Pedal
Resistance Test in
Resistance Module*
Resistance
K +/ 5%
Terminals
A to C
12
A to C
32
A to C
32
A to C
32
A to C
A to C
A to C
12
32
Voltage Signal**
Voltage
% Retarder
+/ 0.2V
Application
100
3.6
Wiring to Control
Device
Device Terminal
No connections
0
100
0
32
58
100
1.1
3.6
1.1
1.9
2.8
3.6
A
B
A
B
C
D
0
14
28
45
65
82
100
50
0
32
68
100
1.1
1.5
1.9
2.3
2.8
3.2
3.6
2.4
1.1
1.9
2.8
3.6
+
1
2
3
4
5
6
No connections
32
68
100
1.9
2.8
3.6
A
B
A and B
A and B
A and B
A and B
21.4
625
3000 AND 4000 PRODUCT FAMILIES TROUBLESHOOTING MANUALALLISON 4th GENERATION CONTROLS
Description
Dedicated Pedal
Resistance Test in
Resistance Module*
Resistance
K +/ 5%
Terminals
No Check
Interface not a
resistance module
Voltage Signal**
Voltage
% Retarder
+/ 0.2V
Application
0
0.71.2
100
3.43.5
* 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.
626
Wiring to Control
Device
Device Terminal
A
B
C
3000 AND 4000 PRODUCT FAMILIES TROUBLESHOOTING MANUALALLISON 4th GENERATION CONTROLS
END VIEW OF
80-WAY CONNECTOR
10
11
14
15
20
61
80
41
60
21
40
20
TO RETARDER
CONTROL DEVICES
RETARDER
REQUEST SENSOR
(RESISTANCE
MODULE)
A
PWM
THROTTLE
SOURCE
TCM
THROTTLE
POSITION
SENSOR (TPS)
OR
ELECTRONIC
BRAKING (EBS)
RTDR PRESSURE
SENSOR
WIRE 156
WIRE 112
WIRE 144
WIRE 158
A
RETARDER TEMP
ENGINE TEMP
TRANSMISSION
ANALOG RETURN
OIL LEVEL
HALL
A
C
EFFECT
B
SUMP TEMP
19
16
15
18
PS1
PS2 NC*
NC*
* NORMALLY
3
17
WIRE 175
WIRE 135
56
12
5V SENSOR VOLTAGE
44
THROTTLE POSITION OR
RTDR PRESSURE SIGNAL
58
ANALOG RETURN
75
RETARDER TEMP
35
16
54
SUMP TEMP
77
WIRE 158
WIRE 112
WIRE 116
WIRE 154
WIRE 177
WIRE 118
18
CLOSED
627
3000 AND 4000 PRODUCT FAMILIES TROUBLESHOOTING MANUALALLISON 4th GENERATION CONTROLS
The components are powered and engine speed is greater than 200 rpm.
DTC P0122 Pedal Position Sensor Circuit High Voltage is not active.
The TCM uses the default throttle value, based on engine torque and speed.
When diagnosing for an intermittent short or open, massage the wiring harness while watching the test
equipment for a change.
628
3000 AND 4000 PRODUCT FAMILIES TROUBLESHOOTING MANUALALLISON 4th GENERATION CONTROLS
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.
Action
Value(s)
Yes
No
Go to Step 2
Go to Section 35,
Beginning the
Troubleshooting
Process
Go to Step 3
Adjust TPS to
proper setting.
Go to Step 14
1.
2.
3.
4.
918V (12V
TCM)
1832V (24V
TCM)
Go to Step 4
Resolve voltage
problem (refer to
DTC P0882 and
DTC P0883)
4.755.0V
Go to Step 5
Go to Step 9
629
3000 AND 4000 PRODUCT FAMILIES TROUBLESHOOTING MANUALALLISON 4th GENERATION CONTROLS
Action
Value(s)
Yes
No
Go to
Diagnostic Aids
Go to Step 6
900015,000
Ohms
Go to Step 7
Go to Step 12
900015,000
Ohms
Go to Step 13
Go to Step 8
Go to Step 11
Go to Step 14
Go to Step 10
Go to Step 13
10
Go to Step 11
Go to
Diagnostic Aids
630
4.755.0V
3000 AND 4000 PRODUCT FAMILIES TROUBLESHOOTING MANUALALLISON 4th GENERATION CONTROLS
Action
Value(s)
11
Yes
No
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.
System OK
13
14
Go to Step 1
631
3000 AND 4000 PRODUCT FAMILIES TROUBLESHOOTING MANUALALLISON 4th GENERATION CONTROLS
END VIEW OF
80-WAY CONNECTOR
10
11
14
15
20
61
80
41
60
21
40
20
TO RETARDER
CONTROL DEVICES
RETARDER
REQUEST SENSOR
(RESISTANCE
MODULE)
A
PWM
THROTTLE
SOURCE
TCM
THROTTLE
POSITION
SENSOR (TPS)
OR
ELECTRONIC
BRAKING (EBS)
RTDR PRESSURE
SENSOR
WIRE 156
WIRE 112
WIRE 144
WIRE 158
A
RETARDER TEMP
ENGINE TEMP
TRANSMISSION
ANALOG RETURN
OIL LEVEL
HALL
A
C
EFFECT
B
SUMP TEMP
19
16
15
18
PS1
PS2 NC*
NC*
* NORMALLY
632
3
17
WIRE 175
WIRE 135
56
12
5V SENSOR VOLTAGE
44
THROTTLE POSITION OR
RTDR PRESSURE SIGNAL
58
ANALOG RETURN
75
RETARDER TEMP
35
16
54
SUMP TEMP
77
WIRE 158
WIRE 112
WIRE 116
WIRE 154
WIRE 177
WIRE 118
18
CLOSED
3000 AND 4000 PRODUCT FAMILIES TROUBLESHOOTING MANUALALLISON 4th GENERATION CONTROLS
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.
The TCM uses the default throttle value, based on engine torque and speed.
When diagnosing for an intermittent short or open, massage the wiring harness while watching the test
equipment for a change.
633
3000 AND 4000 PRODUCT FAMILIES TROUBLESHOOTING MANUALALLISON 4th GENERATION CONTROLS
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.
Action
Was Section 35, Beginning The Troubleshooting
Process, performed?
Value(s)
634
Yes
Go to Step 2
No
Go to Section 35,
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)
Go to Step 5
Go to Step 9
3000 AND 4000 PRODUCT FAMILIES TROUBLESHOOTING MANUALALLISON 4th GENERATION CONTROLS
Action
Value(s)
Yes
No
Go to Step 6
Go to Step 12
900015,000
Ohms
Go to Step 7
Go to Step 12
900015,000
Ohms
Go to Step 13
Go to Step 8
Go to Step 11
Go to Step 14
Go to Step 10
Go to Step 13
10
Go to Step 11
Go to
Diagnostic Aids
4.755.0V
635
3000 AND 4000 PRODUCT FAMILIES TROUBLESHOOTING MANUALALLISON 4th GENERATION CONTROLS
Action
Value(s)
11
Yes
No
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.
System OK
13
14
636
Go to Step 1
TORQUE
CONVERTER
LOCKUP
CONVERTER IN
CONVERTER OUT
LEGEND:
CONVERTER
FLOW
EX
TCC
SOL
EX
SUCTION
EX
FORWARD
KNOCKDOWN
TO
CLUTCHES
AND
CONTROL
MAIN
CIRCUIT
TO COOLER
COOLER/LUBE
EX. BACKFILL
CONVERTER
MAIN MOD
FROM LUBE
CONVERTER
REGULATOR
LOCKUP PRESSURE
MAIN
REGULATOR
EX
MAIN
FILTER
V09282.00.00.eps
SUMP
SUCTION
FILTER
PUMP
EX
Pressure
Relief
MAIN
MAIN MOD
3000 AND 4000 PRODUCT FAMILIES TROUBLESHOOTING MANUALALLISON 4th GENERATION CONTROLS
637
3000 AND 4000 PRODUCT FAMILIES TROUBLESHOOTING MANUALALLISON 4th GENERATION CONTROLS
3000 AND 4000 PRODUCT FAMILIES TROUBLESHOOTING MANUALALLISON 4th GENERATION CONTROLS
A stuck autoflow valve can cause overheating in retarder-equipped transmissions. Refer to section 8 for
general troubleshooting of performance complaints.
Test Description
This DTC requires the use of the J 47275 TCM Breakout and J 47279 Transmission Breakout. The numbers below
refer to step numbers on the diagnostic table.
2. Tests for proper transmission fluid level and condition.
3. Monitors the status of DTC P0218.
4. Checks for hot fluid causing DTC P0218.
5. Tests for proper resistance value in entire circuit.
6. Tests for wire-to-wire shorts, shorts-to-ground, or an open on wire 154.
7. Tests the resistance value of the internal harness and sump temperature sensor.
9. Tests the resistance value of the internal sump temperature sensor.
12. Tests to determine source of overheatthe engine or transmission.
13. Tests for proper cooler pressure drop.
14. Tests for stuck stator.
15. Inspects vehicles engine and transmission cooling systems.
16. Checks TCM.
Action
Value(s)
Yes
No
Go to Step 2
Go to Section 35,
Beginning the
Troubleshooting
Process
Go to Step 3
Go to Step 4
Go to
Diagnostic Aids
639
3000 AND 4000 PRODUCT FAMILIES TROUBLESHOOTING MANUALALLISON 4th GENERATION CONTROLS
Action
Value(s)
Yes
No
Go to Step 12
Go to Step 6
Go to Step 16
Go to Step 6
Go to Step 8
Go to Step 7
Condition now
intermittent.
Go to Step 10
35113653 Ohms
at 20C (68F)
Refer to
Appendix Q
35113653 Ohms
at 20C (68F)
Refer to
Appendix Q
Go to Step 1
Go to Step 17
Go to Step 8
Go to Step 10
Go to Step 11
Go to Step 17
Go to Step 10
10
35113653 Ohms
at 20C (68F)
Refer to
Appendix Q
640
3000 AND 4000 PRODUCT FAMILIES TROUBLESHOOTING MANUALALLISON 4th GENERATION CONTROLS
Action
Value(s)
Yes
No
Go to Step 17
Go to Step 11
Go to Step 13
Go to Step 15
Go to Step 14
Go to Step 15
Go to Step 17
Go to Section 8,
General
Troubleshooting of
Performance
Complaints
Go to Step 17
Condition
intermittent
Go to Step 17
12
13
14
Refer to Table 65
for 4000 Product
Family.
Refer to Table 66
for 3000 Product
Family
16
Go to Step 1
Go to Step 16
641
3000 AND 4000 PRODUCT FAMILIES TROUBLESHOOTING MANUALALLISON 4th GENERATION CONTROLS
Action
Value(s)
Yes
No
Begin the
diagnosis again.
System OK
Go to Step 1
642
3000 AND 4000 PRODUCT FAMILIES TROUBLESHOOTING MANUALALLISON 4th GENERATION CONTROLS
643
3000 AND 4000 PRODUCT FAMILIES TROUBLESHOOTING MANUALALLISON 4th GENERATION CONTROLS
TCM
61
80
41
60
21
40
20
163
170
IGN
SWITCH
110
10a
169
63
IGNITION
POWER
70
10
BATTERY
POWER
BATTERY
POWER
69
GND
GND
TCM
15a
109
12V/24V
BATTERY
V08905.00.00
Circuit Description
The Transmission Control Module (TCM) requires a switched ignition voltage input to operate. This switched
ignition voltage signal starts at the ignition switch or the ignition relay and supplies voltage to pin 163 in the 80way connector at the TCM.
Conditions for Running the DTC
The components are powered and ignition voltage is greater than 9V and less than 18V (12V TCM) or greater
than 18V and less than 32V (24V TCM).
12V TCMIgnition voltage is detected below 8V at 0C (32F) for a total of 5 seconds. The voltage threshold
is temperature dependent varying from 5V at 60C (76F) to 9V at 20C (68F).
24V TCMIgnition voltage is detected below 17V at 0C (32F) for a total of 5 seconds. The voltage
threshold is temperature dependent varying from 14V at 60C (76F) to 18V at 20C (68F).
644
3000 AND 4000 PRODUCT FAMILIES TROUBLESHOOTING MANUALALLISON 4th GENERATION CONTROLS
If the DTC is active while the vehicle is in a forward range, the transmission shifts to neutral, 1st, 3rd, or 5th
range.
If the DTC is active while in reverse or neutral, the transmission shifts to neutral.
If the shift selector is moved to the forward range, the transmission shifts to neutral, 1st, 3rd, or 5th range.
If the shift selector is moved to R (Reverse) or N (Neutral), transmission shifts to neutral. Diagnostic response
honors the latched inhibit at the time the DTC is set. If a latched inhibit is present and the PRNDL is incorrect,
the transmission shifts to neutral range. GPI request is responded to if the PRNDL is correct.
The TCM does not illuminate the CHECK TRANS light (non-OBD II strategy).
A defective vehicle battery may allow this DTC to set. Test the vehicle battery to verify proper voltage and
load capacity.
Vehicle components such as an ignition switch or TCM ignition relay may cause this DTC to set and not be
active, this indicates that an intermittent condition may exist in these components.
Inspect the wiring for poor electrical connections at the TCM. Look for the following conditions:
A bent terminal
A backed-out terminal
A damaged terminal
Poor terminal tension
A chafed wire
A broken wire inside the insulation
When diagnosing for an intermittent short or open, massage the wiring harness while watching the test
equipment for a change.
Test Description
The numbers below refer to the step numbers on the diagnostic table.
2. Tests for the proper ignition input voltage.
3. Tests for an active DTC after clearing.
4. Tests vehicle battery per OEM guidelines.
5. Tests vehicle charging system per OEM guidelines.
Copyright 2008 Allison Transmission, Inc.
645
3000 AND 4000 PRODUCT FAMILIES TROUBLESHOOTING MANUALALLISON 4th GENERATION CONTROLS
Action
Was the Beginning the Troubleshooting Process
(refer to Section 35) performed?
1.
2.
3.
4.
5.
Value(s)
Yes
Go to Step 2
No
Go to
Beginning The
Troubleshooting
Process
(Section 54)
Go to Step 4
Go to Step 3
Go to Step 4
Go to
Diagnostic Aids
Go to Step 5
Go to
Diagnostic Aids
Repair the
charging system
and go to Step 6
Begin the
diagnosis again.
System OK
Voltage should be
above
9V (12V TCM) or
18V (24V TCM) at
20C (68F).
See conditions for
NOTE: This DTC sets when ignition voltage drops setting the DTC.
below a predetermined level that is
temperature dependent for 5 seconds.
Is the ignition voltage below the specified value?
646
Go to Step 1
3000 AND 4000 PRODUCT FAMILIES TROUBLESHOOTING MANUALALLISON 4th GENERATION CONTROLS
Action
Value(s)
Yes
No
Go to Step 2
Go to Section 35,
Beginning the
Troubleshooting
Process
Go to Step 4
Go to Step 2
Go to Step 4
Go to Step 3
Go to Step 3
System OK
647
3000 AND 4000 PRODUCT FAMILIES TROUBLESHOOTING MANUALALLISON 4th GENERATION CONTROLS
END VIEW OF
20-WAY CONNECTOR
1
10
11
14
15
20
61
80
41
60
21
40
20
TRANSMISSION
TRANSID
HSD1
PCS4
PCS6
MAIN MOD
TCM
WIRE 176
20
WIRE 111
WIRE 155
WIRE 178
WIRE 174
76
11
TRANSID
HSD1
ANALOG
INTERFACE
55
78
V BATTERY
74
V09066.00.00
Circuit Description
The TransID (TID) feature enables the TCM to recognize various transmission hardware configurations and select
an appropriate software calibration. The TCM senses the transmission configuration using TID wire 176. In initial
versions of 4th Generation Controls, wire 176 is connected to High Side Driver 1 (HSD1), wire 111, in the internal
wiring harness. HSD1 supplies power to the Main Mod solenoid, and Pressure Control Solenoids (PSC) 4 and 6.
This wiring configuration is designated TID A.
Conditions for Running the DTC
The test is enabled by the TCM calibration.
Conditions for Setting the DTC
DTC P0610 sets if the TCM determines the controls are incompatible with transmission hardware.
Actions Taken When the DTC Sets
648
3000 AND 4000 PRODUCT FAMILIES TROUBLESHOOTING MANUALALLISON 4th GENERATION CONTROLS
Action
Value(s)
Yes
No
Go to Step 2
Go to Section 35,
Beginning the
Troubleshooting
Process
Go to Step 3
Go to Step 4
Go to Step 6
Go to Step 5
Go to Step 6
Go to Step 4
Go to Step 6
Go to Step 5
Begin the
diagnosis again.
System OK
Go to Step 1
649
3000 AND 4000 PRODUCT FAMILIES TROUBLESHOOTING MANUALALLISON 4th GENERATION CONTROLS
DTC P0613 indicates a TCM processing error has occurred. Contact the Allison Transmission Service
Department at 1-800-252-5283.
650
3000 AND 4000 PRODUCT FAMILIES TROUBLESHOOTING MANUALALLISON 4th GENERATION CONTROLS
Then, the TCM requests the J1939 component ID and engine configuration messages from the engine.
The TCM identifies the engine as an approved make and model by matching the component ID with the engine
configuration message.
The test runs for 15 seconds for the first 20 engine starts after the engine is detected on the J1939
communications link.
The TCM requires a SEM engine but the engine does not support SEM, i.e., is not on the approved list.
The TCM requires a SEM and LRTP engine but the engine does not support SEM and LRTP, i.e., is not on the
approved list.
The engine does not respond to a SEM torque reduction request message within 20 ignition cycles.
The engine does not respond to a LRTP torque reduction request message within 20 ignition cycles.
The TCM will allow operation in Reverse and second range only.
651
3000 AND 4000 PRODUCT FAMILIES TROUBLESHOOTING MANUALALLISON 4th GENERATION CONTROLS
Action
Value(s)
Yes
No
Go to Step 2
Go to Section 35,
Beginning the
Troubleshooting
Process
Go to DTC U0115
and resolve before
proceeding to
Step 8
Go to Step 3
Recognized
or
Not Recognized
Go to Step 4
Go to Step 7
ECM Supports or
does not Support
SEM
Go to Step 5
Go to DTC P2637,
Step 3
ECM Supports or
does not Support
LRTP
Go to Step 6
Go to DTC P2641,
Step 3
Go to Step 8
Go to Step 7
Go to Step 8
Go to Step 7
652
3000 AND 4000 PRODUCT FAMILIES TROUBLESHOOTING MANUALALLISON 4th GENERATION CONTROLS
Action
Value(s)
Yes
No
Begin the
diagnosis again.
System OK
Go to Step 1
653
3000 AND 4000 PRODUCT FAMILIES TROUBLESHOOTING MANUALALLISON 4th GENERATION CONTROLS
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).
Engine speed is greater than 200 rpm and less than 7500 rpm for more than 10 seconds.
Action
Value(s)
Yes
No
Go to Step 2
Go to Section 35,
Beginning the
Troubleshooting
Process
1.
2.
3.
4.
5.
Go to Step 3
Go to
Diagnostic Aids
654
3000 AND 4000 PRODUCT FAMILIES TROUBLESHOOTING MANUALALLISON 4th GENERATION CONTROLS
Action
Value(s)
Yes
No
Go to Step 5
Go to Step 4
Go to Step 5
Go to Step 4
Begin the
diagnosis again.
System OK
Go to Step 1
655
3000 AND 4000 PRODUCT FAMILIES TROUBLESHOOTING MANUALALLISON 4th GENERATION CONTROLS
656
Action
Value(s)
Yes
No
Go to Step 2
Go to Section 35,
Beginning the
Troubleshooting
Process
3000 AND 4000 PRODUCT FAMILIES TROUBLESHOOTING MANUALALLISON 4th GENERATION CONTROLS
Action
Value(s)
Yes
No
1.
2.
3.
4.
Go to Step 7
Go to Step 3
Go to Step 4
Go to Step 7
Go to Step 5
Go to Step 6
Go to Step 8
Go to Step 6
Go to Step 8
Go to Step 6
Go to Step 8
Go to Step 7
Begin the
diagnosis again.
System OK
Go to Step 1
657
3000 AND 4000 PRODUCT FAMILIES TROUBLESHOOTING MANUALALLISON 4th GENERATION CONTROLS
DTC P063F Auto Configuration Engine Coolant Temp Input Not Present
Step
Yes
No
Go to Step 2
Go to Section 35,
Beginning the
Troubleshooting
Process
1.
2.
3.
4.
Go to Step 7
Go to Step 3
658
Action
Value(s)
3000 AND 4000 PRODUCT FAMILIES TROUBLESHOOTING MANUALALLISON 4th GENERATION CONTROLS
Action
Value(s)
Yes
No
Go to Step 4
Go to Step 7
Go to Step 5
Go to Step 6
Go to Step 8
Go to Step 6
Go to Step 8
Go to Step 6
Go to Step 8
Go to Step 7
Begin the
diagnosis again.
System OK
Go to Step 1
659
3000 AND 4000 PRODUCT FAMILIES TROUBLESHOOTING MANUALALLISON 4th GENERATION CONTROLS
END VIEW OF
20-WAY CONNECTOR
1
10
11
14
15
20
61
80
41
60
21
40
20
TRANSMISSION
TRANSID
HSD1
PCS4
PCS6
MAIN MOD
TCM
WIRE 176
20
WIRE 111
WIRE 155
WIRE 178
WIRE 174
76
11
TRANSID
HSD1
ANALOG
INTERFACE
55
78
V BATTERY
74
V09066.00.00
Circuit Description
High Side Driver 1 (HSD1) supplies battery voltage to the Main Mod, PCS4 and PCS6 solenoids via wire 111.
HSD1 is continuously ON during normal operation except during brief circuit tests. The Transmission Control
Module (TCM) regulates control current to the solenoids by switching the appropriate low side driver ON and
OFF. DTC P0657 indicates the TCM has detected multiple low side circuits are open while having HSD1 voltage
of over 6 volts. DTC P2669 could be caused by an open condition in the high side wiring attached to HSD1 (wire 111).
Conditions for Running the DTC
HSD1 is commanded ON
Conditions for Setting the DTC
This DTC sets when the TCM detects multiple low side circuits open, but HSD1 voltage is greater than 6 volts.
Actions taken when the DTC Sets
When DTC P0657 is active:
Hydraulic default (SOL OFF) is commanded. The shift selector position and hydraulic state of latch valves determines
660
3000 AND 4000 PRODUCT FAMILIES TROUBLESHOOTING MANUALALLISON 4th GENERATION CONTROLS
A transmission DTC must be active during the troubleshooting process to determine what caused the DTC. Use
the Snapshot feature of Allison DOC For PCService Tool while operating the vehicle in the same
conditions listed in the failure record (available in the Allison DOC For PCService Tool Reports menu).
Manipulating the chassis harness and data link wiring may reveal intermittent shorts to ground, shorts to
another circuit, and open circuits causing a DTC.
Out of specification driveline components can damage transmission components and cause some transmission
DTCs.
NOTE: Allison Transmission components that are damaged because the driveline exceeded Allison
Transmission driveline specifications are not covered under Allison Transmission Warranty.
NOTE: OEM vehicle harness repairs are not covered under Allison Transmission warranty.
NOTE: OEM repairs necessary for transmission DTCs to go inactive are not covered under Allison
Transmission warranty.
The following wiring and connector issues can cause transmission DTCs:
Expanded female terminals in a connector. Use a mating pin or terminal to check for a light drag feel when
the mating terminal or pin is inserted and then slowly removed. There should be some slight friction
between the matching terminal and pin combination. Expanded terminals have no feel of drag when the
matching pin or terminal is inserted and removed.
Broken terminal locks allow the pins or terminals to push back into the connector, resulting in poor
connection or pin-to-pin shorts in the connector. Inspect for broken locks and displaced terminals in
connections. Never use paper clips or other devices to back probe a connector while doing Allison service
work.
Poor pin crimps. Pin crimps should be pull-tested by the technician to verify the crimp is secure to the wire.
If the pin crimp is loose, the pin easily moves or even comes off the wire with a slight tug on the terminal
by the technician. This situation may not reveal itself as an active DTC but instead may exhibit other
symptoms like shift quality issues.
Connector and pin corrosion caused by moisture in connectors. Empty wire locations in connectors must
always have a plug to keep moisture from finding a path into the connector.
Poor harness routing and improper strain relief may cause damage resulting in electrical open and/or short
circuits to wires and connector components.
Copyright 2008 Allison Transmission, Inc.
661
3000 AND 4000 PRODUCT FAMILIES TROUBLESHOOTING MANUALALLISON 4th GENERATION CONTROLS
then always use heat-shrinkable butt splices. Never use wire ties inside the transmission, to hold connector
components together in the place of a connector lock, or in the place of the correct strain relief components
and clips used to fasten harnesses to the vehicle or to retain vehicle connectors unless OEM approved for
the location and vehicle component being repaired.
The following procedures are not documented in any Allison service procedures or in any Allison
Troubleshooting Manual or Service Manual and therefore should not be used as a method to diagnose any
transmission DTC(s), function, or shift quality concern:
Back-probing any connectors used for transmission features or functions may damage and/or unlock the
terminals from the back-probed connector creating permanent or intermittent shorts and/or open circuits. If
possible, use the Breakout Box J 39700, appropriate harness adapters, and appropriate magnetic overlays
to troubleshoot the vehicle.
Load-testing any transmission-related circuits with any other electrical devices such as vehicle lamps or
relays, especially with the TCM connected to the harness. Use Breakout Box J 39700 and appropriate
harnesses with Allison DOC For PCService Tool to monitor the circuit performance in question unless
otherwise specified in the various Troubleshooting Manuals.
Piercing a wire to check for voltages, shorts to grounds or other wires anywhere in the circuit but especially
at the TCM. This creates a leak path for moisture and damages the wire and insulation.
If necessary, call for local distributor and/or factory support before downtime and expense of repair effect the
Allison Customer Experience. The phone number for the Technical Assistance Center in the United States is 1800-252-5283
Always use tools that are in good condition. Refer to the Allison Essential Tools list on the Allison Extranet to
complete any service procedure listed in an Allison publication. Also see appropriate Service Manuals and
Troubleshooting Manuals for service tools information.
Test Description
1. Review of general troubleshooting procedures and DTC service tips
2. Check for active DTC.
3. Check internal transmission harness.
4. Check OEM Harness.
5. Check for other active DTCs.
6. Check TCM.
662
3000 AND 4000 PRODUCT FAMILIES TROUBLESHOOTING MANUALALLISON 4th GENERATION CONTROLS
Action
Value(s)
Yes
No
Go to Step 2
Go to Step 3
Go to Step 7
Go to Step 4
Refer to appropriate
transmission service
manual and repair or
replace the internal
transmission harness.
Go to Step 7
Go to Step 5
663
3000 AND 4000 PRODUCT FAMILIES TROUBLESHOOTING MANUALALLISON 4th GENERATION CONTROLS
Action
Value(s)
Yes
No
Troubleshoot all
other active
codes
Go to Step 6
Go to Step 1
Go to Step 7
Go to Step 1
System OK
664
3000 AND 4000 PRODUCT FAMILIES TROUBLESHOOTING MANUALALLISON 4th GENERATION CONTROLS
END VIEW OF
80-WAY CONNECTOR
END VIEW OF
20-WAY CONNECTOR
1
10
11
14
15
20
61
80
41
60
21
40
20
TRANSMISSION
TRANSID
HSD1
PCS4
PCS6
MAIN MOD
TCM
WIRE 176
20
WIRE 111
WIRE 155
WIRE 178
WIRE 174
76
11
TRANSID
HSD1
ANALOG
INTERFACE
55
78
V BATTERY
74
V09066.00.00
Circuit Description
High Side Driver 1 (HSD1) supplies battery voltage to the Main Mod, PCS4 and PCS6 solenoids via wire 111.
HSD1 is continuously ON during normal operation except during brief circuit tests. The Transmission Control
Module (TCM) regulates control current to the solenoids by switching the appropriate Low Side Driver (LSD) ON
and OFF. DTC P0658 indicates the TCM has detected a supply voltage in the HSD1 circuit of 6V or less. DTC
P0658 could be caused by a short-to-ground in the high side wiring attached to HSD1 (wire 111).
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).
665
3000 AND 4000 PRODUCT FAMILIES TROUBLESHOOTING MANUALALLISON 4th GENERATION CONTROLS
The TCM commands OFF all solenoids (SOL OFF). The shift selector position and hydraulic state of latch
valves determines the range attained.
Inspect the wiring for poor electrical connections at the TCM and transmission connector. Look for the
following conditions:
A bent terminal
A backed-out terminal
A damaged terminal
Poor terminal tension
A chafed wire
A broken wire inside the insulation
Inspect OEM wiring harness routing, look for possible contact points where chafing could occur leading to an
open or short circuit condition. Moving parts on the vehicle could be contacting the harness; this includes
parking brake drum, suspension components, etc.
When diagnosing for an intermittent short or open, massage the wiring harness while watching the test
equipment for a change.
Test Description
This DTC requires the use of the J 47275 TCM Breakout and J 47279 Transmission Breakout. The numbers below
refer to step numbers on the diagnostic table.
2. Tests for the proper ignition voltage.
3. Tests for an active DTC.
4. Tests for a wire-to-wire short, or short-to-ground in the wire 111 of the OEM chassis harness.
6. Tests for wiring defects in the transmission internal harness.
666
Action
Value(s)
Yes
No
Go to Step 2
Go to Section 35,
Beginning the
Troubleshooting
Process
3000 AND 4000 PRODUCT FAMILIES TROUBLESHOOTING MANUALALLISON 4th GENERATION CONTROLS
Action
Value(s)
Yes
No
1. Install the Allison DOC For PCService Tool. 918V (12V TCM)
1832V (24V TCM)
2. Start the engine.
3. Record the failure records.
4. Monitor ignition voltage.
Is the voltage within the specified values?
Go to Step 3
Resolve voltage
problem
Go to Step 4
Go to
Diagnostic Aids
Go to Step 5
Go to Step 6
Go to Step 9
Go to Step 5
667
3000 AND 4000 PRODUCT FAMILIES TROUBLESHOOTING MANUALALLISON 4th GENERATION CONTROLS
Action
Value(s)
Yes
No
Go to Step 7
Go to Step 8
Go to Step 9
Go to Step 7
Go to Step 9
Go to Step 8
Begin the
diagnosis again.
System OK
668
Go to Step 1
3000 AND 4000 PRODUCT FAMILIES TROUBLESHOOTING MANUALALLISON 4th GENERATION CONTROLS
END VIEW OF
80-WAY CONNECTOR
END VIEW OF
20-WAY CONNECTOR
1
10
11
14
15
20
61
80
41
60
21
40
20
TRANSMISSION
TRANSID
HSD1
PCS4
PCS6
MAIN MOD
TCM
WIRE 176
20
WIRE 111
WIRE 155
WIRE 178
WIRE 174
76
11
TRANSID
HSD1
ANALOG
INTERFACE
55
78
V BATTERY
74
V09066.00.00
Circuit Description
High Side Driver 1 (HSD1) supplies battery voltage to the Main Mod, PCS4 and PCS6 solenoids via wire 111.
HSD1 is continuously ON during normal operation except during brief circuit tests. The Transmission Control
Module (TCM) regulates control current to the solenoids by switching the appropriate Low Side Driver ON and
OFF. DTC P0659 indicates the TCM has detected greater than or equal to 6V in the HSD1 circuit when HSD1 is
OFF during TCM initialization. DTC P0659 could be caused by an open or short-to-battery in the high side wiring
attached to HSD1 (wire 111).
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).
669
3000 AND 4000 PRODUCT FAMILIES TROUBLESHOOTING MANUALALLISON 4th GENERATION CONTROLS
The TCM commands OFF all solenoids (SOL OFF). The shift selector position and hydraulic state of latch
valves determines range attained.
You may have to drive the vehicle in order to experience a fault. Use the data obtained from failure records to
determine transmission range and/or certain vehicle operating variables such as temperature, run time, etc. This
data can be useful in reproducing the failure mode when DTC was set.
Inspect the wiring for poor electrical connections at the TCM and transmission connector. Look for the
following conditions:
A bent terminal
A backed-out terminal
A damaged terminal
Poor terminal tension
A chafed wire
A broken wire inside the insulation
Inspect OEM wiring harness routing, look for possible contact points where chafing could occur leading to an
open or short circuit condition. Moving parts on the vehicle could be contacting the harness; this includes
parking brake drum, suspension components, etc.
When diagnosing for an intermittent short or open, massage the wiring harness while watching the test
equipment for a change.
Test Description
This DTC requires the use of the J 47275 TCM Breakout and J 47279 Transmission Breakout. The numbers below
refer to step numbers on the diagnostic table.
2. Tests for the proper ignition voltage.
3. Tests for an active DTC.
4. Tests for an excessive voltage drop (open) in wire 111 of the OEM harness.
5. Tests for a wire-to-wire short, or short-to-ground in the wire 111 of the OEM chassis harness.
7. Tests for wiring defects in the transmission internal harness.
670
3000 AND 4000 PRODUCT FAMILIES TROUBLESHOOTING MANUALALLISON 4th GENERATION CONTROLS
Action
Value(s)
Yes
No
Go to Step 2
Go to Section 35,
Beginning the
Troubleshooting
Process
1. Install the Allison DOC For PCService Tool. 918V (12V TCM)
1832V (24V TCM)
2. Start the engine.
3. Record the failure records.
4. Monitor ignition voltage.
Is the voltage within the specified values?
Go to Step 3
Resolve voltage
problem
Go to Step 4
Go to
Diagnostic Aids
Go to Step 6
Go to Step 5
NOTE: This DTC detects an open or short-tobattery condition in the HSD1 electrical
circuit.
Did DTC P0659 return?
4
671
3000 AND 4000 PRODUCT FAMILIES TROUBLESHOOTING MANUALALLISON 4th GENERATION CONTROLS
Action
Value(s)
Yes
No
Go to Step 6
Go to Step 7
Go to Step 10
Go to Step 6
Go to Step 8
Go to Step 9
Go to Step 10
Go to Step 8
Go to Step 10
Go to Step 9
Begin the
diagnosis again.
System OK
672
Go to Step 1
3000 AND 4000 PRODUCT FAMILIES TROUBLESHOOTING MANUALALLISON 4th GENERATION CONTROLS
END VIEW OF
20-WAY CONNECTOR
1
10
11
14
15
20
61
80
41
60
21
40
20
TRANSMISSION
TRANSID
HSD1
PCS4
PCS6
MAIN MOD
TCM
WIRE 176
20
WIRE 111
WIRE 155
WIRE 178
WIRE 174
76
11
TRANSID
HSD1
ANALOG
INTERFACE
55
78
V BATTERY
74
V09066.00.00
Circuit Description
The TransID (TID) feature enables the TCM to recognize various transmission hardware configurations and select
an appropriate software calibration. The TCM senses the transmission configuration using TID wire 176. In initial
versions of Allison 4th Generation Controls, wire 176 is connected to High Side Driver 1 (HSD1) via wire 111, in
the internal wiring harness. HSD1 supplies the Main Mod solenoid, PCS4, and PCS6. This wiring configuration is
designated TID A.
Conditions for Running the DTC
The test is enabled by the TCM calibration.
Conditions for Setting the DTC
DTC P0702 sets if the TCM is unable to determine the TransID level of the transmission.
Actions Taken When the DTC Sets
673
3000 AND 4000 PRODUCT FAMILIES TROUBLESHOOTING MANUALALLISON 4th GENERATION CONTROLS
Action
Value(s)
Yes
No
Go to Step 2
Go to Section 35,
Beginning the
Troubleshooting
Process
Go to Step 4
Go to Step 3
Go to Step 8
674
Go to Step 6
Go to Step 5
3000 AND 4000 PRODUCT FAMILIES TROUBLESHOOTING MANUALALLISON 4th GENERATION CONTROLS
Action
Value(s)
Yes
No
Go to Step 8
Go to Step 8
Go to Step 7
Go to Step 8
Go to Step 7
Begin the
diagnosis again.
System OK
Go to Step 1
Table 67.
Wire 176 will be connected to the following wire in the
transmission internal harness:
TID
Pin 20 connected to
TBD
TBD
Table 68.
Wire 176 will be connected to the following wire via the
transmission internal harness:
TID
A
Pin 76 connected to
Pin 11 (wire 111)
675
3000 AND 4000 PRODUCT FAMILIES TROUBLESHOOTING MANUALALLISON 4th GENERATION CONTROLS
676
Pin 76 connected to
TBD
3000 AND 4000 PRODUCT FAMILIES TROUBLESHOOTING MANUALALLISON 4th GENERATION CONTROLS
80
41
60
21
40
20
SERVICE BRAKE
SWITCH
SAE J1939
VEHICLE COMMUNICATION
INTERFACE
TCM
See appropriate
Installation Schematic
installation drawing for
wire and pin numbers.
OPTIONAL
CUSTOMER-FURNISHED
VEHICLE INTERFACE
WIRING CONNECTOR
TCM
OPTIONAL
CUSTOMER-FURNISHED
VEHICLE INTERFACE
WIRING CONNECTOR
N.O.
COM N.C.
V09144.00.00
Circuit Description
The Transmission Control Module (TCM) can be calibrated to receive a service brake status input from either an
analog input wire or the digital data link. A mechanical switch attached to the brake pedal sends a signal to either
the TCM directly or to another electronic controller in the vehicle. When another controller is used, the TCM
receives service brake status as a digital message over the vehicles communications data link.
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.
The TCM senses three acceleration events with service brake signal ON.
The TCM senses three deceleration events with service brake signal OFF.
Copyright 2008 Allison Transmission, Inc.
677
3000 AND 4000 PRODUCT FAMILIES TROUBLESHOOTING MANUALALLISON 4th GENERATION CONTROLS
DTC P0703 indicates the TCM has detected service brake status ON for 3 acceleration events or service brake
status OFF for 3 deceleration events. The code can be caused by:
Faulty wiring
Faulty connections to the service brake switch
A faulty service brake switch
Another controller improperly broadcasting service brake status on the data link when the brake switch is
not installed or operating
A faulty TCM.
Inspect the wiring for poor electrical connections at the TCM and service brake switch. 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
J1939 service brake status can be read on Allison DOC For PCService Tool. Monitor data link
communications using Data Bus Viewer.
Test Description
This DTC requires the use of the J 47275 TCM Breakout Box. The numbers below refer to step numbers on the
diagnostic table.
2.
4.
5.
6.
7.
9. This step observes service brake switch status on the digital data link.
678
3000 AND 4000 PRODUCT FAMILIES TROUBLESHOOTING MANUALALLISON 4th GENERATION CONTROLS
Action
Value(s)
Yes
No
Go to Step 2
Go to Section 35,
Beginning the
Troubleshooting
Process
1.
2.
3.
4.
Go to Step 3
Go to
Diagnostic Aids
Go to Step 4
Go to Step 9
Go to Step 5
Go to Step 6
Go to Step 9
Go to
Diagnostic Aids
Go to Step 8
Go to Step 7
Go to Step 9
Go to Step 8
679
3000 AND 4000 PRODUCT FAMILIES TROUBLESHOOTING MANUALALLISON 4th GENERATION CONTROLS
Action
Value(s)
Yes
No
Go to Step 11
Go to Step 8
Go to
Diagnostic Aids
Go to Step 10
10
Go to Step 11
Go to Step 10
Begin the
diagnosis again.
System OK
680
Go to Step 1
3000 AND 4000 PRODUCT FAMILIES TROUBLESHOOTING MANUALALLISON 4th GENERATION CONTROLS
END VIEW OF
20-WAY CONNECTOR
K
D
END VIEW OF
80-WAY CONNECTOR
S
W
A
E
61
80
41
60
21
40
20
T
L
D N R
1
D N R
TCM
A
B
C
E
L
P
STRIP SHIFT
SELECTOR
SS-1
WIRE 173
SS-2
WIRE 153
SS-4
WIRE 114
SS-P
WIRE 178
LAMP
GROUND
DIGITAL
GROUND
WIRE 150
WIRE 103
73
53
14
DIGITAL
INTERFACE
38
50
3
R
V09229.00.00
Circuit Description
The 3000 and 4000 Product Family transmission control module (TCM) can receive input from a strip-type shift
selector. This type of shift selector communicates with the TCM via 4-bit parallel data wires. The strip shift
selector button position determines the switch state (low or high voltage) of each parallel data wire. The TCM
interprets each particular combination of switch states into a specific range selection, i.e. Reverse, Neutral, and
DRIVE. The TCM sets a DTC P0708 if the switch state of the four parallel data wires does not agree with a valid
switch combination.
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.
681
3000 AND 4000 PRODUCT FAMILIES TROUBLESHOOTING MANUALALLISON 4th GENERATION CONTROLS
Inspect the wiring for poor electrical connections at the TCM and transmission connector. Look for the
following conditions:
A bent terminal
A backed-out terminal
A damaged terminal
Poor terminal tension
A chafed wire
A broken wire inside the insulation
Inspect OEM wiring harness routing, look for possible contact points where chafing could occur leading to an
open or short circuit condition. Moving parts on the vehicle could be contacting the harness; this includes
parking brake drum, suspension components, etc.
When diagnosing for an intermittent short or open, massage the wiring harness while watching the test
equipment for a change.
Test Description
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 function of the strip shift selector.
3. This step measures the switch states (low or high voltage) for each button position.
4. Tests for wiring defects in the OEM wiring harness.
682
3000 AND 4000 PRODUCT FAMILIES TROUBLESHOOTING MANUALALLISON 4th GENERATION CONTROLS
Action
Value(s)
Yes
No
Go to Step 2
Go to Section 35,
Beginning the
Troubleshooting
Process
1.
2.
3.
4.
Go to
Diagnostic Aids
Go to Step 3
Go to
Diagnostic Aids
Go to Step 4
683
3000 AND 4000 PRODUCT FAMILIES TROUBLESHOOTING MANUALALLISON 4th GENERATION CONTROLS
Action
Value(s)
Yes
No
Go to Step 5
Go to Step 6
Go to Step 7
Go to Step 5
Go to Step 7
Go to Step 6
Begin the
diagnosis again.
System OK
Go to Step 1
684
Wire Number
SS-2
SS-4
153
114
Low**
Low**
High***
High***
Low**
High***
Low**
High***
Low**
Low**
High***
Low**
SS-Parity
138
High***
High***
Low**
High***
Low**
High***
3000 AND 4000 PRODUCT FAMILIES TROUBLESHOOTING MANUALALLISON 4th GENERATION CONTROLS
END VIEW OF
80-WAY CONNECTOR
10
11
14
15
20
61
80
41
60
21
40
20
TO RETARDER
CONTROL DEVICES
RETARDER
REQUEST SENSOR
(RESISTANCE
MODULE)
A
PWM
THROTTLE
SOURCE
TCM
THROTTLE
POSITION
SENSOR (TPS)
OR
ELECTRONIC
BRAKING (EBS)
RTDR PRESSURE
SENSOR
WIRE 156
WIRE 112
WIRE 144
WIRE 158
A
RETARDER TEMP
ENGINE TEMP
TRANSMISSION
ANALOG RETURN
OIL LEVEL
HALL
A
C
EFFECT
B
SUMP TEMP
19
16
15
18
PS1
PS2 NC*
NC*
3
17
WIRE 175
WIRE 135
56
12
5V SENSOR VOLTAGE
44
THROTTLE POSITION OR
RTDR PRESSURE SIGNAL
58
ANALOG RETURN
75
RETARDER TEMP
35
16
54
SUMP TEMP
77
WIRE 158
WIRE 112
WIRE 116
WIRE 154
WIRE 177
WIRE 118
18
* NORMALLY CLOSED
V11114.00.00
685
3000 AND 4000 PRODUCT FAMILIES TROUBLESHOOTING MANUALALLISON 4th GENERATION CONTROLS
The TCM provides a 5V reference voltage to the OLS. A microprocessor in the OLS produces a signal voltage that
is proportional to the level of fluid in the transmission sump. The TCM interprets this voltage as transmission fluid
level.
Conditions for Running the DTC
Engine speed is greater than 1500 rpm.
Conditions for Setting the DTC
DTC P070C sets if the TCM is calibrated to receive the OLS signal, and the signal voltage is less than 0.1V for six
consecutive samples.
Actions Taken When the DTC Sets
When DTC P070C is active, the following conditions occur:
DTC P070C indicates the TCM has detected a voltage signal from the OLS in the low error zone. The code can
be caused by:
Extremely low transmission fluid level
Faulty external wiring harness
Faulty connections to the OLS
Faulty internal wiring harness
Faulty OLS
Faulty TCM.
DTC P070C can be caused by an open or short-to-ground in either the 5V reference wire 112 or transmission
fluid level signal wire 116. The OLS shares the common 5V reference voltage wire with the optional retarder
request sensor and throttle position sensor (TPS). An open or short-to-ground in the common 5V reference
wire causes a Sensor Failed Low code for the other devices as well. An open or short-to ground on wire 116
will cause a DTC P070C only.
686
3000 AND 4000 PRODUCT FAMILIES TROUBLESHOOTING MANUALALLISON 4th GENERATION CONTROLS
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 proper transmission fluid level.
3. Tests for an active DTC.
4. Tests for proper 5V reference voltage to OLS.
5. Tests for opens or short-to-ground on wire 112.
6. Tests for TCM function and OLS signal circuit integrity.
Action
Value(s)
Yes
No
Go to Step 2
Go to Section 35,
Beginning the
Troubleshooting
Process
Go to Step 3
1.
2.
3.
4.
Go to Step 4
Go to
Diagnostic Aids
687
3000 AND 4000 PRODUCT FAMILIES TROUBLESHOOTING MANUALALLISON 4th GENERATION CONTROLS
Action
Value(s)
Yes
No
4.645.36V
Go to Step 6
Go to Step 5
Go to Step 8
Go to Step 6
1.
2.
3.
4.
5.
Go to Step 9
Go to Step 7
Go to Step 8
Go to Step 16
Go to Step 17
Go to Step 8
4.645.36V
688
3000 AND 4000 PRODUCT FAMILIES TROUBLESHOOTING MANUALALLISON 4th GENERATION CONTROLS
Action
Value(s)
Yes
No
Go to Step 10
Go to Step 11
Go to Step 17
Go to Step 10
Go to Step 15
Go to Step 12
11
4.645.36V
12
Go to Step 13
Go to Step 14
13
Go to Step 15
Go to Step 13
Go to Step 15
Go to Step 14
15
Go to Step 17
16
Go to Step 17
Go to Step 16
Begin the
diagnosis again.
System OK
Go to Step 1
689
3000 AND 4000 PRODUCT FAMILIES TROUBLESHOOTING MANUALALLISON 4th GENERATION CONTROLS
END VIEW OF
80-WAY CONNECTOR
10
11
14
15
20
61
80
41
60
21
40
20
TO RETARDER
CONTROL DEVICES
RETARDER
REQUEST SENSOR
(RESISTANCE
MODULE)
A
PWM
THROTTLE
SOURCE
TCM
THROTTLE
POSITION
SENSOR (TPS)
OR
ELECTRONIC
BRAKING (EBS)
RTDR PRESSURE
SENSOR
WIRE 156
WIRE 112
WIRE 144
WIRE 158
A
RETARDER TEMP
ENGINE TEMP
TRANSMISSION
ANALOG RETURN
OIL LEVEL
HALL
A
C
EFFECT
B
SUMP TEMP
19
16
15
18
PS1
PS2 NC*
NC*
3
17
WIRE 175
WIRE 135
56
12
5V SENSOR VOLTAGE
44
THROTTLE POSITION OR
RTDR PRESSURE SIGNAL
58
ANALOG RETURN
75
RETARDER TEMP
35
16
54
SUMP TEMP
77
WIRE 158
WIRE 112
WIRE 116
WIRE 154
WIRE 177
WIRE 118
18
* NORMALLY CLOSED
V11114.00.00
690
3000 AND 4000 PRODUCT FAMILIES TROUBLESHOOTING MANUALALLISON 4th GENERATION CONTROLS
DTC P070D can be caused by a short-to-battery on the 5V reference wire 112 or OLS signal wire 116. DTC
P070D can also be caused by an open in the analog return wire 158. The OLS shares a common 5V reference
voltage wire 112 with the optional retarder request sensor and throttle position sensor (TPS). A short-to-battery
on the 5V reference wire or an open in the analog return wire causes a Sensor Failed High code for the other
devices as well. A short-to-battery on the OLS signal wire causes a DTC P070D only.
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
Copyright 2008 Allison Transmission, Inc.
691
3000 AND 4000 PRODUCT FAMILIES TROUBLESHOOTING MANUALALLISON 4th GENERATION CONTROLS
Action
Value(s)
Yes
No
Go to Step 2
Go to Section 35,
Beginning the
Troubleshooting
Process
Go to Step 3
1.
2.
3.
4.
Go to Step 4
Go to
Diagnostic Aids
Go to Step 6
Go to Step 5
692
4.645.36V
3000 AND 4000 PRODUCT FAMILIES TROUBLESHOOTING MANUALALLISON 4th GENERATION CONTROLS
Action
Value(s)
Yes
No
Go to Step 8
Go to Step 6
1.
2.
3.
4.
5.
Go to Step 9
Go to Step 7
Go to Step 8
Go to Step 16
Go to Step 17
Go to Step 8
Go to Step 10
Go to Step 11
Go to Step 17
Go to Step 10
10
693
3000 AND 4000 PRODUCT FAMILIES TROUBLESHOOTING MANUALALLISON 4th GENERATION CONTROLS
Action
Value(s)
Yes
No
11
Go to Step 15
Go to Step 12
12
Go to Step 13
Go to Step 14
13
Go to Step 15
Go to Step 13
Go to Step 15
Go to Step 14
Go to Step 17
Go to Step 15
Go to Step 17
Go to Step 16
Begin the
diagnosis again.
System OK
15
16
17
694
Go to Step 1
3000 AND 4000 PRODUCT FAMILIES TROUBLESHOOTING MANUALALLISON 4th GENERATION CONTROLS
END VIEW OF
80-WAY CONNECTOR
10
11
14
15
20
61
80
41
60
21
40
20
TO RETARDER
CONTROL DEVICES
RETARDER
REQUEST SENSOR
(RESISTANCE
MODULE)
A
PWM
THROTTLE
SOURCE
TCM
THROTTLE
POSITION
SENSOR (TPS)
OR
ELECTRONIC
BRAKING (EBS)
RTDR PRESSURE
SENSOR
WIRE 156
WIRE 112
WIRE 144
WIRE 158
A
RETARDER TEMP
ENGINE TEMP
TRANSMISSION
ANALOG RETURN
OIL LEVEL
HALL
A
C
EFFECT
B
SUMP TEMP
19
16
15
18
PS1
PS2 NC*
NC*
3
17
WIRE 175
WIRE 135
56
12
5V SENSOR VOLTAGE
44
THROTTLE POSITION OR
RTDR PRESSURE SIGNAL
58
ANALOG RETURN
75
RETARDER TEMP
35
16
54
SUMP TEMP
77
WIRE 158
WIRE 112
WIRE 116
WIRE 154
WIRE 177
WIRE 118
18
* NORMALLY CLOSED
V11114.00.00
695
3000 AND 4000 PRODUCT FAMILIES TROUBLESHOOTING MANUALALLISON 4th GENERATION CONTROLS
The TCM detects a temperature change that is under a calibration limit when compared to samples of the
minimum and maximum temperature values.
The TFT has an unrealistic temperature change of more than 10C (50F) for 10 occurrences.
The temperature from start-up changes by 40C (104F) or more within a duration of 6 or more seconds.
Inspect the wiring for poor electrical connections at the TCM and transmission connector. Look for the
following conditions:
A bent terminal
A backed-out terminal
A damaged terminal
Poor terminal tension
A chafed wire
A broken wire inside the insulation
696
3000 AND 4000 PRODUCT FAMILIES TROUBLESHOOTING MANUALALLISON 4th GENERATION CONTROLS
When diagnosing for an intermittent short or open, massage the wiring harness while watching the test
equipment for a change.
Transmission fluid temperature on Allison DOC For PCService Tool should rise steadily during warmup
cycles and then stabilize.
Test Description
This DTC requires the use of the J 47275 TCM Breakout and J 47279 Transmission Breakout. The numbers below
refer to step numbers on the diagnostic table.
2. Tests for proper transmission fluid level and condition.
3. This step verifies which condition has set the DTC P0711.
4. Tests for the proper 5V reference voltage at TCM with OEM harness connected.
5. Tests for proper 5V reference voltage at TCM without OEM harness.
6. Tests for wire-to-wire shorts, shorts-to-ground, or an open condition on wire 154.
7. Tests for proper system circuit resistance value.
8. Tests the resistance value of the internal harness and TFT sensor.
10. Tests the resistance value of the internal TFT sensor.
Action
Value(s)
Yes
No
Go to Step 2
Go to Section 35,
Beginning the
Troubleshooting
Process
Go to Step 3
Go to Fluid Check
Procedure (refer to
Mechanics Tips)
Go to Step 4
Go to
Diagnostic Aids
1.
2.
3.
4.
5.
1.5C (2.7F)
per second
697
3000 AND 4000 PRODUCT FAMILIES TROUBLESHOOTING MANUALALLISON 4th GENERATION CONTROLS
Action
Value(s)
Yes
No
1.
2.
3.
4.
5.
4.755.0V
Go to Step 7
Go to Step 5
4.755.0V
Go to Step 6
Go to Step 13
Go to Step 9
Go to
Diagnostic Aids
35113653 Ohms
at 20C (68F)
Refer to
Appendix Q
Go to
Diagnostic Aids
Go to Step 8
35113653 Ohms
at 20C (68F)
Refer to
Appendix Q
Go to Step 9
Go to Step 10
Go to Step 14
Go to Step 9
3000 AND 4000 PRODUCT FAMILIES TROUBLESHOOTING MANUALALLISON 4th GENERATION CONTROLS
Action
Value(s)
Yes
No
10
35113653 Ohms
at 20C (68F)
Refer to
Appendix Q
Go to Step 11
Go to Step 12
11
Go to Step 14
Go to Step 14
Go to Step 14
Begin the
diagnosis again.
System OK
Go to Step 1
699
3000 AND 4000 PRODUCT FAMILIES TROUBLESHOOTING MANUALALLISON 4th GENERATION CONTROLS
END VIEW OF
80-WAY CONNECTOR
10
11
14
15
20
61
80
41
60
21
40
20
TO RETARDER
CONTROL DEVICES
RETARDER
REQUEST SENSOR
(RESISTANCE
MODULE)
A
PWM
THROTTLE
SOURCE
TCM
THROTTLE
POSITION
SENSOR (TPS)
OR
ELECTRONIC
BRAKING (EBS)
RTDR PRESSURE
SENSOR
WIRE 156
WIRE 112
WIRE 144
WIRE 158
A
RETARDER TEMP
ENGINE TEMP
TRANSMISSION
ANALOG RETURN
OIL LEVEL
HALL
A
C
EFFECT
B
SUMP TEMP
19
16
15
18
PS1
PS2 NC*
NC*
3
17
WIRE 175
WIRE 135
56
12
5V SENSOR VOLTAGE
44
THROTTLE POSITION OR
RTDR PRESSURE SIGNAL
58
ANALOG RETURN
75
RETARDER TEMP
35
16
54
SUMP TEMP
77
WIRE 158
WIRE 112
WIRE 116
WIRE 154
WIRE 177
WIRE 118
18
* NORMALLY CLOSED
V11114.00.00
6100
3000 AND 4000 PRODUCT FAMILIES TROUBLESHOOTING MANUALALLISON 4th GENERATION CONTROLS
The components are powered and engine speed is greater than 200 rpm and less than 7500 rpm for 5 seconds.
When engine coolant temperature sensor is present, engine is running. If engine runtime is less than 10
minutes, then engine coolant temperature must be above 20C (68F) for more than 20 seconds.
The TCM is detecting voltage. An extremely low input voltage implies low thermistor resistance, which
corresponds to an unrealistically high transmission fluid temperature measurement.
Inspect the wiring for poor electrical connections at the TCM and service brake switch. 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.
6101
3000 AND 4000 PRODUCT FAMILIES TROUBLESHOOTING MANUALALLISON 4th GENERATION CONTROLS
Test Description
This DTC requires the use of the J 47275 TCM Breakout and J 47279 Transmission Breakout. The numbers below
refer to step numbers on the diagnostic table.
1. Tests for proper transmission fluid level and condition.
2. This step verifies which condition has set the DTC P0712.
3. Tests for the proper 5V reference voltage at TCM with OEM harness connected.
4. Tests for wire-to-wire shorts, shorts-to-ground, or an open on wire 154.
5. Tests for 5V reference voltage without OEM harness.
6. Tests for proper system circuit resistance value.
7. Tests the resistance value of the internal harness and TFT sensor.
10. Tests the resistance value of the internal TFT sensor.
Action
Value(s)
Yes
No
Go to Step 2
Go to Section 35,
Beginning the
Troubleshooting
Process
Go to Step 3
1.
2.
3.
4.
5.
>128C (262F)
Go to Step 4
Go to
Diagnostic Aids
1.
2.
3.
4.
5.
4.75 to 5.0V
Go to Step 6
Go to Step 5
6102
3000 AND 4000 PRODUCT FAMILIES TROUBLESHOOTING MANUALALLISON 4th GENERATION CONTROLS
Action
Value(s)
Yes
No
4.755.0V
Go to Step 6
Go to Step 13
Go to
Diagnostic Aids
Go to Step 7
35113653 Ohms
at 20C (68F)
Refer to
Appendix Q
Go to
Diagnostic Aids
Go to Step 8
35113653 Ohms
at 20C (68F)
Go to Step 9
Go to Step 10
Go to Step 14
Go to Step 9
Go to Step 11
Go to Step 12
Refer to
Appendix Q
10
35113653 Ohms
at 20C (68F)
Refer to
Appendix Q
6103
3000 AND 4000 PRODUCT FAMILIES TROUBLESHOOTING MANUALALLISON 4th GENERATION CONTROLS
Action
Value(s)
Yes
No
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.
System OK
13
14
6104
Go to Step 1
3000 AND 4000 PRODUCT FAMILIES TROUBLESHOOTING MANUALALLISON 4th GENERATION CONTROLS
END VIEW OF
80-WAY CONNECTOR
10
11
14
15
20
61
80
41
60
21
40
20
TO RETARDER
CONTROL DEVICES
RETARDER
REQUEST SENSOR
(RESISTANCE
MODULE)
A
PWM
THROTTLE
SOURCE
TCM
THROTTLE
POSITION
SENSOR (TPS)
OR
ELECTRONIC
BRAKING (EBS)
RTDR PRESSURE
SENSOR
WIRE 156
WIRE 112
WIRE 144
WIRE 158
A
RETARDER TEMP
ENGINE TEMP
TRANSMISSION
ANALOG RETURN
OIL LEVEL
HALL
A
C
EFFECT
B
SUMP TEMP
19
16
15
18
PS1
PS2 NC*
NC*
3
17
WIRE 175
WIRE 135
56
12
5V SENSOR VOLTAGE
44
THROTTLE POSITION OR
RTDR PRESSURE SIGNAL
58
ANALOG RETURN
75
RETARDER TEMP
35
16
54
SUMP TEMP
77
WIRE 158
WIRE 112
WIRE 116
WIRE 154
WIRE 177
WIRE 118
18
* NORMALLY CLOSED
V11114.00.00
6105
3000 AND 4000 PRODUCT FAMILIES TROUBLESHOOTING MANUALALLISON 4th GENERATION CONTROLS
The components are powered and engine speed is greater than 200 rpm and less than 7500 rpm for 5 seconds.
When engine coolant temperature sensor is present, engine is running. If engine runtime is less than
10 minutes, then engine coolant temperature must be above 20C (68F) for more than 20 seconds.
The TCM is detecting voltage. A high input voltage implies high thermistor resistance, which
corresponds to an extremely cold transmission fluid temperature measurement.
3000 AND 4000 PRODUCT FAMILIES TROUBLESHOOTING MANUALALLISON 4th GENERATION CONTROLS
When diagnosing for an intermittent short or open, massage the wiring harness while watching the test
equipment for a change.
Test Description
This DTC requires the use of the J 47275 TCM Breakout and J 47279 Transmission Breakout. The numbers below
refer to step numbers on the diagnostic table.
2. Tests for proper transmission fluid level and condition.
3. Verifies which condition has set the DTC P0712.
4. Tests for the proper 5V reference voltage at TCM with OEM harness connected.
5. Tests for proper 5V reference voltage at TCM without the OEM harness.
6. Tests for wiring defects in external harness.
7. Tests for proper system circuit resistance value.
8. Tests the resistance value of the internal harness and TFT sensor.
10. Tests the resistance value of the internal TFT sensor.
Action
Value(s)
Yes
No
Go to Step 2
Go to Section 35,
Beginning the
Troubleshooting
Process
Go to Step 3
1.
2.
3.
4.
5.
Go to Step 4
Go to
Diagnostic Aids
4.75 to 5.0V
Go to Step 7
Go to Step 5
6107
3000 AND 4000 PRODUCT FAMILIES TROUBLESHOOTING MANUALALLISON 4th GENERATION CONTROLS
Action
Value(s)
Yes
No
4.755.0V
Go to Step 6
Go to Step 13
Go to Step 9
Go to
Diagnostic Aids
Go to
Diagnostic Aids
Go to Step 8
Go to Step 9
Go to Step 10
Go to Step 14
Go to Step 9
35113653 Ohms
at 20C (68F)
35113653 Ohms
at 20C (68F)
Refer to
Appendix Q
Refer to
Appendix Q
6108
3000 AND 4000 PRODUCT FAMILIES TROUBLESHOOTING MANUALALLISON 4th GENERATION CONTROLS
Action
Value(s)
Yes
No
10
Go to Step 11
Go to Step 12
11
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.
System OK
13
14
Go to Step 1
6109
3000 AND 4000 PRODUCT FAMILIES TROUBLESHOOTING MANUALALLISON 4th GENERATION CONTROLS
END VIEW OF
20-WAY CONNECTOR
END VIEW OF
80-WAY CONNECTOR
10
11
14
15
20
61
80
41
60
21
40
20
3000 SERIES
TURBINE
SPEED
SENSOR
A
B
4000 SERIES
A
TURBINE
SPEED
SENSOR
A
B
WIRE 180
WIRE 120
80
TURBINE SPEED HI
20
TURBINE SPEED LO
TEMP (F)
TCM
TEMP (C)
40
40
340
300
68
20
450
400
230
110
V09137.00.01.A
6110
3000 AND 4000 PRODUCT FAMILIES TROUBLESHOOTING MANUALALLISON 4th GENERATION CONTROLS
If failure occurs while in a forward range and a shift has been completed, the transmission will remain in the
current range.
If failure occurs while in a forward range and a shift is in progress, the transmission will return to the previous
range, except in post-shift state, then the transmission will continue to the commanded range.
6111
3000 AND 4000 PRODUCT FAMILIES TROUBLESHOOTING MANUALALLISON 4th GENERATION CONTROLS
Inspect the wiring for poor electrical connections at the TCM and service brake switch. 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
If the condition is intermittent, connect the Allison DOC For PCService Tool and observe the speed sensor
indicated by the code. If the signal is erratic, investigate and eliminate the following:
Intermittent wiring connection
Excessive vibration (driveline or engine torsionals)
Irregular sensor gap (loose sensor, loose tone wheel, or damaged tone wheel)
Install a known good speed sensor and see if normal function is restored to rule out an internal short or open in
the sensor removed.
Check that the speed sensor wiring consists of twisted pairs at the rate of 12 to 16 twists per 300 mm. These
twists must extend the entire length of the wiring harness to within at least 50 mm of the speed sensor
connector.
Install a known good TCM, if available. If the DTC does not return, reinstall the old TCM to verify the repair.
Test Description
The numbers below refer to step numbers on the diagnostic table.
2. Tests for proper ignition voltage.
3. Tests for proper turbine speed sensor resistance at the TCM side of the harness.
4. Tests for turbine speed sensor resistance.
Action
Value(s)
Yes
No
Go to Step 2
Go to Section 35,
Beginning the
Troubleshooting
Process
Go to Step 3
Resolve voltage
problems (refer to
DTC P0882 and
P0883)
3000 AND 4000 PRODUCT FAMILIES TROUBLESHOOTING MANUALALLISON 4th GENERATION CONTROLS
Action
Value(s)
Yes
No
Refer to Speed
Sensor
Temperature
Resistance Table
610
Go to
Diagnostic Aids
Go to Step 4
Refer to Speed
Sensor
Temperature
Resistance Table
610
Go to Step 5
Go to Step 6
Go to Step 7
Go to Step 5
Go to Step 7
Go to Step 6
Begin the
diagnosis again.
System OK
Go to Step 1
Temp F
Temp C
250
200
40
40
340
300
68
20
450
400
230
110
6113
3000 AND 4000 PRODUCT FAMILIES TROUBLESHOOTING MANUALALLISON 4th GENERATION CONTROLS
END VIEW OF
20-WAY CONNECTOR
END VIEW OF
80-WAY CONNECTOR
10
11
14
15
20
61
80
41
60
21
40
20
3000 SERIES
TURBINE
SPEED
SENSOR
A
B
4000 SERIES
A
TURBINE
SPEED
SENSOR
A
B
WIRE 180
WIRE 120
80
TURBINE SPEED HI
20
TURBINE SPEED LO
TEMP (F)
TCM
TEMP (C)
40
40
340
300
68
20
450
400
230
110
V09137.00.01.A
6114
3000 AND 4000 PRODUCT FAMILIES TROUBLESHOOTING MANUALALLISON 4th GENERATION CONTROLS
Shifting complete.
Engine running.
400 rpm.
Conditions for Setting the DTC
DTC P0717 sets when one of the following conditions occur:
Unrealistic large change in turbine speed. A failure pending is set if the TCM detects a change in turbine speed
of more than 800 rpm. The transmission locks in current range in response to a failure pending condition.
Unrealistic low value in turbine speed. A failure pending is set if turbine speed is detected below 61 rpm. A
failure sets when turbine speed is below 61 rpm and output speed is detected above 500 rpm for more than
1 second.
If failure occurs while in a forward range and a shift has been completed, the transmission will remain in the
current range.
If failure occurs while in a forward range and a shift is in progress, the transmission will return to the previous
range, except in post-shift state, then the transmission will continue to the commanded range.
6115
3000 AND 4000 PRODUCT FAMILIES TROUBLESHOOTING MANUALALLISON 4th GENERATION CONTROLS
Inspect the wiring for poor electrical connections at the TCM and service brake switch. 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
If the condition is intermittent, connect the Allison DOC For PCService Tool and observe the speed sensor
indicated by the code. If the signal is erratic, investigate and eliminate the following:
Intermittent wiring connection
Excessive vibration (driveline or engine torsionals)
Irregular sensor gap (loose sensor, loose tone wheel, or damaged tone wheel)
Install a known good speed sensor and see if normal function is restored to rule out an internal short or open in
the sensor removed.
Check that the speed sensor wiring consists of twisted pairs at the rate of 12 to 16 twists per 300 mm. These
twists must extend the entire length of the wiring harness to within at least 50 mm of the speed sensor
connector.
Test Description
The numbers below refer to step numbers on the diagnostic table.
1. Tests ignition voltage.
2. Tests for proper turbine speed sensor resistance at the TCM side of the harness.
3. Tests for turbine speed sensor resistance.
6116
Action
Value(s)
Yes
No
Go to Step 2
Go to Section 35,
Beginning the
Troubleshooting
Process
3000 AND 4000 PRODUCT FAMILIES TROUBLESHOOTING MANUALALLISON 4th GENERATION CONTROLS
Action
Value(s)
Install the Allison DOC For PCService Tool. 918V (12V TCM)
1832V (24V TCM)
Start the engine.
Record the failure records.
Clear the DTCs.
Using Allison DOC For PCService Tool,
measure ignition voltage.
Is voltage within specified values?
Yes
No
Go to Step 3
Resolve voltage
problems (refer to
DTC P0882 and
P0883)
1.
2.
3.
4.
5.
Refer to Speed
Sensor
Temperature
Resistance Table
611
Go to
Diagnostic Aids
Go to Step 4
Refer to Speed
Sensor
Temperature
Resistance Table
611
Go to Step 5
Go to Step 6
Go to Step 7
Go to Step 5
Go to Step 7
Go to Step 6
Begin the
diagnosis again.
System OK
Go to Step 1
Temp F
Temp C
250
200
40
40
340
300
68
20
450
400
230
110
6117
3000 AND 4000 PRODUCT FAMILIES TROUBLESHOOTING MANUALALLISON 4th GENERATION CONTROLS
END VIEW OF
80-WAY CONNECTOR
61
80
41
60
21
40
20
ABS INPUT ()
ABS INPUT ()
ANTI-LOCK
BRAKE
CONTROLS
TCM
21
WIRE 121
ABS
RESPONSE
BRAKE
PRESSURE
SWITCH
N.C.
WIRE 121
ABS RESPONSE
OPTIONAL
CUSTOMER- FURNISHED
VEHICLE INTERFACE
WIRING CONNECTOR
SWITCHED
POWER
COM N.O.
RELAY
SHOWN
DE-ENERGIZED
ANTI-LOCK
BRAKE
CONTROLS
WIRE 103
SIGNAL RETURN
ANTI-LOCK
BRAKE
CONTROLS
SAE J1939
VEHICLE COMMUNICATION
INTERFACE
See appropriate
Installation Schematic
installation drawing for
wire and pin numbers.
BRAKE
PRESSURE
SWITCH
N.C.
WIRE 121
ABS RESPONSE
COM N.O.
TCM
OPTIONAL
CUSTOMER- FURNISHED
VEHICLE INTERFACE
WIRING CONNECTOR
RELAY
SHOWN
DE-ENERGIZED
V09143.00.00
6118
3000 AND 4000 PRODUCT FAMILIES TROUBLESHOOTING MANUALALLISON 4th GENERATION CONTROLS
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.
When an analog input wire is used, the ABS signal is received on wire 121. The ABS controller may directly
pull wire 121 to ground or use a relay to complete a circuit between wire 121 and wire 103. If a data link is
used, the TCM receives ABS status as part of J1939 message parameter PGN 61441, Electronic Brake
Controller 1 (EBC1).
DTC P0719 indicates the TCM has detected ABS status ON for a single acceleration event. The code can be
caused by:
Faulty wiring
Faulty connections to the ABS relay
A faulty ABS relay
Another controller improperly broadcasting ABS status on the data link when ABS is not installed or
operating
A fault in the ABS system itself
A faulty TCM
Copyright 2008 Allison Transmission, Inc.
6119
3000 AND 4000 PRODUCT FAMILIES TROUBLESHOOTING MANUALALLISON 4th GENERATION CONTROLS
Inspect the wiring for poor electrical connections at the TCM and service brake switch. 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
Read J 1939 ABS status on Allison DOC For PCService Tool. Monitor data link communications using
Data Bus Viewer.
Test Description
The numbers below refer to step numbers on the diagnostic table.
2. Tests for an active DTC.
3. This step determines if ABS status is being communicated by a data link message.
Yes
No
Action
Value(s)
Go to Step 2
Go to Section 35,
Beginning the
Troubleshooting
Process
1.
2.
3.
4.
Go to Step 3
Go to
Diagnostic Aids
Go to Step 4
Go to Step 5
Go to Step 8
Go to Step 4
6120
3000 AND 4000 PRODUCT FAMILIES TROUBLESHOOTING MANUALALLISON 4th GENERATION CONTROLS
Action
Value(s)
Yes
No
Go to Step 7
Go to Step 6
Go to Step 8
Go to Step 7
Go to Step 8
Go to Step 7
Begin the
diagnosis again.
System OK
Go to Step 1
6121
3000 AND 4000 PRODUCT FAMILIES TROUBLESHOOTING MANUALALLISON 4th GENERATION CONTROLS
END VIEW OF
80-WAY CONNECTOR
61
80
41
60
21
40
20
SERVICE BRAKE
PRESSURE
SWITCH
SWITCH CLOSES
WHEN DOOR
IS OPENED
SWITCH CLOSES
WHEN BRAKES
ARE APPLIED
23
TCM
DOOR SWITCH
(OPTIONAL)
OPTIONAL
CUSTOMER-FURNISHED
VEHICLE INTERFACE
WIRING CONNECTOR
RELS
ENABLE
(OPTIONAL)
SWITCHED
POWER
V09145.00.00
Circuit Description
The Transmission Control Module (TCM) can be calibrated to receive an input from the service brakes to activate
and deactivate the Reduced Engine Load at Stop (RELS) feature. The input signal consists of switched power
provided through a normally open service brake pressure switch. The switch closes when brakes are applied to
supply switched power to the RELS input pin at the TCM. Supplemental controls such as a door switch or RELS
enable switch may be wired in series with the brake switch.
When RELS is active, the TCM automatically commands transmission operation at a reduced load state similar to
neutral. The vehicle must be at a stop with the service brakes applied and the throttle closed. RELS is de-activated
when the service brake pressure switch is opened and switched power is removed from the RELS input pin at the
TCM. The service brake input on SAE J1939 communications link CANNOT be used as an input for RELS.
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).
Engine speed is greater than 200 rpm and less than 7500 rpm for 5 seconds.
6122
3000 AND 4000 PRODUCT FAMILIES TROUBLESHOOTING MANUALALLISON 4th GENERATION CONTROLS
DTC P071A sets if the TCM is calibrated to receive the RELS input signal.
DTC P071A indicates the TCM has detected a RELS input signal during one acceleration event. The code can
be caused by:
Faulty wiring
Faulty connections to service brake switch
A faulty service brake switch
Faulty TCM.
Inspect the wiring for poor electrical connections at the TCM and service brake pressure switch. 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 status of analog input wire 123.
4. Tests for the presence of ignition voltage on wire 123.
5. Tests for proper service brake switch function.
Copyright 2008 Allison Transmission, Inc.
6123
3000 AND 4000 PRODUCT FAMILIES TROUBLESHOOTING MANUALALLISON 4th GENERATION CONTROLS
Action
Value(s)
Yes
No
Go to Step 2
Go to Section 35,
Beginning the
Troubleshooting
Process
1.
2.
3.
4.
Go to Step 3
Go to
Diagnostic Aids
Go to
Diagnostic Aids
Go to Step 4
Go to Step 5
Go to Step 8
Go to Step 7
Go to Step 6
Go to Step 9
6124
3000 AND 4000 PRODUCT FAMILIES TROUBLESHOOTING MANUALALLISON 4th GENERATION CONTROLS
Action
Value(s)
Yes
No
Go to Step 9
Go to Step 7
Go to Step 9
Go to Step 8
Begin the
diagnosis again.
System OK
Go to Step 1
6125
3000 AND 4000 PRODUCT FAMILIES TROUBLESHOOTING MANUALALLISON 4th GENERATION CONTROLS
END VIEW OF
80-WAY CONNECTOR
64
1
3
42
9
TCM
69
OPTIONAL
CUSTOMERFURNISHED
VEHICLE
INTERFACE
WIRING
CONNECTOR(S)
61
80
41
60
21
40
20
AUXILIARY
FUNCTION
SENSE SWITCH 2
SWITCH IS CLOSED
WHEN AUXILIARY
EQUIPMENT IS
OPERATING
OPTIONAL
VIM
BATTERY
GROUND
SWITCHED POWER
SERVICE
TRANS
INPUT 2
AUXILIARY
FUNCTION
SELECT
SWITCH 1
SWITCH IS
CLOSED WHEN
AUXILIARY
EQUIPMENT
IS OPERATING
SERVICE
TRANS
N.C.
COM N.O.
WIRE 164
RELAY SHOWN DE-ENERGIZED
NOTE: Both input signals must turn on within 120 seconds. If the state of
the two input signals is different for longer than this time period, the SERVICE
TRANS light will be illuminated. A code will be stored in memory, and
Neutral-to-Range shifts will NOT be inhibited.
NOTE: The SERVICE TRANS light must be mounted in the dash and in
clear view of the operator. Preferred lens color is red (amber is acceptable).
V09141.00.00
Circuit Description
Some emergency vehicles are equipped with an input function known as Auxiliary Function Range Inhibit
(Special), which prevents inadvertent range selection when auxiliary equipment is operating. This function is
enabled under the following conditions:
In a typical installation, a dash-mounted auxiliary equipment selector switch completes the circuit between wires
101 and 103. A second switch closes during operation of the auxiliary equipment to complete the circuit between
wire 142 and battery ground. Both switches must be closed for the function to be enabled. When the two input
wires (101 and 142) are ON, the TCM inhibits all neutral-to-range shifts. The inhibit remains in effect until either
of the two input wires change state to OFF, or transmission output speed exceeds a preset value. The TCM sets
DTC P071D if it detects the two input wires in two different states (ON or OFF) for longer than 120 seconds.
6126
3000 AND 4000 PRODUCT FAMILIES TROUBLESHOOTING MANUALALLISON 4th GENERATION CONTROLS
The TCM may illuminate SERVICE TRANS light based on OEM wiring. Refer to Appendix P, Dual
Input Auxiliary Function Range Inhibit.
Inspect the wiring for poor electrical connections at the TCM and auxiliary equipment switches. 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
Read the status of analog input wires 101 and 142 on Allison DOC For PCService Tool.
Test Description
The numbers below refer to step numbers on the diagnostic table.
2. Tests for an active DTC.
3. Tests for status of analog input wires 101 and 142.
Copyright 2008 Allison Transmission, Inc.
6127
3000 AND 4000 PRODUCT FAMILIES TROUBLESHOOTING MANUALALLISON 4th GENERATION CONTROLS
Action
Value(s)
Yes
No
Go to Step 2
Go to Section 35,
Beginning the
Troubleshooting
Process
1.
2.
3.
4.
5.
Go to Step 3
Go to
Diagnostic Aids
Go to Step 5
Go to Step 4
Go to Step 5
Go to Step 4
Begin the
diagnosis again.
System OK
6128
Go to Step 1
3000 AND 4000 PRODUCT FAMILIES TROUBLESHOOTING MANUALALLISON 4th GENERATION CONTROLS
END VIEW OF
20-WAY CONNECTOR
END VIEW OF
80-WAY CONNECTOR
10
11
14
15
20
61
80
41
60
21
40
20
OUTPUT
SPEED
SENSOR
WIRE 160
OUTPUT SPEED HI
40
OUTPUT SPEED LO
TCM
B
WIRE 140
60
TEMP (F)
TEMP (C)
40
40
340
300
68
20
450
400
230
110
V09135.00.01
Circuit Description
Speed sensors are variable reluctance devices that convert mechanical motion to an AC voltage. Each sensor
consists of a wire coil wrapped around a pole piece that is adjacent to a permanent magnet. These elements are
contained in a housing that is mounted adjacent to a rotating ferrous member. Two signal wires extend from one
end of the housing and an exposed end of the pole piece is at the opposite end of the housing. The permanent
magnet produces lines of flux around the pole piece. As a ferrous object (a tooth on the tone wheel) approaches and
passes through the gap at the end of the pole piece, an AC voltage pulse is induced in the wire coil. The
Transmission Control Module (TCM) calculates the frequency of these AC pulses and converts it to a speed value.
The AC voltage generated varies from 150mV at low speed to 15V at high speed. The signal wires from the sensor
are formed as twisted pairs to cancel magnetically induced fields. The cable is also shielded to protect from
voltage-related fields. Using two-wire differential input at the TCM eliminates noise from other sources.
Copyright 2008 Allison Transmission, Inc.
6129
3000 AND 4000 PRODUCT FAMILIES TROUBLESHOOTING MANUALALLISON 4th GENERATION CONTROLS
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).
Unrealistic large changes in output speed. Failure is set if an unrealistic change in transmission output speed is
detected at or above 500 rpm for 0.15 seconds.
Noisy output speed. Noise is determined with two counters. A low counter is incremented when output speed
change is below 500 rpm for 80 samples. A high counter is incremented when output speed change is above
800 rpm. When both counters accumulate 5 events, a failure is set.
If failure occurs while in a forward range and a shift has been completed, the transmission will remain in the
current range.
If failure occurs while in a forward range and a shift is in progress, the transmission will return to the previous
range, except in post-shift state, then the transmission will continue to the commanded range.
Inspect the wiring for poor electrical connections at the TCM and service brake switch. 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
6130
3000 AND 4000 PRODUCT FAMILIES TROUBLESHOOTING MANUALALLISON 4th GENERATION CONTROLS
If the condition is intermittent, connect the Allison DOC For PCService Tool and observe the speed sensor
indicated by the code. If the signal is erratic, investigate and eliminate the following:
Intermittent wiring connection
Excessive vibration (driveline or engine torsionals)
Irregular sensor gap (loose sensor, loose tone wheel, or damaged tone wheel)
Install a known good speed sensor and see if normal function is restored to rule out an internal short or open in
the sensor removed.
Check that the speed sensor wiring consists of twisted pairs at the rate of 12 to 16 twists per 300 mm. These
twists must extend the entire length of the wiring harness to within at least 50 mm of the speed sensor
connector.
Install a known good TCM, if available. If the DTC does not return, reinstall the old TCM to verify the repair.
Test Description
The numbers below refer to step numbers on the diagnostic table.
4. Tests for proper ignition voltage.
5. Tests for proper output speed sensor resistance at the OEM-side of the harness.
6. Tests for output speed sensor resistance.
Yes
No
Action
Value(s)
Go to Step 2
Go to Section 35,
Beginning the
Troubleshooting
Process
1.
2.
3.
4.
5.
Go to Step 3
Resolve voltage
problems (refer to
DTC P0882 and
P0883)
Refer to Speed
Sensor
Temperature
Resistance Table
612
Go to
Diagnostic Aids
Go to Step 4
Refer to Speed
Sensor
Temperature
Resistance Table
612
Go to Step 5
Go to Step 6
Install the Allison DOC For PCService Tool. 918V (12V TCM)
1832V (24V TCM)
Start the engine.
Record the failure records.
Clear the DTCs.
Using Allison DOC For PCService Tool,
measure ignition voltage.
Is voltage within specified values?
6131
3000 AND 4000 PRODUCT FAMILIES TROUBLESHOOTING MANUALALLISON 4th GENERATION CONTROLS
Action
Value(s)
Yes
No
Go to Step 7
Go to Step 5
Go to Step 7
Go to Step 6
Begin the
diagnosis again.
System OK
Go to Step 1
6132
Temp F
Temp C
250
200
40
40
340
300
68
20
450
400
230
110
3000 AND 4000 PRODUCT FAMILIES TROUBLESHOOTING MANUALALLISON 4th GENERATION CONTROLS
END VIEW OF
20-WAY CONNECTOR
END VIEW OF
80-WAY CONNECTOR
10
11
14
15
20
61
80
41
60
21
40
20
OUTPUT
SPEED
SENSOR
WIRE 160
OUTPUT SPEED HI
40
OUTPUT SPEED LO
TCM
WIRE 140
60
TEMP (F)
TEMP (C)
40
40
340
300
68
20
450
400
230
110
V09135.00.01
Circuit Description
Speed sensors are variable reluctance devices that convert mechanical motion to an AC voltage. Each sensor
consists of a wire coil wrapped around a pole piece that is adjacent to a permanent magnet. These elements are
contained in a housing that is mounted adjacent to a rotating ferrous member. Two signal wires extend from one
end of the housing and an exposed end of the pole piece is at the opposite end of the housing. The permanent
magnet produces lines of flux around the pole piece. As a ferrous object (a tooth of the tone wheel) approaches and
passes through the gap at the end of the pole piece, an AC voltage pulse is induced in the wire coil. The
Transmission Control Module (TCM) calculates the frequency of these AC pulses and converts it to a speed value.
The AC voltage generated varies from 150mV at low speed to 15V at high speed. The signal wires from the sensor
are formed as twisted pairs to cancel magnetically induced fields. The cable is also shielded to protect from
voltage-related fields. Using two-wire differential input at the TCM eliminates noise from other sources.
Copyright 2008 Allison Transmission, Inc.
6133
3000 AND 4000 PRODUCT FAMILIES TROUBLESHOOTING MANUALALLISON 4th GENERATION CONTROLS
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).
Unrealistic large change in output speed. A failure pending is set if the TCM detects a change in output speed
of more than 600 rpm. A failure is set if range attained is Neutral.
Unrealistic low value in output speed. A failure pending is set if output speed is detected below 61 rpm.
A failure sets when output speed is below 61 rpm in third, fourth, or fifth range for more than 1 second.
A failure is also set when output speed is below 61 rpm in second range for more than one 1 second when
net engine torque is +/- 1 Nm or turbine speed is greater than 800 rpm.
Actions Taken When the DTC Sets
When DTC P0722 is active, the following conditions occur:
If failure occurs while in a forward range and a shift has been completed, the transmission will remain in the
current range.
If failure occurs while in a forward range and a shift is in progress, the transmission will return to the previous
range, except in post-shift state, then the transmission will continue to the commanded range.
3000 AND 4000 PRODUCT FAMILIES TROUBLESHOOTING MANUALALLISON 4th GENERATION CONTROLS
Inspect the wiring for poor electrical connections at the TCM and service brake switch. 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
If the condition is intermittent, connect the Allison DOC For PCService Tool and observe the speed sensor
indicated by the code. If the signal is erratic, investigate and eliminate the following:
Intermittent wiring connection
Excessive vibration (driveline or engine torsionals)
Irregular sensor gap (loose sensor, loose tone wheel, or damaged tone wheel)
Install a known good speed sensor and see if normal function is restored to rule out an internal short or open in
the sensor removed.
Check that the speed sensor wiring consists of twisted pairs at the rate of 12 to 16 twists per 300 mm. These
twists must extend the entire length of the wiring harness to within at least 50 mm of the speed sensor
connector.
Test Description
The numbers below refer to step numbers on the diagnostic table.
2. Tests ignition voltage.
3. Tests for proper output speed sensor resistance at the OEM-side of the harness.
4. Tests for output speed sensor resistance.
Action
Value(s)
Yes
No
Go to Step 2
Go to Section 35,
Beginning the
Troubleshooting
Process
1.
2.
3.
4.
5.
Go to Step 3
Resolve voltage
problems (refer to
DTC P0882 and
P0883)
Install the Allison DOC For PCService Tool. 918V (12V TCM)
1832V (24V TCM)
Start the engine.
Record the failure records.
Clear the DTCs.
Using Allison DOC For PCService Tool,
measure ignition voltage.
Is voltage within specified values?
Copyright 2008 Allison Transmission, Inc.
6135
3000 AND 4000 PRODUCT FAMILIES TROUBLESHOOTING MANUALALLISON 4th GENERATION CONTROLS
Action
Value(s)
Yes
No
Refer to Speed
Sensor
Temperature
Resistance Table
613
Go to
Diagnostic Aids
Go to Step 4
Refer to Speed
Sensor
Temperature
Resistance Table
613
Go to Step 5
Go to Step 6
Go to Step 7
Go to Step 5
Go to Step 7
Go to Step 6
Begin the
diagnosis again.
System OK
Go to Step 1
6136
Temp F
Temp C
250
200
40
40
340
300
68
20
450
400
230
110
3000 AND 4000 PRODUCT FAMILIES TROUBLESHOOTING MANUALALLISON 4th GENERATION CONTROLS
END VIEW OF
20-WAY CONNECTOR
END VIEW OF
80-WAY CONNECTOR
10
11
14
15
20
61
80
41
60
21
40
20
ENGINE
SPEED
SENSOR
WIRE 159
59
ENGINE SPEED HI
39
ENGINE SPEED LO
TCM
B
WIRE 139
TEMP (F)
TEMP (C)
40
40
340
300
68
20
450
400
230
110
V09136.00.01
Circuit Description
Speed sensors are variable reluctance devices that convert mechanical motion to an AC voltage. Each sensor
consists of a wire coil wrapped around a pole piece that is adjacent to a permanent magnet. These elements are
contained in a housing that is mounted adjacent to a rotating ferrous member. Two signal wires extend from one
end of the housing and an exposed end of the pole piece is at the opposite end of the housing. The permanent
magnet produces lines of flux around the pole piece. As a ferrous object (a rib on torque converter impeller)
approaches and passes through the gap at the end of the pole piece, an AC voltage pulse is induced in the wire coil.
The Transmission Control Module (TCM) calculates the frequency of these AC pulses and converts it to a speed
value. The AC voltage generated varies from 150mV at low speed to 15V at high speed. The signal wires from the
sensor are formed as twisted pairs to cancel magnetically induced fields. The cable is also shielded to protect from
voltage-related fields. Using two-wire differential input at the TCM eliminates noise from other sources.
Copyright 2008 Allison Transmission, Inc.
6137
3000 AND 4000 PRODUCT FAMILIES TROUBLESHOOTING MANUALALLISON 4th GENERATION CONTROLS
Unrealistic large changes in engine speed. Failure is set if an unrealistic change in transmission engine speed is
detected at or above 600 rpm for 0.15 seconds.
Noisy engine speed. Noise is determined with two counters. A low counter is incremented when engine speed
change is below 650 rpm for 80 samples. A high counter is incremented when engine speed change is above
1050 rpm. When both counters accumulate 5 events, a failure is set.
3000 AND 4000 PRODUCT FAMILIES TROUBLESHOOTING MANUALALLISON 4th GENERATION CONTROLS
Action
Value(s)
Yes
No
Go to Step 2
Go to Section 35,
Beginning the
Troubleshooting
Process
1.
2.
3.
4.
5.
Go to Step 3
Resolve voltage
problems (refer to
DTC P0882 and
P0883)
Refer to Speed
Sensor Resistance
Table 614
Go to
Diagnostic Aids
Go to Step 4
Refer to Speed
Sensor Resistance
Table 614
Go to Step 5
Go to Step 6
Go to Step 7
Go to Step 5
Go to Step 7
Go to Step 6
6139
3000 AND 4000 PRODUCT FAMILIES TROUBLESHOOTING MANUALALLISON 4th GENERATION CONTROLS
Action
Value(s)
Yes
No
Begin the
diagnosis again.
System OK
Go to Step 1
6140
Temp F
Temp C
250
200
40
40
340
300
68
20
450
400
230
110
3000 AND 4000 PRODUCT FAMILIES TROUBLESHOOTING MANUALALLISON 4th GENERATION CONTROLS
END VIEW OF
20-WAY CONNECTOR
END VIEW OF
80-WAY CONNECTOR
10
11
14
15
20
61
80
41
60
21
40
20
ENGINE
SPEED
SENSOR
WIRE 159
59
ENGINE SPEED HI
39
ENGINE SPEED LO
TCM
B
WIRE 139
TEMP (F)
TEMP (C)
40
40
340
300
68
20
450
400
230
110
V09136.00.01
Circuit Description
Speed sensors are variable reluctance devices that convert mechanical motion to an AC voltage. Each sensor
consists of a wire coil wrapped around a pole piece that is adjacent to a permanent magnet. These elements are
contained in a housing that is mounted adjacent to a rotating ferrous member. Two signal wires extend from one
end of the housing and an exposed end of the pole piece is at the opposite end of the housing. The permanent
magnet produces lines of flux around the pole piece. As a ferrous object (a rib on the torque converter impeller)
approaches and passes through the gap at the end of the pole piece, an AC voltage pulse is induced in the wire coil.
The Transmission Control Module (TCM) calculates the frequency of these AC pulses and converts it to a speed
value. The AC voltage generated varies from 150mV at low speed to 15V at high speed. The signal wires from the
sensor are formed as twisted pairs to cancel magnetically induced fields. The cable is also shielded to protect from
voltage-related fields. Using two-wire differential input at the TCM eliminates noise from other sources.
Copyright 2008 Allison Transmission, Inc.
6141
3000 AND 4000 PRODUCT FAMILIES TROUBLESHOOTING MANUALALLISON 4th GENERATION CONTROLS
Unrealistic large change in engine speed. A failure pending is set if the TCM detects a change in engine speed
of more than 1040 rpm.
Unrealistic low value in engine speed. A failure is set if engine speed is detected below 61 rpm for 4 seconds.
The TCM defaults engine speed to turbine speed. Turbine speed is used to determine the missing engine speed.
If the condition is intermittent, connect the Allison DOC For PCService Tool and observe the speed sensor
indicated by the code. If the signal is erratic, investigate and eliminate the following:
Intermittent wiring connection
Excessive vibration (driveline or engine torsionals)
Irregular sensor gap (loose sensor, damaged torque converter ribs).
Install a known good speed sensor and see if normal function is restored to rule out an internal short or open in
the sensor removed.
Inspect that the speed sensor wiring consists of twisted pairs at the rate of 12 to 16 twists per 300 mm. These
twists must extend the entire length of the wiring harness to within at least 50 mm of the speed sensor
connector.
6142
3000 AND 4000 PRODUCT FAMILIES TROUBLESHOOTING MANUALALLISON 4th GENERATION CONTROLS
Action
Value(s)
Yes
No
Go to Step 2
Go to Section 35,
Beginning the
Troubleshooting
Process
1.
2.
3.
4.
5.
Go to Step 3
Resolve voltage
problems (refer to
DTC P0882 and
P0883)
Refer to Speed
Sensor
Temperature
Resistance Table
615
Go to
Diagnostic Aids
Go to Step 4
Refer to Speed
Sensor
Temperature
Resistance Table
615
Go to Step 5
Go to Step 6
Go to Step 7
Go to Step 5
Go to Step 7
Go to Step 6
Install the Allison DOC For PCService Tool. 918V (12V TCM)
1832V (24V TCM)
Start the engine.
Record the failure records.
Clear the DTCs.
Using Allison DOC For PCService Tool,
measure ignition voltage.
Is voltage within specified values?
6143
3000 AND 4000 PRODUCT FAMILIES TROUBLESHOOTING MANUALALLISON 4th GENERATION CONTROLS
Action
Value(s)
Yes
No
Begin the
diagnosis again.
System OK
Go to Step 1
6144
Temp F
Temp C
250
200
40
40
340
300
68
20
450
400
230
110
3000 AND 4000 PRODUCT FAMILIES TROUBLESHOOTING MANUALALLISON 4th GENERATION CONTROLS
6145
3000 AND 4000 PRODUCT FAMILIES TROUBLESHOOTING MANUALALLISON 4th GENERATION CONTROLS
Action
Value(s)
Yes
No
Go to Step 2
Go to Section 35,
Beginning the
Troubleshooting
Process
Go to Step 3
Go to Step 4
Go to General
Troubleshooting,
Section 8
Go to the
appropriate speed
sensor DTC
Go to Step 5
6146
3000 AND 4000 PRODUCT FAMILIES TROUBLESHOOTING MANUALALLISON 4th GENERATION CONTROLS
Action
Value(s)
5
WARNING: To avoid injury or property
damage caused by sudden and unexpected
vehicle movement, do not start a stationary
stall test until you:
Put the transmission in N (Neutral).
Apply the parking brake and service brake.
Chock the wheels and take any other steps
necessary to prevent the vehicle from
moving.
Warn personnel to keep clear of the vehicle
and its path.
Yes
No
Go to
Diagnostic Aids
Go to Step 6
Go to Step 7
Go to Step 8
Go to Step 10
Go to
Diagnostic Aids
Go to Step 11
Go to Step 9
6147
3000 AND 4000 PRODUCT FAMILIES TROUBLESHOOTING MANUALALLISON 4th GENERATION CONTROLS
Action
Value(s)
Yes
No
Go to Step 11
Go to Step 9
Go to Step 11
Go to Step 10
Begin the
diagnosis again.
System OK
Incorrect C2 pressurePCS2
Incorrect C4 pressurePCS4
Is the replacement complete?
10
11
6148
Go to Step 1
3000 AND 4000 PRODUCT FAMILIES TROUBLESHOOTING MANUALALLISON 4th GENERATION CONTROLS
No shift in progress.
The TCM attempts to shift to second range. If unsuccessful, the TCM will shift to fifth range.
While diagnostic response is active, the TCM ignores shift selector inputs.
The CHECK TRANS light illuminates.
DTC is stored in TCM history.
The TCM inhibits TCC engagement.
The TCM freezes shift adapts (DNA).
Incorrect ratio codes typically indicate mechanical problems with specific clutches for range indicated, i.e. C1
and C5 for first range.
An incorrect ratio DTC may indicate a mechanically failed clutch control solenoid. Review the DTC
information for the specific solenoid.
Incorrect TCM calibration will cause this DTC to set. Verify that the Calibration Identification Number (CIN)
is compatible with the model of transmission installed in the vehicle.
Output speed or turbine speed tone wheel damage may cause erratic speed sensor input allowing this code to
set.
Copyright 2008 Allison Transmission, Inc.
6149
3000 AND 4000 PRODUCT FAMILIES TROUBLESHOOTING MANUALALLISON 4th GENERATION CONTROLS
Action
Value(s)
Yes
No
Go to Step 2
Go to Section 35,
Beginning the
Troubleshooting
Process
Go to Step 3
Go to Step 4
Go to General
Troubleshooting,
Section 8
3000 Product
Family
Close ratio=3.49:1
Wide ratio=4.59:1
Go to Step 5
Go to
Diagnostic Aids
Go to the
appropriate speed
sensor DTC
Go to Step 6
6150
4000 Product
Family
Close ratio=3.51:1
Wide ratio=4.70:1
3000 AND 4000 PRODUCT FAMILIES TROUBLESHOOTING MANUALALLISON 4th GENERATION CONTROLS
Action
Value(s)
6
WARNING: To avoid injury or property
damage caused by sudden and unexpected
vehicle movement, do not start a stationary
stall test until you:
Put the transmission in N (Neutral).
Apply the parking brake and service brake.
Chock the wheels and take any other steps
necessary to prevent the vehicle from
moving.
Warn personnel to keep clear of the vehicle
and its path.
Yes
No
Go to
Diagnostic Aids
Go to Step 7
Go to Step 8
Go to Step 9
Go to Step 11
Go to
Diagnostic Aids
Go to Step 12
Go to Step 10
6151
3000 AND 4000 PRODUCT FAMILIES TROUBLESHOOTING MANUALALLISON 4th GENERATION CONTROLS
Action
Value(s)
10
Yes
No
Go to Step 12
Go to Step 10
Go to Step 12
Go to Step 11
Begin the
diagnosis again.
System OK
Incorrect C1 pressurePCS1
Incorrect C5 pressurePCS3
Is the replacement complete?
11
12
6152
Go to Step 1
3000 AND 4000 PRODUCT FAMILIES TROUBLESHOOTING MANUALALLISON 4th GENERATION CONTROLS
No shift in progress.
The TCM will attempt to shift to third range. If unsuccessful, the TCM commands fifth range.
While diagnostic response is active, the TCM ignores shift selector inputs.
Incorrect ratio codes typically indicate mechanical problems with specific clutches for range indicated, i.e. C1
and C4 for second range.
An incorrect ratio DTC may indicate a mechanically failed clutch control solenoid. Review the DTC
information for the specific solenoid.
Incorrect TCM calibration will cause this DTC to set. Verify that the Calibration Identification Number (CIN)
is compatible with the model of transmission installed in the vehicle.
Output speed or turbine speed tone wheel damage may cause erratic speed sensor input allowing this code to
set.
Copyright 2008 Allison Transmission, Inc.
6153
3000 AND 4000 PRODUCT FAMILIES TROUBLESHOOTING MANUALALLISON 4th GENERATION CONTROLS
Action
Value(s)
Yes
No
Go to Step 2
Go to Section 35,
Beginning the
Troubleshooting
Process
Go to Step 3
Go to Step 4
Go to General
Troubleshooting,
Section 8
3000 Product
Family
Close ratio= 1.86:1
Wide ratio= 2.25:1
Go to Step 5
Go to
Diagnostic Aids
Go to the
appropriate speed
sensor DTC
Go to Step 6
6154
4000 Product
Family
Close ratio= 1.91:1
Wide ratio= 2.21:1
3000 AND 4000 PRODUCT FAMILIES TROUBLESHOOTING MANUALALLISON 4th GENERATION CONTROLS
Action
Value(s)
6
WARNING: To avoid injury or property
damage caused by sudden and unexpected
vehicle movement, do not start a stationary
stall test until you:
Put the transmission in N (Neutral).
Apply the parking brake and service brake.
Chock the wheels and take any other steps
necessary to prevent the vehicle from
moving.
Warn personnel to keep clear of the vehicle
and its path.
Yes
No
Go to
Diagnostic Aids
Go to Step 7
Go to Step 8
Go to Step 9
Go to Step 11
Go to
Diagnostic Aids
Go to Step 12
Go to Step 10
6155
3000 AND 4000 PRODUCT FAMILIES TROUBLESHOOTING MANUALALLISON 4th GENERATION CONTROLS
Action
Value(s)
10
Yes
No
Go to Step 12
Go to Step 10
Go to Step 12
Go to Step 11
Begin the
diagnosis again.
System OK
Incorrect C1 pressurePCS1
Incorrect C4 pressurePCS4
Is the replacement complete?
11
12
6156
Go to Step 1
3000 AND 4000 PRODUCT FAMILIES TROUBLESHOOTING MANUALALLISON 4th GENERATION CONTROLS
No shift in progress.
The TCM attempts to shift to fourth range. If unsuccessful, the TCM commands sixth range.
While diagnostic response is active, the TCM ignores shift selector inputs.
Incorrect ratio codes typically indicate mechanical problems with specific clutches for range indicated, i.e. C1
and C3 for third range.
An incorrect ratio DTC may indicate a mechanically failed clutch control solenoid. Review the DTC
information for the specific solenoid.
Incorrect TCM calibration will cause this DTC to set. Verify that the Calibration Identification Number (CIN)
is compatible with the model of transmission installed in vehicle.
Output speed or turbine speed tone wheel damage may cause erratic speed sensor input allowing this code to
set.
Copyright 2008 Allison Transmission, Inc.
6157
3000 AND 4000 PRODUCT FAMILIES TROUBLESHOOTING MANUALALLISON 4th GENERATION CONTROLS
Action
Value(s)
Yes
No
Go to Step 2
Go to Section 35,
Beginning the
Troubleshooting
Process
Go to Step 3
Go to Step 4
Go to General
Troubleshooting,
Section 8
3000 Product
Family
Close ratio= 1.41:1
Wide ratio= 1.54:1
Go to Step 5
Go to
Diagnostic Aids
Go to the
appropriate speed
sensor DTC
Go to Step 6
6158
4000 Product
Family
Close ratio= 1.43:1
Wide ratio= 1.53:1
Watch for erratic
speed sensor
signals
3000 AND 4000 PRODUCT FAMILIES TROUBLESHOOTING MANUALALLISON 4th GENERATION CONTROLS
Action
Value(s)
Yes
No
Go to
Diagnostic Aids
Go to Step 7
Go to Step 8
Go to Step 9
Go to Step 11
Go to
Diagnostic Aids
Go to Step 12
Go to Step 10
6159
3000 AND 4000 PRODUCT FAMILIES TROUBLESHOOTING MANUALALLISON 4th GENERATION CONTROLS
Action
Value(s)
10
Yes
No
Go to Step 12
Go to Step 10
Go to Step 12
Go to Step 11
Begin the
diagnosis again.
System OK
Incorrect C1 pressurePCS1
Incorrect C3 pressurePCS3
Is the replacement complete?
11
12
6160
Go to Step 1
3000 AND 4000 PRODUCT FAMILIES TROUBLESHOOTING MANUALALLISON 4th GENERATION CONTROLS
No shift in progress.
The TCM attempts to shift to fifth range. If unsuccessful, the TCM commands third range.
While diagnostic response is active, the TCM ignores shift selector inputs.
You may have to clear the DTC and drive the vehicle in order to experience a fault. Use the data obtained from
failure records to determine transmission range and/or certain vehicle operating variables such as temperature,
run time, etc. This data can be useful in reproducing failures mode where DTC was set.
Incorrect ratio codes typically indicate mechanical problems with specific clutches for range indicated, i.e. C1
and C2 for fourth range.
An incorrect ratio DTC may indicate a mechanically failed clutch control solenoid. Review the DTC
information for the specific solenoid.
Output speed or turbine speed tone wheel damage may cause erratic speed sensor input allowing this code to
set.
Copyright 2008 Allison Transmission, Inc.
6161
3000 AND 4000 PRODUCT FAMILIES TROUBLESHOOTING MANUALALLISON 4th GENERATION CONTROLS
Action
Value(s)
Yes
No
Go to Step 2
Go to Section 35,
Beginning the
Troubleshooting
Process
Go to Step 3
Go to Step 4
Go to General
Troubleshooting,
Section 8
Go to the
appropriate speed
sensor DTC
Go to Step 5
6162
3000 AND 4000 PRODUCT FAMILIES TROUBLESHOOTING MANUALALLISON 4th GENERATION CONTROLS
Action
Value(s)
Yes
No
Go to
Diagnostic Aids
Go to Step 6
Go to Step 7
Go to Step 8
Go to Step 10
Go to
Diagnostic Aids
Go to Step 11
Go to Step 9
6163
3000 AND 4000 PRODUCT FAMILIES TROUBLESHOOTING MANUALALLISON 4th GENERATION CONTROLS
Action
Value(s)
Yes
No
Go to Step 11
Go to Step 9
Go to Step 11
Go to Step 10
Begin the
diagnosis again.
System OK
Incorrect C1 pressurePCS1
Incorrect C2 pressurePCS2
Is the replacement complete?
10
11
6164
Go to Step 1
3000 AND 4000 PRODUCT FAMILIES TROUBLESHOOTING MANUALALLISON 4th GENERATION CONTROLS
No shift in progress.
The TCM attempts to shift to sixth range. If unsuccessful, the TCM will attempt to shift to third range. If
unsuccessful, the TCM commands second range.
While diagnostic response is active, the TCM ignores shift selector inputs.
You may have to clear the DTC and drive the vehicle in order to experience a fault. Use the data obtained from
failure records to determine transmission range and/or certain vehicle operating variables such as temperature,
run time, etc. This data can be useful in reproducing the failure mode where the DTC was set.
Incorrect ratio codes typically indicate mechanical problems with specific clutches for range indicated, i.e. C2
and C3 for fifth range.
An incorrect ratio DTC may indicate a mechanically failed clutch control solenoid. Review the DTC
information for the specific solenoid.
Output speed or turbine speed tone wheel damage may cause erratic speed sensor input allowing this code to
set.
Copyright 2008 Allison Transmission, Inc.
6165
3000 AND 4000 PRODUCT FAMILIES TROUBLESHOOTING MANUALALLISON 4th GENERATION CONTROLS
Action
Value(s)
Yes
No
Go to Step 2
Go to Section 35,
Beginning the
Troubleshooting
Process
Go to Step 3
6166
Go to Step 4
Go to General
Troubleshooting,
Section 8
Go to the
appropriate speed
sensor DTC
Go to Step 5
3000 AND 4000 PRODUCT FAMILIES TROUBLESHOOTING MANUALALLISON 4th GENERATION CONTROLS
Action
Value(s)
Yes
No
Go to
Diagnostic Aids
Go to Step 6
Go to Step 7
Go to Step 8
Go to Step 10
Go to
Diagnostic Aids
Go to Step 11
Go to Step 9
6167
3000 AND 4000 PRODUCT FAMILIES TROUBLESHOOTING MANUALALLISON 4th GENERATION CONTROLS
Action
Value(s)
Yes
No
Go to Step 11
Go to Step 9
Go to Step 11
Go to Step 10
Begin the
diagnosis again.
System OK
Incorrect C2 pressurePCS2
Incorrect C3 pressurePCS3
Is the replacement complete?
10
11
6168
Go to Step 1
3000 AND 4000 PRODUCT FAMILIES TROUBLESHOOTING MANUALALLISON 4th GENERATION CONTROLS
No shift in progress.
You may have to clear the DTC and drive the vehicle in order to experience a fault. Use the data obtained from
failure records to determine transmission range and/or certain vehicle operating variables such as temperature,
run time, etc. This data can be useful in reproducing the failure mode where the DTC was set.
Incorrect ratio codes typically indicate mechanical problems with specific clutches for range indicated, i.e. C3
and C5 for reverse range.
An incorrect ratio DTC may indicate a mechanically failed clutch control solenoid. Review the DTC
information for the specific solenoid.
Copyright 2008 Allison Transmission, Inc.
6169
3000 AND 4000 PRODUCT FAMILIES TROUBLESHOOTING MANUALALLISON 4th GENERATION CONTROLS
Action
Value(s)
Yes
No
Go to Step 2
Go to Section 35,
Beginning the
Troubleshooting
Process
Go to Step 3
Go to Step 4
Go to General
Troubleshooting,
Section 8
Go to the
appropriate speed
sensor DTC
Go to Step 5
6170
3000 AND 4000 PRODUCT FAMILIES TROUBLESHOOTING MANUALALLISON 4th GENERATION CONTROLS
Action
Value(s)
Yes
No
Go to
Diagnostic Aids
Go to Step 6
Go to Step 7
Go to Step 8
Go to Step 10
Go to
Diagnostic Aids
Go to Step 11
Go to Step 9
6171
3000 AND 4000 PRODUCT FAMILIES TROUBLESHOOTING MANUALALLISON 4th GENERATION CONTROLS
Action
Value(s)
Yes
No
Go to Step 11
Go to Step 9
Go to Step 11
Go to Step 10
Begin the
diagnosis again.
System OK
Incorrect C3 pressurePCS2
Incorrect C5 pressurePCS3
Is the replacement complete?
10
11
6172
Go to Step 1
3000 AND 4000 PRODUCT FAMILIES TROUBLESHOOTING MANUALALLISON 4th GENERATION CONTROLS
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).
Engine speed is greater than 200 rpm and less than 7500 rpm.
Six seconds or more have elapsed since torque converter clutch (TCC) was applied in a range.
6173
3000 AND 4000 PRODUCT FAMILIES TROUBLESHOOTING MANUALALLISON 4th GENERATION CONTROLS
Action
Value(s)
Yes
No
Go to Step 2
Go to Section 35,
Beginning the
Troubleshooting
Process
Go to Step 3
>150 rpm
Go to Step 4
Go to
Diagnostic Aids
Go to Step 5
Go to General
Troubleshooting,
Section 8
Go to Step 8
Go to Step 6
Go to Step 9
Go to Step 7
6174
3000 AND 4000 PRODUCT FAMILIES TROUBLESHOOTING MANUALALLISON 4th GENERATION CONTROLS
Action
Value(s)
Yes
No
Go to Step 9
Go to Step 7
Go to Step 9
Go to Step 8
Begin the
diagnosis again.
System OK
Is replacement complete?
8
Go to Step 1
6175
3000 AND 4000 PRODUCT FAMILIES TROUBLESHOOTING MANUALALLISON 4th GENERATION CONTROLS
MAIN PRESSURE
(BEFORE FILTER)
EX
FILTERED
MAIN
PS 2
CONTROL MAIN
TCC FLOW
PUMP
FILTERED
MAIN
SUCTION FILTER
EX
SUMP
LUBE
MAIN
FLOW
V11111.00.00
Circuit Description
Diagnostic Pressure Switch 1 (PS1) is a normally closed (NC) switch. In the NC position the switch completes a
circuit between wire 177 (PS1 switch input) and wire 158 (analog return). The Transmission Control Module
(TCM) believes PS1 is closed if the TCM senses battery ground from wire 158 (analog return) on wire 177. This
PS1 switch state is shown on Allison DOC For PCService Tool as PS1 EXHAUSTED. When the switch gets
pressurized, PS1 should open and cause an open circuit in wire 177. The open circuit condition allows the TCM to
pull pin 77 (which is also tied to wire 177) up to approximately 5 volts. This PS1 switch state condition is shown on
Allison DOC For PCService Tool as PS1 PRESSURIZED.
The 3000/4000 uses C1 and C2 latch valves to control the mapping of each pressure control solenoid to individual
clutches. There are four discrete latch valve states with corresponding unique solenoid mappings. Transmission
operation transitions between these mappings as different clutch and solenoid combinations are used. PS1 is used
to hydraulically sense the mapping states as they occur to signal the TCM to confirm the following control valve
functions:
6176
3000 AND 4000 PRODUCT FAMILIES TROUBLESHOOTING MANUALALLISON 4th GENERATION CONTROLS
When the C5 clutch is filled, such as in reverse, neutral, or first range, PS1 senses PCS2 solenoid regulator
valve position to verify proper C3 clutch control in these three ranges.
When the C5 clutch is exhausted, such as in second through sixth ranges, PS1 monitors C1 and C2 latch valve
position.
The TCM expects PS1 to indicate PRESSURIZED in Reverse and 2nd through 5th ranges. The TCM expects PS1 to
indicate EXHAUSTED in N5, Low (for 7 speeds), 1st and 6th ranges.
Conditions for Running the DTC
TCM initialization is complete
Allison DOC For PCService Tool can be used to clear the code.
The TCM automatically clears the DTC from the TCM history if the vehicle completes 40 engine starts
without a reoccurrence of the code.
Diagnostic Aids
DTC P0752 sets when Shift Solenoid 1 (SS1) is commanded OFF and PS1 status remains PRESSURIZED for
more than 2 seconds. The intent of this DTC is to detect a stuck latch valve in the stroked state, mechanical
solenoid failure, or a circuit short-to-ground.
6177
3000 AND 4000 PRODUCT FAMILIES TROUBLESHOOTING MANUALALLISON 4th GENERATION CONTROLS
If there are other vehicle DTCs, the cause for transmission-related DTCs might be external to the transmission
and those vehicle systems must be corrected in order for the transmission DTCs to be resolved.
A transmission DTC must be active during the troubleshooting process to determine what caused the DTC. Use
the Snapshot feature of Allison DOC For PCService Tool while operating the vehicle in the same
conditions listed in the failure record, available in the Allison DOC For PCService Tool Reports Menu.
Manipulating the chassis harness and data link wiring may reveal intermittent shorts to ground, shorts to
another circuit, and open circuits causing a DTC.
Out of specification driveline components can damage transmission components and cause some transmission
DTCs.
NOTE: Allison Transmission components that are damaged because the driveline exceeded Allison
Transmission driveline specifications are not covered under Allison Transmission Warranty.
NOTE: OEM vehicle harness repairs are not covered under Allison Transmission warranty.
The following wiring and connector issues can cause transmission DTCs:
Expanded female terminals in a connector. Use a mating pin or terminal to check for a light drag feel when
the mating terminal or pin is inserted and slowly removed. There should be some slight friction between
the matching terminal and pin combination. Expanded terminals have no feel of drag when the matching
pin or terminal is inserted and removed.
Broken terminal locks allow the pins or terminals to push back into the connector resulting in poor
connection or pin to pin shorts in the connector. Inspect for broken locks and displaced terminals in
connections. Never use paper clips or other devices to back probe a connector while doing Allison service
work.
Poor pin crimps. Pin crimps should be pull-tested by the technician to verify the crimp is secure to the wire.
If the pin crimp is loose, the pin easily moves or even comes off the wire with a slight tug on the terminal
by the technician. This situation may not reveal itself as an active DTC but instead may exhibit other
symptoms like shift quality issues.
Connector and pin corrosion caused by moisture in connectors. Empty wire locations in connectors must
always have a plug to keep moisture from finding a path into the connector.
Poor harness routing and improper strain relief may cause damage resulting in electrical open and/or short
circuits to wires and connector components.
Butt splices and wire ties are not an ideal solution for any transmission repair. If butt splices will be used,
then always use heat-shrinkable butt splices. Never use wire ties inside the transmission, to hold connector
components together in the place of a connector lock, or in the place of the correct strain relief components
and clips used to fasten harnesses to the vehicle or to retain vehicle connectors unless OEM approved for
the location and vehicle component being repaired.
The following procedures are not documented in any Allison service procedures or in any Allison
Troubleshooting Manual or Service Manual and therefore should not be used as a method to diagnose any
transmission DTC(s), function, or shift quality concern:
Back probing any connectors used for transmission features or functions may damage and/or unlock the
terminals from the back-probed connector creating permanent or intermittent shorts and/or open circuits. If
possible, use the Breakout Box J 39700, appropriate harness adapters, and appropriate magnetic overlays
to troubleshoot the vehicle.
Load-testing any transmission-related circuits with any other electrical devices such as vehicle lamps or
relays, especially with the TCM connected to the harness. Use Breakout Box J 39700 and appropriate
harnesses with Allison DOC For PCService Tool to monitor the circuit performance in question unless
otherwise specified in the various Troubleshooting Manuals to use a digital volt-Ohm meter (DVOM) with
the Breakout.
6178
3000 AND 4000 PRODUCT FAMILIES TROUBLESHOOTING MANUALALLISON 4th GENERATION CONTROLS
especially at the TCM. This creates a leak path for moisture and damages the wire and insulation.
If needed, call for local distributor and/or factory support before downtime and expense of repair effect the
Allison Customer Experience. The phone number for the Technical Assistance Center in the United States is 1800-252-5283
Always use tools that are in good condition. Refer to the Allison Essential Tools list on the Allison Extranet to
complete any service procedure listed in an Allison publication. Also see appropriate Service Manuals and
Troubleshooting Manuals for service tools information.
6179
3000 AND 4000 PRODUCT FAMILIES TROUBLESHOOTING MANUALALLISON 4th GENERATION CONTROLS
Action
Value(s)
Yes
No
Go to Step 2
Review the
information in
Section 3-5,
Section 6-6, and
Diagnostic Aids
listed for this DTC
Go to Step 1
Go to Step 3
Go to Step 4
Review the
information in
Section 3-5,
Section 6-6, and
also Diagnostic
Aids listed for this
specific DTC
Go to Step 11
Go to Step 5
Go to Step 6
Go to Step 8
6180
Go to Step 11
3000 AND 4000 PRODUCT FAMILIES TROUBLESHOOTING MANUALALLISON 4th GENERATION CONTROLS
Action
Value(s)
Yes
No
Go to Step 7
There is an open
circuit in chassis
harness wire 177
and/or wire 158.
Go to Step 8
Go to Step 9
Go to Step 10
Replace or repair
the internal
harness.
Refer to OEM
vehicle wiring
specifications and
OEM vehicle
wiring repair
procedures to
correct the issue.
Section 4-1, Wire
Test Procedures
provides overview
information for
making continuity
checks.
Go to Step 11
Go to Step 11
Go to Step 11
6181
3000 AND 4000 PRODUCT FAMILIES TROUBLESHOOTING MANUALALLISON 4th GENERATION CONTROLS
Action
10
11
Value(s)
Yes
No
Go to Step 11
Go to Step 10
Go to Step 1
System OK
6182
Clear inactive
codes from history
Repair complete
3000 AND 4000 PRODUCT FAMILIES TROUBLESHOOTING MANUALALLISON 4th GENERATION CONTROLS
While diagnostic response is active, the TCM ignores shift selector inputs.
PCS2 supplies hydraulic pressure to the C3 clutch in reverse and to the C2 clutch in fourth range through sixth
range. To determine which clutch circuit is suspect, review the Allison DOC For PCService Tool failure
record data for previous or current range information when the DTC was set.
If the condition is intermittent, connect Allison DOC For PCService Tool and observe the speed sensor
indicated by the code. If the signal is erratic, investigate and eliminate the following:
Intermittent wiring connection
Copyright 2008 Allison Transmission, Inc.
6183
3000 AND 4000 PRODUCT FAMILIES TROUBLESHOOTING MANUALALLISON 4th GENERATION CONTROLS
Test Description
The numbers below refer to step numbers on the diagnostic table.
2. Tests for proper transmission fluid level.
3. Tests for active DTCs.
4. Tests ignition voltage.
5. Tests speed sensor readings.
6. Tests for C2 and C3 clutch pressure from PCS2.
7. Tests for evidence of clutch failure.
8. Tests for stuck or sticking valves and damaged valve body gaskets.
Yes
No
Action
Value(s)
Go to Step 2
Go to Section 35,
Beginning the
Troubleshooting
Process
Go to Step 3
1.
2.
3.
4.
5.
Go to Step 4
Go to
Diagnostic Aids
Go to Step 5
Go to General
Troubleshooting,
Section 8
Go to the
appropriate speed
sensor DTC
Go to Step 6
1.
2.
3.
4.
6184
Install the Allison DOC For PCService Tool. 918V (12V TCM)
1832V (24V TCM)
Start the engine.
Record the DTC failure record data.
Using the Allison DOC For PCService Tool,
measure ignition voltage.
Is the voltage within the specified value?
Watch for erratic
speed sensor
signals
3000 AND 4000 PRODUCT FAMILIES TROUBLESHOOTING MANUALALLISON 4th GENERATION CONTROLS
Action
Value(s)
Yes
No
Go to Step 7
Go to Step 8
Go to Step 10
Go to
Diagnostic Aids
Go to Step 11
Go to Step 9
Replace PCS2.
Go to Step 11
Go to Step 9
Go to Step 11
Go to Step 10
Begin the
diagnosis again.
System OK
11
Go to Step 1
6185
3000 AND 4000 PRODUCT FAMILIES TROUBLESHOOTING MANUALALLISON 4th GENERATION CONTROLS
While the diagnostic response is active, the TCM ignores shift selectors inputs.
PCS2 supplies hydraulic pressure to C3 clutch in reverse and to C2 clutch in fourth range through sixth range.
To determine which clutch circuit is suspect, review the Allison DOC For PCService Tool failure record
data for previous or current range information when the DTC was set.
PCS1 and PCS2 are normally high solenoids. PCS1 and PCS2 supply full hydraulic pressure when their coils
are de-energized, and no output pressure when receiving maximum current from the TCM.
6186
3000 AND 4000 PRODUCT FAMILIES TROUBLESHOOTING MANUALALLISON 4th GENERATION CONTROLS
If the condition is intermittent, connect Allison DOC For PCService Tool and observe the speed sensor
indicated by the code. If the signal is erratic, investigate and eliminate the following:
Intermittent wiring connection
Excessive vibration (driveline or engine torsionals)
Irregular sensor gap (loose sensor, loose tone wheel, or damaged tone wheel)
Test Description
The numbers below refer to step numbers on the diagnostic table.
2. Tests for proper transmission fluid level.
3. Tests for active DTCs.
4. Tests ignition voltage.
5. Tests speed sensor readings.
6. Tests for C2 or C3 clutch pressure from PCS2.
7. Tests for evidence of clutch failure.
8. Tests for stuck or sticking valves and damaged valve body gaskets.
Yes
No
Action
Value(s)
Go to Step 2
Go to Section 35,
Beginning the
Troubleshooting
Process
Go to Step 3
1.
2.
3.
4.
5.
Go to Step 4
Go to
Diagnostic Aids
Go to Step 5
Go to General
Troubleshooting,
Section 8
1.
2.
3.
4.
Install the Allison DOC For PCService Tool. 918V (12V TCM)
1832V (24V TCM)
Start the engine.
Record the DTC failure record data.
Using the Allison DOC For PCService Tool,
measure ignition voltage.
Is the voltage within the specified value?
Copyright 2008 Allison Transmission, Inc.
6187
3000 AND 4000 PRODUCT FAMILIES TROUBLESHOOTING MANUALALLISON 4th GENERATION CONTROLS
Action
Value(s)
Yes
No
Go to the
appropriate speed
sensor DTC
Go to Step 6
Go to Step 7
Go to Step 8
Go to Step 10
Go to
Diagnostic Aids
Go to Step 11
Go to Step 9
Replace PCS2.
Go to Step 11
Go to Step 9
Go to Step 11
Go to Step 10
6188
3000 AND 4000 PRODUCT FAMILIES TROUBLESHOOTING MANUALALLISON 4th GENERATION CONTROLS
Action
Value(s)
Yes
No
Begin the
diagnosis again.
System OK
Go to Step 1
6189
3000 AND 4000 PRODUCT FAMILIES TROUBLESHOOTING MANUALALLISON 4th GENERATION CONTROLS
When DTC P0796 occurs, the TCM will command previous range.
While the Diagnostic Response is active, the TCM will ignore shift selector inputs.
This DTC indicates the oncoming clutch being controlled by PCS3 is not applied or applied too slowly.
Common causes include:
Erratic turbine or output speed signals.
A leak or obstruction in a specific clutch apply circuit.
A defective solenoid.
A stuck PCS3 regulator valve.
A stuck C1 or C2 logic latch valve.
PCS3 supplies hydraulic pressure to C5 clutch in reverse, neutral and first range; and to C3 clutch in third and
fifth ranges. To determine which clutch circuit is suspect, review the Allison DOC For PCService Tool
failure record data for previous or current range information when the DTC was set.
6190
3000 AND 4000 PRODUCT FAMILIES TROUBLESHOOTING MANUALALLISON 4th GENERATION CONTROLS
If the condition is intermittent, connect Allison DOC For PCService Tool and observe the speed sensor
indicated by the code. If the signal is erratic, investigate and eliminate the following:
Intermittent wiring connection
Excessive vibration (driveline or engine torsionals)
Irregular sensor gap (loose sensor, loose tone wheel, or damaged tone wheel)
Test Description
The numbers below refer to step numbers on the diagnostic table.
2. Tests for proper transmission fluid level.
3. Tests for active DTCs.
4. Tests ignition voltage.
5. Tests speed sensor readings.
6. Tests for C3 and C5 clutch pressure from PCS3.
7. Tests for evidence of clutch failure.
8. Tests for stuck or sticking valves and damaged valve body gaskets.
Yes
No
Action
Value(s)
Go to Step 2
Go to Section 35,
Beginning the
Troubleshooting
Process
Go to Step 3
1.
2.
3.
4.
5.
Go to Step 4
Go to
Diagnostic Aids
Go to Step 5
Go to General
Troubleshooting,
Section 8
1.
2.
3.
4.
Install the Allison DOC For PCService Tool. 918V (12V TCM)
1832V (24V TCM)
Start the engine.
Record the DTC failure record data.
Using the Allison DOC For PCService Tool,
measure ignition voltage.
Is the voltage within the specified value?
Copyright 2008 Allison Transmission, Inc.
6191
3000 AND 4000 PRODUCT FAMILIES TROUBLESHOOTING MANUALALLISON 4th GENERATION CONTROLS
Action
Value(s)
Yes
No
Go to the
appropriate speed
sensor DTC
Go to Step 6
Go to Step 7
Go to Step 8
Go to Step 10
Go to
Diagnostic Aids
Go to Step 11
Go to Step 9
Replace PCS3.
Go to Step 11
Go to Step 9
Go to Step 11
Go to Step 10
6192
3000 AND 4000 PRODUCT FAMILIES TROUBLESHOOTING MANUALALLISON 4th GENERATION CONTROLS
Action
Value(s)
Yes
No
Begin the
diagnosis again.
System OK
Go to Step 1
6193
3000 AND 4000 PRODUCT FAMILIES TROUBLESHOOTING MANUALALLISON 4th GENERATION CONTROLS
When DTC P0797 occurs, the TCM will command previous range.
While Diagnostic Response is active, the TCM will ignore shift selector inputs.
This DTC indicates the off-going clutch being controlled by PCS3 is not released or released too slowly.
Common causes include:
Erratic turbine and output speed sensor readings.
An obstruction in the C3 or C5 clutch exhaust circuit.
A defective PCS3 solenoid.
A stuck PCS3 regulator valve.
PCS3 supplies hydraulic pressure to C5 clutch in reverse, neutral and first range; and to C3 clutch in third and
fifth ranges. To determine which clutch circuit is suspect, review the Allison DOC For PCService Tool
failure record data for previous or current range information when the DTC was set.
6194
3000 AND 4000 PRODUCT FAMILIES TROUBLESHOOTING MANUALALLISON 4th GENERATION CONTROLS
If the condition is intermittent, connect Allison DOC For PCService Tool and observe the speed sensor
indicated by the code. If the signal is erratic, investigate and eliminate the following:
Intermittent wiring connection
Excessive vibration (driveline or engine torsionals)
Irregular sensor gap (loose sensor, loose tone wheel, or damaged tone wheel)\
Test Description
The numbers below refer to step numbers on the diagnostic table.
2. Tests for proper transmission fluid level.
3. Tests for active DTCs.
4. Tests ignition voltage.
5. Tests speed sensor readings.
6. Tests for C3 or C5 clutch pressure from PCS3.
7. Tests for evidence of clutch failure.
8. Tests for stuck or sticking valves and damaged valve body gaskets.
Yes
No
Action
Value(s)
Go to Step 2
Go to Section 35,
Beginning the
Troubleshooting
Process
Go to Step 3
1.
2.
3.
4.
5.
Go to Step 4
Go to
Diagnostic Aids
Go to Step 5
Go to General
Troubleshooting,
Section 8
1.
2.
3.
4.
Install the Allison DOC For PCService Tool. 918V (12V TCM)
1832V (24V TCM)
Start the engine.
Record the DTC failure record data.
Using the Allison DOC For PCService Tool,
measure ignition voltage.
Is the voltage within the specified value?
Copyright 2008 Allison Transmission, Inc.
6195
3000 AND 4000 PRODUCT FAMILIES TROUBLESHOOTING MANUALALLISON 4th GENERATION CONTROLS
Action
Value(s)
Yes
No
Go to the
appropriate speed
sensor DTC
Go to Step 6
Go to Step 7
Go to Step 8
Go to Step 10
Go to
Diagnostic Aids
Go to Step 11
Go to Step 9
Replace PCS3.
Go to Step 11
Go to Step 9
Go to Step 11
Go to Step 10
6196
3000 AND 4000 PRODUCT FAMILIES TROUBLESHOOTING MANUALALLISON 4th GENERATION CONTROLS
Action
Value(s)
Yes
No
Begin the
diagnosis again
System OK
Go to Step 1
6197
3000 AND 4000 PRODUCT FAMILIES TROUBLESHOOTING MANUALALLISON 4th GENERATION CONTROLS
END VIEW OF
80-WAY CONNECTOR
10
11
14
15
20
61
80
41
60
21
40
20
TO RETARDER
CONTROL DEVICES
RETARDER
REQUEST SENSOR
(RESISTANCE
MODULE)
A
PWM
THROTTLE
SOURCE
TCM
THROTTLE
POSITION
SENSOR (TPS)
OR
ELECTRONIC
BRAKING (EBS)
RTDR PRESSURE
SENSOR
WIRE 156
WIRE 112
WIRE 144
WIRE 158
A
RETARDER TEMP
ENGINE TEMP
TRANSMISSION
ANALOG RETURN
OIL LEVEL
HALL
A
C
EFFECT
B
SUMP TEMP
19
16
15
18
PS1
PS2 NC*
NC*
* NORMALLY
3
17
WIRE 175
WIRE 135
56
12
5V SENSOR VOLTAGE
44
THROTTLE POSITION OR
RTDR PRESSURE SIGNAL
58
ANALOG RETURN
75
RETARDER TEMP
35
16
54
SUMP TEMP
77
WIRE 158
WIRE 112
WIRE 116
WIRE 154
WIRE 177
WIRE 118
18
CLOSED
V11114.00.00
6198
3000 AND 4000 PRODUCT FAMILIES TROUBLESHOOTING MANUALALLISON 4th GENERATION CONTROLS
clutches. There are four discrete latch valve states with corresponding unique solenoid mappings. Transmission
operation transitions between these mappings as different clutch and solenoid combinations are used. PS1 is used
to hydraulically sense the mapping states as they occur to signal the TCM to confirm the following control valve
functions:
When the C5 clutch is filled, such as in reverse, neutral, or first range, PS1 senses PCS2 solenoid regulator
valve position to verify proper C3 clutch control in these three ranges.
When the C5 clutch is exhausted, such as in second through sixth ranges, PS1 monitors C1 and C2 latch valve
position.
The TCM expects PS1 to indicate PRESSURIZED in Reverse and 2nd through 5th ranges. The TCM expects PS1 to
indicate EXHAUSTED in N5, Low (for 7 speeds), 1st and 6th ranges.
Conditions for Running the DTC
The transmission locks in current range and ignores shift selector commands
The TCM must see a normal shutdown and power up without failing the diagnostic test
The TCM automatically clears the DTC from the TCM history if the vehicle completes 40 engine starts
without a reoccurrence of the code.
Copyright 2008 Allison Transmission, Inc.
6199
3000 AND 4000 PRODUCT FAMILIES TROUBLESHOOTING MANUALALLISON 4th GENERATION CONTROLS
If there are other vehicle DTCs, the cause for transmission-related DTCs might be external to the transmission
and those vehicle systems must be corrected in order for the transmission DTCs to be resolved.
A transmission DTC must be active during the troubleshooting process to determine what caused the DTC. Use
the Snapshot feature of Allison DOC For PCService Tool while the vehicle is operated in the same
conditions listed in the failure record available in the Allison DOC For PCService Tool Reports Menu for
the specific DTC that was active.
Manipulating the chassis harness and data link wiring may reveal intermittent shorts to ground, shorts to
another circuit, and open circuits causing a DTC.
Out-of-specification driveline components can damage transmission components and cause some transmission
DTCs.
NOTE: Allison Transmission components that are damaged because the driveline exceeded Allison
Transmission driveline specifications are not covered under Allison Transmission Warranty.
NOTE: OEM vehicle harness repairs are not covered under Allison Transmission warranty.
The following wiring and connector issues can cause transmission DTCs:
Expanded female terminals in a connector. Use a mating pin or terminal to check for a light drag feel when
the mating terminal or pin is inserted and slowly removed. There should be some slight friction between
the matching terminal and pin combination. Expanded terminals have no feel of drag when the matching
pin or terminal is inserted and removed.
Broken terminal locks allow the pins or terminals to push back into the connector resulting in poor
connection or pin to pin shorts in the connector. Inspect for broken locks and displaced terminals in
connections. Never use paper clips or other devices to back-probe a connector while doing Allison service
work.
Poor pin crimps. Pin crimps should be pull-tested by the technician to verify the crimp is secure to the wire.
If the pin crimp is loose, the pin easily moves or even comes off the wire with a slight tug on the terminal
by the technician. This situation may not reveal itself as an active DTC but instead may exhibit other
symptoms like shift quality issues.
Connector and pin corrosion caused by moisture in connectors. Empty wire locations in connectors must
always have a plug to keep moisture from finding a path into the connector.
6200
3000 AND 4000 PRODUCT FAMILIES TROUBLESHOOTING MANUALALLISON 4th GENERATION CONTROLS
then always use heat-shrinkable butt splices. Never use wire ties inside the transmission, to hold connector
components together in the place of a connector lock, or in the place of the correct strain relief components
and clips used to fasten harnesses to the vehicle or to retain vehicle connectors unless OEM approved for
the location and vehicle component being repaired.
The following procedures are not documented in any Allison service procedures or in any Allison
Troubleshooting Manual or Service Manual and therefore should not be used as a method to diagnose any
transmission DTC(s), function, or shift quality concern:
Back-probing any connectors used for transmission features or functions may damage and/or unlock the
terminals from the back-probed connector creating permanent or intermittent shorts and/or open circuits. If
possible, use the Breakout Box J 39700, appropriate harness adapters, and appropriate magnetic overlays
to troubleshoot the vehicle.
Load-testing any transmission-related circuits with any other electrical devices such as vehicle lamps or
relays, especially with the TCM connected to the harness. Use Breakout Box J 39700 and appropriate
harnesses with Allison DOC For PCService Tool to monitor the circuit performance in question unless
otherwise specified in the various Troubleshooting Manuals to use a digital volt-Ohm meter (DVOM) with
the Breakout.
Piercing a wire to check for voltages, shorts-to-grounds or other wires anywhere in the circuit but
especially at the TCM. This creates a leak path for moisture and damages the wire and insulation.
If needed, call for local distributor and/or factory support before downtime and expense of repair effect the
Allison Customer Experience. The phone number for the Technical Assistance Center in the United States is 1800-252-5283
Always use tools that are in good condition. Refer to the Allison Essential Tools list on the Allison Extranet to
complete any service procedure listed in an Allison publication. Also see appropriate Service Manuals and
Troubleshooting Manuals for service tools information.
6201
3000 AND 4000 PRODUCT FAMILIES TROUBLESHOOTING MANUALALLISON 4th GENERATION CONTROLS
Action
Value(s)
Yes
No
Go to Step 2
Review the
information in
Section 3-5,
Section 6-6, and
Diagnostic Aids
listed for this DTC
Go to Step 1
Go to Step 3
6202
Go to Step 5
Go to Step 4
3000 AND 4000 PRODUCT FAMILIES TROUBLESHOOTING MANUALALLISON 4th GENERATION CONTROLS
Go to Step 5
Go to Step 8
Go to Step 6
Go to Step 7
Go to Step 7
Go to Step 14
6203
3000 AND 4000 PRODUCT FAMILIES TROUBLESHOOTING MANUALALLISON 4th GENERATION CONTROLS
Go to Step 9
Go to Step 10
Go to Step 5
Go to Step 14
6204
3000 AND 4000 PRODUCT FAMILIES TROUBLESHOOTING MANUALALLISON 4th GENERATION CONTROLS
There is a short
from wire 177 to
another wire or
chassis ground in
the OEM chassis
harness
Go to Step 10
Refer to OEM
vehicle wiring
specifications and
OEM vehicle
wiring repair
procedures to
correct the issue.
NOTE: OEM
vehicle
harness
repairs are
not
covered
under
Allison
Transmissi
on
warranty.
Go to Step 14
10
11
Go to Step 11
Replace or repair
the internal
harness.
Go to Step 12
Go to Step 14
6205
3000 AND 4000 PRODUCT FAMILIES TROUBLESHOOTING MANUALALLISON 4th GENERATION CONTROLS
Go to Step 13
Replace PS1
Go to Step 14
13
Go to Step 14
Go to Step 13
14
Go to Step 1
System OK
6206
Clear inactive
codes from history
Repair complete
3000 AND 4000 PRODUCT FAMILIES TROUBLESHOOTING MANUALALLISON 4th GENERATION CONTROLS
END VIEW OF
80-WAY CONNECTOR
10
11
14
15
20
61
80
41
60
21
40
20
TO RETARDER
CONTROL DEVICES
RETARDER
REQUEST SENSOR
(RESISTANCE
MODULE)
A
PWM
THROTTLE
SOURCE
TCM
THROTTLE
POSITION
SENSOR (TPS)
OR
ELECTRONIC
BRAKING (EBS)
RTDR PRESSURE
SENSOR
WIRE 156
WIRE 112
WIRE 144
WIRE 158
A
RETARDER TEMP
ENGINE TEMP
TRANSMISSION
ANALOG RETURN
OIL LEVEL
HALL
A
C
EFFECT
B
SUMP TEMP
19
16
15
18
PS1
PS2 NC*
NC*
* NORMALLY
3
17
WIRE 175
WIRE 135
56
12
5V SENSOR VOLTAGE
44
THROTTLE POSITION OR
RTDR PRESSURE SIGNAL
58
ANALOG RETURN
75
RETARDER TEMP
35
16
54
SUMP TEMP
77
WIRE 158
WIRE 112
WIRE 116
WIRE 154
WIRE 177
WIRE 118
18
CLOSED
V11114.00.00
6207
3000 AND 4000 PRODUCT FAMILIES TROUBLESHOOTING MANUALALLISON 4th GENERATION CONTROLS
When the C5 clutch is filled, such as in reverse, neutral, or first range, PS1 senses PCS2 solenoid regulator
valve position to verify proper C3 clutch control in these three ranges.
When the C5 clutch is exhausted, such as in second through sixth ranges, PS1 monitors C1 and C2 latch valve
position.
The TCM expects PS1 to indicate PRESSURIZED in Reverse and 2nd through 5th ranges. The TCM expects
PS1 to indicate EXHAUSTED in N5, Low (for 7 speeds), 1st and 6th ranges.
The transmission locks in current range and ignores shift selector commands
The TCM automatically clears the DTC from the TCM history if the vehicle completes 40 engine starts
without a reoccurrence of the code.
Diagnostic Aids
This DTC occurs when the PS1 indicates PRESSURIZED and the TCM expects PS1 switch state to indicate
EXHAUSTED instead.
6208
3000 AND 4000 PRODUCT FAMILIES TROUBLESHOOTING MANUALALLISON 4th GENERATION CONTROLS
If there are other vehicle DTCs, the cause for transmission-related DTCs might be external to the transmission
and those vehicle systems must be corrected in order for the transmission DTCs to be resolved.
A transmission DTC must be active during the troubleshooting process to determine what caused the DTC. Use
the Snapshot feature of Allison DOC For PCService Tool while operating the vehicle in the same
conditions listed in the failure record available in the Allison DOC For PCService Tool Reports menu.
Manipulating the chassis harness and data link wiring may reveal intermittent shorts to ground, shorts to
another circuit, and open circuits causing a DTC.
Out-of-specification driveline components can damage transmission components and cause some transmission
DTCs.
NOTE: Allison Transmission components that are damaged because the driveline exceeded Allison
Transmission driveline specifications are not covered under Allison Transmission Warranty.
NOTE: OEM vehicle harness repairs are not covered under Allison Transmission warranty.
The following wiring and connector issues can cause transmission DTCs:
Expanded female terminals in a connector. Use a mating pin or terminal to check for a light drag feel when
the mating terminal or pin is inserted and slowly removed. There should be some slight friction between
the matching terminal and pin combination. Expanded terminals have no feel of drag when the matching
pin or terminal is inserted and removed.
Broken terminal locks allow the pins or terminals to push back into the connector, resulting in poor
connection or pin to pin shorts in the connector. Inspect for broken locks and displaced terminals in
connections. Never use paper clips or other devices to back-probe a connector while doing Allison service
work.
Poor pin crimps. Pin crimps should be pull-tested by the technician to verify the crimp is secure to the wire.
If the pin crimp is loose, the pin easily moves or even comes off the wire with a slight tug on the terminal
by the technician. This situation may not reveal itself as an active DTC but instead may exhibit other
symptoms like shift quality issues.
Connector and pin corrosion caused by moisture in connectors. Empty wire locations in connectors must
always have a plug to keep moisture from finding a path into the connector.
Poor harness routing and improper strain relief may cause damage resulting in electrical open and/or short
circuits to wires and connector components.
Butt splices and wire ties are not an ideal solution for any transmission repair. If butt splices will be used,
then always use heat-shrinkable butt splices. Never use wire ties inside the transmission, to hold connector
components together in the place of a connector lock, or in the place of the correct strain relief components
Copyright 2008 Allison Transmission, Inc.
6209
3000 AND 4000 PRODUCT FAMILIES TROUBLESHOOTING MANUALALLISON 4th GENERATION CONTROLS
The following procedures are not documented in any Allison service procedures or in any Allison
Troubleshooting Manual or Service Manual, and therefore should not be used as a method to diagnose any
transmission DTC(s), function, or shift quality concern:
Back-probing any connectors used for transmission features or functions may damage and/or unlock the
terminals from the back-probed connector creating permanent or intermittent shorts and/or open circuits. If
possible, use the Breakout Box J 39700, appropriate harness adapters, and appropriate magnetic overlays
to troubleshoot the vehicle.
Load-testing any transmission-related circuits with any other electrical devices such as vehicle lamps, or
relays, especially with the TCM connected to the harness. Use Breakout Box J-39700 and appropriate
harnesses with Allison DOC For PCService Tool to monitor the circuit performance in question unless
otherwise specified in the various Troubleshooting Manuals to use a digital volt-Ohm meter (DVOM) with
the Breakout.
Piercing a wire to check for voltages, shorts to grounds or other wires anywhere in the circuit but especially
at the TCM. This creates a leak path for moisture and damages the wire and insulation.
If necessary, call for local distributor and/or factory support before downtime and expense of repair effect the
Allison Customer Experience. The phone number for the Technical Assistance Center in the United States is 1800-252-5283
Always use tools that are in good condition. Refer to the Allison Essential Tools list on the Allison Extranet to
complete any service procedure listed in an Allison publication. Also see appropriate Service Manuals and
Troubleshooting Manuals for service tools information.
3000 AND 4000 PRODUCT FAMILIES TROUBLESHOOTING MANUALALLISON 4th GENERATION CONTROLS
Action
Value(s)
Yes
No
Go to Step 2
Review the
information in
Section 3-5,
Section 6-6, and
Diagnostic Aids
listed for this DTC
Go to Step 1
Go to Step 3
Go to Step 5
Go to Step 4
Go to Step 5
Go to Step 8
6211
3000 AND 4000 PRODUCT FAMILIES TROUBLESHOOTING MANUALALLISON 4th GENERATION CONTROLS
Action
Value(s)
Yes
No
Go to Step 6
Go to Step 7
Go to Step 7
Go to Step 9
Go to Step 13
There is an open
circuit between
wire 177 and wire
158 in the OEM
chassis harness
Refer to OEM
vehicle wiring
specifications and
OEM vehicle
wiring repair
procedures to
correct the issue.
NOTE: OEM
vehicle harness
repairs are not
covered under
Allison
Transmission
warranty.
Go to Step 13
6212
3000 AND 4000 PRODUCT FAMILIES TROUBLESHOOTING MANUALALLISON 4th GENERATION CONTROLS
Action
Value(s)
Yes
No
Go to DTC P0842
Troubleshooting
Tree
Go to Step 13
Go to Step 11
There is an open
circuit for PS1
circuit.
Go to Step 10
Replace or repair
the internal
harness.
Go to Step 13
6213
3000 AND 4000 PRODUCT FAMILIES TROUBLESHOOTING MANUALALLISON 4th GENERATION CONTROLS
Action
11
Value(s)
Yes
No
Go to Step 12
12
Go to Step 13
Go to Step 12
13
Go to Step 1
System OK
6214
Go to Step 13
Clear inactive
codes from history
Repair complete
3000 AND 4000 PRODUCT FAMILIES TROUBLESHOOTING MANUALALLISON 4th GENERATION CONTROLS
END VIEW OF
80-WAY CONNECTOR
10
11
14
15
20
61
80
41
60
21
40
20
TO RETARDER
CONTROL DEVICES
RETARDER
REQUEST SENSOR
(RESISTANCE
MODULE)
A
PWM
THROTTLE
SOURCE
TCM
THROTTLE
POSITION
SENSOR (TPS)
OR
ELECTRONIC
BRAKING (EBS)
RTDR PRESSURE
SENSOR
WIRE 156
WIRE 112
WIRE 144
WIRE 158
A
RETARDER TEMP
ENGINE TEMP
TRANSMISSION
ANALOG RETURN
OIL LEVEL
HALL
A
C
EFFECT
B
SUMP TEMP
19
16
15
18
PS1
PS2 NC*
NC*
* NORMALLY
3
17
WIRE 175
WIRE 135
56
12
5V SENSOR VOLTAGE
44
THROTTLE POSITION OR
RTDR PRESSURE SIGNAL
58
ANALOG RETURN
75
RETARDER TEMP
35
16
54
SUMP TEMP
77
WIRE 158
WIRE 112
WIRE 116
WIRE 154
WIRE 177
WIRE 118
18
CLOSED
V11114.00.00
6215
3000 AND 4000 PRODUCT FAMILIES TROUBLESHOOTING MANUALALLISON 4th GENERATION CONTROLS
If PS2 indicates EXHAUSTED while in converter mode, then DTC P0847 sets to indicate that the switch state
does not match the commanded mode of operation.
After converter mode cycling, if PS2 switch state oscillates between PRESSURIZED and EXHAUSTED more
than the switch would be expected to in that given period of time based on fluid temperature, and then settles
on an unexpected switch state value for the mode of operation, then P0847 will set.
DTC P0847 is stored in the TCM DTC history for a number of ignition cycles.
3000 AND 4000 PRODUCT FAMILIES TROUBLESHOOTING MANUALALLISON 4th GENERATION CONTROLS
If Prognostics is enabled but W118 is not installed by the vehicle OEM, then DTC P0848 will goes active when
the ignition is ON but engine not running.
If there are other vehicle DTCs, the cause for transmission-related DTCs might be external to the transmission
and those vehicle systems must be corrected in order for the transmission DTCs to be resolved.
A transmission DTC must be active during the troubleshooting process to determine what caused the DTC. Use
the Snapshot feature of Allison DOC For PCService Tool while operating the vehicle in the same
conditions listed in the failure record, available in the Allison DOC For PCService Tool Reports menu.
Manipulating the chassis harness and data link wiring may reveal intermittent shorts to ground, shorts to
another circuit, and open circuits causing a DTC.
Out of specification driveline components can damage transmission components and cause some transmission
DTCs.
NOTE: Allison Transmission components that are damaged because the driveline exceeded Allison
Transmission driveline specifications are not covered under Allison Transmission Warranty.
NOTE: OEM vehicle harness repairs are not covered under Allison Transmission warranty.
The following wiring and connector issues can cause transmission DTCs:
Expanded female terminals in a connector. Use a mating pin or terminal to check for a light drag feel when
the mating terminal or pin is inserted and slowly removed. There should be some slight friction between
the matching terminal and pin combination. Expanded terminals have no feel of drag when the matching
pin or terminal is inserted and removed.
Broken terminal locks allow their pins or terminals to push back into the connector resulting in poor
connection or pin to pin shorts in the connector. Inspect for broken locks and displaced terminals in
connections. Never use paper clips or other devices to back-probe a connector while doing Allison service
work.
Poor pin crimps. Pin crimps should be pull-tested by the technician to verify the crimp is secure to the wire.
If the pin crimp is loose, the pin easily moves or even comes off the wire with a slight tug on the terminal
by the technician. This situation may not reveal itself as an active DTC but instead may exhibit other
symptoms like shift quality issues.
Connector and pin corrosion caused by moisture in connectors. Empty wire locations in connectors must
always have a plug to keep moisture from finding a path into the connector.
Poor harness routing and improper strain relief may cause damage resulting in electrical open and/or short
circuits to wires and connector components.
Butt splices and wire ties are not an ideal solution for any transmission repair. If butt splices will be used,
then always use heat-shrinkable butt splices. Never use wire ties inside the transmission, to hold connector
Copyright 2008 Allison Transmission, Inc.
6217
3000 AND 4000 PRODUCT FAMILIES TROUBLESHOOTING MANUALALLISON 4th GENERATION CONTROLS
The following procedures are not documented in any Allison service procedures or in any Allison
Troubleshooting Manual or Service Manual, and therefore should not be used as a method to diagnose any
transmission DTC(s), function, or shift quality concern:
Back-probing any connectors used for transmission features or functions may damage and/or unlock the
terminals from the back-probed connector creating permanent or intermittent shorts and/or open circuits. If
possible, use the Breakout Box J 39700, appropriate harness adapters, and appropriate magnetic overlays
to troubleshoot the vehicle.
Load-testing any transmission-related circuits with any other electrical devices such as vehicle lamps, or
relays, especially with the TCM connected to the harness. Use Breakout Box J 39700 and appropriate
harnesses with Allison DOC For PCService Tool to monitor the circuit performance in question unless
otherwise specified in the various Troubleshooting Manuals to use a digital volt-Ohm meter (DVOM) with
the Breakout.
Piercing a wire to check for voltages, shorts-to-grounds or other wires anywhere in the circuit but
especially at the TCM. This creates a leak path for moisture and damages the wire and insulation.
If needed, call for local distributor and/or factory support before downtime and expense of repair effect the
Allison Customer Experience. The phone number for the Technical Assistance Center in the United States is 1800-252-5283
Always use tools that are in good condition. Refer to the Allison Essential Tools list on the Allison Extranet to
complete any service procedure listed in an Allison publication. Also see appropriate Service Manuals and
Troubleshooting Manuals for service tools information.
3000 AND 4000 PRODUCT FAMILIES TROUBLESHOOTING MANUALALLISON 4th GENERATION CONTROLS
Action
Value(s)
Yes
No
Go to Step 2
Go to Step 3
Troubleshoot TCC
Codes
Go to Step 4
Go to Step 5
Go to Step 10
Go to Step 6
Go to Step 7
6219
3000 AND 4000 PRODUCT FAMILIES TROUBLESHOOTING MANUALALLISON 4th GENERATION CONTROLS
Action
Value(s)
Yes
No
Go to Step 8
6220
Go to Step 6
Go to Step 10
Go to Step 9
3000 AND 4000 PRODUCT FAMILIES TROUBLESHOOTING MANUALALLISON 4th GENERATION CONTROLS
Action
Value(s)
Yes
No
Replace PS2
Go to Step 10
Go to Step 10
Go to Step 1
System OK
Clear inactive codes from
history
Repair complete
6221
3000 AND 4000 PRODUCT FAMILIES TROUBLESHOOTING MANUALALLISON 4th GENERATION CONTROLS
If PS2 indicates EXHAUSTED while in converter mode, than P0848 sets to indicate the switch state does not
match the commanded mode of operation.
If ignition is ON and the engine is not running and PS2 is open circuit, i.e., PS2 would show PRESSURIZED,
than P0848 will set.
NOTE: This condition occurs whenever the vehicle OEM does not include W118 in the chassis harness but
enables the Prognostics package and the operator keys the ignition without starting the engine.
After converter mode cycling, if PS2 switch state oscillates between PRESSURIZED and EXHAUSTED more
than the switch would be expected to in that given period of time based on fluid temperature, and then settles
on an unexpected switch state value for the mode of operation, then P0848 will set.
DTC P0847 is stored in the TCM DTC history for a number of ignition cycles.
6222
3000 AND 4000 PRODUCT FAMILIES TROUBLESHOOTING MANUALALLISON 4th GENERATION CONTROLS
If Prognostics is enabled but W118 is not installed by the vehicle OEM, then P0848 goes active when the
ignition is ON but engine not running.
NOTE: OEM vehicle harness repairs are not covered under Allison Transmission warranty.
If there are other vehicle DTCs, the cause for transmission-related DTCs might be external to the transmission
and those vehicle systems must be corrected in order for the transmission DTCs to be resolved.
A transmission DTC must be active during the troubleshooting process to determine what caused the DTC. Use
the Snapshot feature of Allison DOC For PCService Tool while operating the vehicle in the same
conditions listed in the failure record (available in the Allison DOC For PCService Tool Reports menu).
Manipulating the chassis harness and data link wiring may reveal intermittent shorts to ground, shorts to
another circuit, and open circuits causing a DTC.
Out of specification driveline components can damage transmission components and cause some transmission
DTCs.
NOTE: Allison Transmission components damaged because the driveline exceeded Allison Transmission
driveline specifications are not covered under Allison Transmission Warranty. This type of transmission
component damage is considered to be caused by abuse.
NOTE: OEM vehicle harness repairs are not covered under Allison Transmission warranty.
OEM chassis wiring issues should be considered as possible causes for every DTC. Possible wiring and
connector issues include:
Expanded female terminals in a connector. Use a mating pin or terminal to check for a light drag feel when
the mating terminal or pin is inserted and slowly removed. There should be some slight friction between
the matching terminal and pin combination. Expanded terminals have no feel of drag when the matching
pin or terminal is inserted and removed.
Broken terminal locks allow the pins or terminals to push back into the connector resulting in poor
connection or pin to pin shorts in the connector. Inspect for broken locks and displaced terminals in
connections. Never use paper clips or other devices to back-probe a connector while doing Allison service
work.
Poor pin crimps. Pin crimps should be pull-tested by the technician to verify the crimp is secure to the wire.
If the pin crimp is loose, the pin easily moves or even comes off the wire with a slight tug on the terminal
Copyright 2008 Allison Transmission, Inc.
6223
3000 AND 4000 PRODUCT FAMILIES TROUBLESHOOTING MANUALALLISON 4th GENERATION CONTROLS
The following procedures are not documented in any Allison service procedures or in any Allison
Troubleshooting Manual or Service Manual, and therefore should not be used as a method to diagnose any
transmission DTC(s) or Service Manual and therefore should not be used as a method to diagnose any
transmission DTC(s), function, or shift quality concern:
Back-probing any connectors used for transmission features or functions may damage and/or unlock the
terminals from the back-probed connector creating permanent or intermittent shorts and/or open circuits. If
possible, use the Breakout Box J 39700, appropriate harness adapters, and appropriate magnetic overlays
to troubleshoot the vehicle.
Load-testing any transmission-related circuits with any other electrical devices such as vehicle lamps, or
relays, especially with the TCM connected to the harness. Use Breakout Box J 39700 and appropriate
harnesses with Allison DOC For PCService Tool to monitor the circuit performance in question unless
otherwise specified in the various Troubleshooting Manuals to use a digital volt-Ohm meter (DVOM) with
the Breakout.
Piercing a wire to check for voltages, shorts-to-grounds or other wires anywhere in the circuit but
especially at the TCM. This creates a leak path for moisture and damages the wire and insulation.
If needed, call for local distributor and/or factory support before downtime and expense of repair effect the
Allison Customer Experience. The phone number for the Technical Assistance Center in the United States is 1800-252-5283
Always use tools that are in good condition. Refer to the Allison Essential Tools list on the Allison Extranet to
complete any service procedure listed in an Allison publication. Also see appropriate Service Manuals and
Troubleshooting Manuals for service tools information.
3000 AND 4000 PRODUCT FAMILIES TROUBLESHOOTING MANUALALLISON 4th GENERATION CONTROLS
Action
Value(s)
Yes
No
Go to Step 2
Review the
information in
Section 3-5,
Section 6-6, and
Diagnostic Aids
listed for this DTC
Go to Step 1
Go to Step 3
Troubleshoot TCC
Codes
Go to Step 4
Go to Step 5
Review the
information in
Section 3-5,
Section 6-6, and
also Diagnostic
Aids listed for this
specific DTC
Go to Step 11
Go to Step 6
Go to Step 7
6225
3000 AND 4000 PRODUCT FAMILIES TROUBLESHOOTING MANUALALLISON 4th GENERATION CONTROLS
Go to Step 8
Go to Step 9
Go to Step 10
Disassemble and
inspect control
module for stuck
valve, debris, or
blockage of
hydraulic path to
PS2 for unfiltered
main pressure,
TCC (lockup)
pressure, or
control main
pressure
Go to Step 11
Replace any
component in
Filter Life
Indicator Valve
Body that is
keeping the FLI
valve from moving
completely and
freely when dry
and by its own
weight in the bore
Go to Step 11
Go to Step 11
9
6226
3000 AND 4000 PRODUCT FAMILIES TROUBLESHOOTING MANUALALLISON 4th GENERATION CONTROLS
There is an open
The DTC has
circuit in chassis
become
harness wire 118
intermittent.
and/or wire 158.
manipulate the
chassis harness
and repeat Step 10. NOTE: wire 118 is
required when the
Prognostics feature
is enabled in the
TCM. DTC P0848
occurs if wire 118
is not installed.
Refer to OEM
vehicle wiring
specifications and
OEM vehicle
wiring repair
procedures to
correct the issue.
Section 4-1, Wire
Test Procedures
provides overview
information for
making continuity
checks.
Go to Step 11
11
Go to Step 1
System OK
Clear inactive
codes from history
Repair complete
6227
3000 AND 4000 PRODUCT FAMILIES TROUBLESHOOTING MANUALALLISON 4th GENERATION CONTROLS
80
41
60
21
40
20
163
170
110
15a
10a
169
IGN
SWITCH
109
63
IGNITION
POWER
70
10
BATTERY
POWER
BATTERY
POWER
69
GND
GND
TCM
12V/24V
BATTERY
V09140.00.00
Circuit Description
The Transmission Control Module (TCM) requires a switched ignition voltage input and a direct battery voltage
input. This switched ignition voltage signal originates from the ignition switch or an ignition relay to supply
voltage to pin 63 in the 80-way connector at the TCM. Battery direct voltage is supplied to pins 10 and 70 at the
80-way connector.
Conditions for Running the DTC
This test is continuously enabled.
Conditions for Setting the DTC
DTC P0880 sets during the next ignition cycle if battery power is lost before the power down process is complete
and the engine is running.
Actions Taken When the DTC Sets
When DTC P0880 is active, the following conditions occur:
6228
3000 AND 4000 PRODUCT FAMILIES TROUBLESHOOTING MANUALALLISON 4th GENERATION CONTROLS
DTC P0880 may set if battery disconnects are opened before switching OFF ignition.
Inspect the wiring for poor electrical connections at the TCM. Look for the following conditions:
A bent terminal
A backed-out terminal
A damaged terminal
Poor terminal tension
A chafed wire
A broken wire inside the insulation
When diagnosing for an intermittent short or open, massage the wiring harness while watching the test
equipment for a change.
Test Description
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 proper battery voltage.
3. Tests for proper charging system operation.
4. Tests for proper system voltage.
5. Tests for proper ignition voltage.
Action
Value(s)
Yes
No
Go to Step 2
Go to Section 35,
Beginning the
Troubleshooting
Process
Go to Step 3
Resolve battery
problem.
Go to Step 7
Go to Diagnostic
Aids if no charging
system issue is
found
Go to Step 4
6229
3000 AND 4000 PRODUCT FAMILIES TROUBLESHOOTING MANUALALLISON 4th GENERATION CONTROLS
Action
Value(s)
Yes
No
1315V (12V
TCM)
2530V (24V
TCM)
Go to Step 5
Go to Diagnostic
Aids if no charging
system issue is
found
0.5V
Go to Step 6
Go to
Diagnostic Aids
Go to Step 7
Go to Step 6
Begin the
diagnosis again.
System OK
6230
Go to Step 1
3000 AND 4000 PRODUCT FAMILIES TROUBLESHOOTING MANUALALLISON 4th GENERATION CONTROLS
END VIEW OF
80-WAY CONNECTOR
61
80
41
60
21
40
20
163
170
110
15a
10a
169
IGN
SWITCH
109
63
IGNITION
POWER
70
10
BATTERY
POWER
BATTERY
POWER
69
GND
GND
TCM
12V/24V
BATTERY
V09140.00.00
Circuit Description
The Transmission Control Module (TCM) requires a switched ignition voltage input and a direct battery voltage
input. This switched ignition voltage signal originates from the ignition switch or an ignition relay to supply
voltage to pin 63 in the 80-way connector at the TCM. Battery voltage is supplied to pins 10 and 70 at the 80-way
connector.
Conditions for Running the DTC
Engine speed is greater than 500 rpm for at least 1.5 seconds.
Conditions for Setting the DTC
DTC P0881 sets under the following conditions:
The TCM detects direct battery voltage below 5.5V. When battery voltage drops below 5.5V for 10 samples, a
fault pending is reported. DTC P0881 is set if voltage remains below 5.5V for 20 samples.
The TCM detects a large variation in direct battery voltage. When battery voltage varies by 4.0V or more for
10 samples, a fault pending is reported. DTC P0881 is set if ignition or battery voltage varies by 4.0V or more
for 20 samples.
Copyright 2008 Allison Transmission, Inc.
6231
3000 AND 4000 PRODUCT FAMILIES TROUBLESHOOTING MANUALALLISON 4th GENERATION CONTROLS
direct feed terminal (10 or 70), or an internal TCM failure due to a burnt trace.
A vehicle charging system failure may cause this DTC under certain circumstances.
This code may indicate that an internal voltage problem has occurred inside the TCM. The use of a substitute
TCM would be a good way to diagnose this problem.
Inspect the wiring for poor electrical connections at the TCM. Look for the following conditions:
A bent terminal
A backed-out terminal
A damaged terminal
Poor terminal tension
A chafed wire
A broken wire inside the insulation
When diagnosing for an intermittent short or open, massage the wiring harness while watching the test
equipment for a change.
Test Description
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 proper direct battery input voltage.
4. Tests for shorts or open conditions at direct battery input circuit.
6232
3000 AND 4000 PRODUCT FAMILIES TROUBLESHOOTING MANUALALLISON 4th GENERATION CONTROLS
Action
Value(s)
Yes
No
Go to Step 2
Go to Section 35,
Beginning the
Troubleshooting
Process
1.
2.
3.
4.
5.
Go to Step 3
Go to
Diagnostic Aids
Go to Diagnostic
Aids if no charging
system issue is
found
Go to Step 4
Go to Step 5
Go to
Diagnostic Aids
Begin the
diagnosis again.
System OK
11.512.5V
Go to Step 1
6233
3000 AND 4000 PRODUCT FAMILIES TROUBLESHOOTING MANUALALLISON 4th GENERATION CONTROLS
END VIEW OF
80-WAY CONNECTOR
61
80
41
60
21
40
20
163
170
110
15a
10a
169
IGN
SWITCH
109
63
IGNITION
POWER
70
10
BATTERY
POWER
BATTERY
POWER
69
GND
GND
TCM
12V/24V
BATTERY
V09140.00.00
Circuit Description
The Transmission Control Module (TCM) receives power directly from the battery. Wires 110 and 170 supply
direct battery power to pins 10 and 70 respectively at the TCM.
Conditions for Running the DTC
Engine has been running for more than 10 seconds and engine speed is greater than 450 rpm.
Conditions for Setting the DTC
DTC P0882 sets under the following condition:
The TCM detects battery voltage below 8V at 0C (32F) for six times. The voltage threshold is temperature
dependent varying from 5V at 60C (76F) to 9V at 20C (68F).
6234
3000 AND 4000 PRODUCT FAMILIES TROUBLESHOOTING MANUALALLISON 4th GENERATION CONTROLS
Hydraulic default (SOL OFF) is commanded. The shift selector position and hydraulic state of latch valves
determine the range attained.
A defective vehicle battery may allow this DTC to set. Test the vehicle battery to verify proper voltage and
load capacity.
Intermittent faults may exist in vehicle components such as a poor connection at the battery posts. Such faults
would cause this DTC to set and not remain active.
Inspect the wiring for poor electrical connections at the TCM. Look for the following conditions:
A bent terminal
A backed-out terminal
A damaged terminal
Poor terminal tension
A chafed wire
A broken wire inside the insulation
When diagnosing for an intermittent short or open, massage the wiring harness while watching the test
equipment for a change.
Test Description
The numbers below refer to step numbers on the diagnostic table.
2. Tests for proper battery voltage.
3. Tests for an active DTC.
4. Tests vehicle battery per OEM guidelines.
5. Tests vehicle charging system per OEM guidelines.
Copyright 2008 Allison Transmission, Inc.
6235
3000 AND 4000 PRODUCT FAMILIES TROUBLESHOOTING MANUALALLISON 4th GENERATION CONTROLS
Action
Value(s)
1.
2.
3.
4.
5.
Yes
No
Go to Step 2
Go to Section 35,
Beginning the
Troubleshooting
Process
Go to Step 4
Go to Step 3
Go to Step 4
Go to
Diagnostic Aids
Go to Step 5
Replace vehicle
battery.
Go to
Diagnostic Aids
Repair the
charging system.
Go to Step 6
Begin the
diagnosis again.
System OK
Install the Allison DOC For PCService Tool. 918V (12V TCM)
1832V (24V TCM)
Turn ON the ignition, leave engine OFF.
Record the failure records.
Clear the DTC.
Observe the battery voltage value on Allison
DOC For PCService Tool.
6236
Go to Step 6
Go to Step 1
3000 AND 4000 PRODUCT FAMILIES TROUBLESHOOTING MANUALALLISON 4th GENERATION CONTROLS
END VIEW OF
80-WAY CONNECTOR
61
80
41
60
21
40
20
163
170
110
15a
10a
169
IGN
SWITCH
109
63
IGNITION
POWER
70
10
BATTERY
POWER
BATTERY
POWER
69
GND
GND
TCM
12V/24V
BATTERY
V09140.00.00
Circuit Description
The Transmission Control Module (TCM) receives power directly from the battery. Wires 110 and 170 supply
direct battery power to pins 10 and 70 respectively at the TCM.
Conditions for Running the DTC
Engine has been running for more than 10 seconds and engine speed is greater than 450 rpm.
Conditions for Setting the DTC
DTC P0883 sets under the following conditions:
12V TCMThe TCM detects an ignition voltage greater than or equal to 16V for 6 out of 10 samples.
24V TCMThe TCM detects an ignition voltage greater than or equal to 32V for 6 out of 10 samples.
Copyright 2008 Allison Transmission, Inc.
6237
3000 AND 4000 PRODUCT FAMILIES TROUBLESHOOTING MANUALALLISON 4th GENERATION CONTROLS
Intermittent faults may exist in vehicle components such as a poor connection at the battery posts. Such faults
would cause this DTC to set and not remain active.
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.
DTC P0883 may set if an A41 or A42 TCM is installed in a 24V electrical system.
Test Description
The numbers below refer to step numbers on the diagnostic table.
2. Tests for proper battery voltage.
3. Tests for an active DTC.
4. Tests vehicle charging system per OEM guidelines.
6238
3000 AND 4000 PRODUCT FAMILIES TROUBLESHOOTING MANUALALLISON 4th GENERATION CONTROLS
Action
Value(s)
1.
2.
3.
4.
5.
Refer to
Conditions for
Setting DTC
Yes
No
Go to Step 2
Go to Section 35,
Beginning the
Troubleshooting
Process
Go to Step 4
Go to Step 3
Go to Step 4
Go to
Diagnostic Aids
Go to
Diagnostic Aids
Repair the
charging system.
Go to Step 5
Begin the
diagnosis again.
System OK
Go to Step 1
6239
3000 AND 4000 PRODUCT FAMILIES TROUBLESHOOTING MANUALALLISON 4th GENERATION CONTROLS
3000 AND 4000 PRODUCT FAMILIES TROUBLESHOOTING MANUALALLISON 4th GENERATION CONTROLS
NOTE: If Prognostics is enabled but wire 118 is not detected, than P0848 goes active with a CHECK TRANS
light.
Lockup is applied
NOTE: Lockup is not necessary for the notification strategy of a restricted filter via flashing the SERVICE TRANS
indicator for up to 2 minutes after D (Drive) is selected (flashing wrench icon in an Allison selector).
NOTE: Status of filter restriction is kept in TCM Power-off Data, therefore a flashing SERVICE TRANS may still
occur at temperatures above and below this temperature band if detected during prior operation of the
transmission.
Conditions for Setting the DTC
If main filter restriction is detected, then PS2 is PRESSURIZED and opens the switch which then allows TCM
pin 18 to see the pull-up voltage of about 5 volts that is inside the TCM.
NOTE: Allison DOC For PCService Tool will show PS2 PRESSURIZED in this condition, which is the
indication that TCM pull-up voltage is sensed at pin 18 when PS2 opens.
Action Taken When the DTC Sets
DTC P088A is stored in the TCM DTC history for a number of ignition cycles.
The SERVICE TRANS indicator (wrench icon in an Allison selector) flashes up to 2 minutes as soon as the
operator selects range for the first time.
Allison DOC For PCService Tool can clear the DTC from TCM history.
The operator clears the indicator when viewing Filter Monitor data in the selector and holding the MODE
button for up to 10 seconds if a CMC is not enabled. That disables that feature to reset the FM through the
selector.
FM may also be reset by selecting N R N R N D N on the shift selector, pausing briefly (less than 3 seconds)
between each selector movement when the ignition is on and the engine not running.
The TCM automatically clears inactive DTC(s) from the TCM history after a number of engine starts.
Diagnostic Aids
This feature is for use with Allison approved TES 295 fluids only and Allison High Capacity Filters.
Required calendar-based fluid change intervals are not monitored by this feature and remain applicable.
If there is TCM history of active or inactive P0847 or P0848 along with P088A or P088B, then the main and
lube filters are not likely to be restricted and are not causing DTC P088A or P088B. Instead, use DTC P0847 or
P0848 steps, whichever is active or in TCM history.
Copyright 2008 Allison Transmission, Inc.
6241
3000 AND 4000 PRODUCT FAMILIES TROUBLESHOOTING MANUALALLISON 4th GENERATION CONTROLS
Action
Value(s)
Yes
No
Go to Step 2
Go to Step 3
Go to Step 9
Go to the
specific DTC
that is active or
in TCM History
Go to Step 4
Go to Step 5
Go to Step 8
Go to Step 6
Go to Step 2
Go to Step 7
Go to Step 6
6242
3000 AND 4000 PRODUCT FAMILIES TROUBLESHOOTING MANUALALLISON 4th GENERATION CONTROLS
Action
Value(s)
Yes
No
Go to Step 10
Go to Step 7
Replace the
Allison shift
selector
Go to Step 2
Go to Step 10
Replace the
Allison shift
selector
Go to Step 2
Go to Step 10
6243
3000 AND 4000 PRODUCT FAMILIES TROUBLESHOOTING MANUALALLISON 4th GENERATION CONTROLS
Action
Did the DTC return?
Value(s)
Yes
No
Go to Step 1
6244
3000 AND 4000 PRODUCT FAMILIES TROUBLESHOOTING MANUALALLISON 4th GENERATION CONTROLS
6245
3000 AND 4000 PRODUCT FAMILIES TROUBLESHOOTING MANUALALLISON 4th GENERATION CONTROLS
Enabled by calibration
NOTE: If Prognostics is enabled but wire 118 is not detected, than P0848 goes active with a CHECK TRANS
light.
Lockup is applied
NOTE: Lockup is not necessary for the notification strategy of a restricted filter via flashing the SERVICE TRANS
indicator for up to 2 minutes after D (Drive) is selected (seen as the flashing wrench in an Allison
selector).
NOTE: Status of filter restriction is kept in TCM power-off data, therefore a flashing SERVICE TRANS may still
occur at temperatures above and below this temperature band if detected during prior operation of the
transmission.
Conditions for Setting the DTC
If main filter restriction is detected, then PS2 is PRESSURIZED and opens the switch which then allows TCM
pin 18 to see the pull-up voltage of about 5 volts that is inside the TCM.
If P088A was active and Filter Life Monitor was not reset in time
NOTE: Allison DOC For PCService Tool shows PS2 PRESSURIZED in this condition, which is the
indication that TCM pull-up voltage is sensed at pin 18 when PS2 opens.
Action Taken When the DTC Sets
DTC P088B is stored in the TCM DTC history for a number of ignition cycles.
The SERVICE TRANS indicator (wrench icon in an Allison selector) flashes for up to 2 minutes as soon as the
operator selects range for the first time.
The feature is designed to reset itself automatically when the main filter has been changed and appropriate
conditions are met to reset the feature.
Allison DOC For PCService Tool clears the DTC from TCM history.
The operator clears the indicator when viewing Filter Monitor data in the selector and holding the MODE
button for up to 10 seconds if a CMC is not enabled that disables that feature to reset the FM through the
selector.
FM may also be reset by selecting N R N R N D N on the shift selector, pausing briefly (less than 3 seconds)
between each selector movement when the ignition is on and the engine not running.
The TCM automatically clears inactive DTC(s) from the TCM history after a number of engine starts.
6246
3000 AND 4000 PRODUCT FAMILIES TROUBLESHOOTING MANUALALLISON 4th GENERATION CONTROLS
This feature is for use with Allison approved TES 295 fluids only and Allison High Capacity Filters.
Required calendar-based fluid change intervals are not monitored by this feature and remain applicable.
If there is TCM history of active or inactive P0847 or P0848 along with P088A or P088B, then the main and
lube filters are not likely to be restricted and are not causing DTC P088A or P088B. Instead, use DTC P0847 or
P0848 steps, whichever is active or in TCM history.
Test Description
1. Review of general troubleshooting procedures and DTC service tips.
2. Confirms code active.
3. Checks for possible switch or hydraulic issue not related to restricted filter.
4. Checks for indicator operation.
5. Confirms whether filter restriction is true.
6. Was filter maintenance done?
7. Was system reset performed?
8. Checks for selector icon stuck OFF.
9. Checks for selector stuck ON.
10. Checks code is inactive and System OK.
Action
Value(s)
Yes
No
Go to Step 2
Review the
information in
Section 3-5,
Section 6-6, and
Diagnostic Aids
listed for this DTC
Go to Step 1
Go to Step 3
Go to Step 9
Go to the specific
DTC that is active
or in TCM History
Go to Step 4
Go to Step 5
Go to Step 8
Go to Step 6
Go to Step 2
Go to Step 7
Go to Step 6
6247
3000 AND 4000 PRODUCT FAMILIES TROUBLESHOOTING MANUALALLISON 4th GENERATION CONTROLS
Action
Value(s)
Yes
No
Go to Step 10
Go to Step 7
Go to Step 2
Go to Step 10
Go to Step 2
Go to Step 10
Go to Step 1
Clear inactive
codes
System OK
Repair complete
6248
3000 AND 4000 PRODUCT FAMILIES TROUBLESHOOTING MANUALALLISON 4th GENERATION CONTROLS
While diagnostic response is active, the TCM ignores shift selector inputs.
You may have to clear the DTC and drive the vehicle in order to experience a fault. Use the data obtained from
failure records to determine transmission range and/or certain vehicle operating variables such as temperature,
run time, etc. This data can be useful in reproducing failures mode where DTC was set.
If this code is accompanied by a P0842, troubleshoot and correct the cause of the P0842 first.
Copyright 2008 Allison Transmission, Inc.
6249
3000 AND 4000 PRODUCT FAMILIES TROUBLESHOOTING MANUALALLISON 4th GENERATION CONTROLS
Yes
No
Action
Value(s)
Go to Step 2
Go to Section 35,
Beginning the
Troubleshooting
Process
Go to Step 3
Go to Step 5
Go to Step 5
Go to
Diagnostic Aids
1.
2.
3.
4.
5.
Go to Step 6
Go to Step 10
Go to Step 7
Go to Step 8
6250
Go to DTC P0842
and resolve
before proceeding
to Step 4
3000 AND 4000 PRODUCT FAMILIES TROUBLESHOOTING MANUALALLISON 4th GENERATION CONTROLS
Action
Value(s)
Yes
No
Go to Step 11
Go to
Diagnostic Aids
Go to Step 12
Go to Step 9
Go to Step 12
Go to Step 9
Go to Step 12
Go to Step 10
Go to Step 12
Go to Step 11
Begin the
diagnosis again.
System OK
Incorrect C1 pressurePCS1
Incorrect C5 pressurePCS3
Is the replacement complete?
10
11
12
Go to Step 1
6251
3000 AND 4000 PRODUCT FAMILIES TROUBLESHOOTING MANUALALLISON 4th GENERATION CONTROLS
Required calendar-based fluid change intervals are not monitored by this feature and remain applicable.
Test Description
1. Review of general troubleshooting procedures and DTC service tips.
2. Confirms code active.
3. Confirms the status of the service icon.
4. Checks indicator state change with action request.
5. Confirms remaining oil life.
6. Resets performed.
6252
3000 AND 4000 PRODUCT FAMILIES TROUBLESHOOTING MANUALALLISON 4th GENERATION CONTROLS
Action
Value(s)
Yes
No
Go to Step 2
Review the
information in
Section 3-5,
Section 6-6, and
Diagnostic Aids
listed for this DTC
Go to Step 1
Go to Step 3
Go to Step 9
Go to Step 5
Go to Step 4
Go to Step 2
Go to Step 8
Go to Step 6
Go to Step 7
Go to Step 9
Go to Step 6
Go to Step 2
6253
3000 AND 4000 PRODUCT FAMILIES TROUBLESHOOTING MANUALALLISON 4th GENERATION CONTROLS
Action
Value(s)
Yes
Go to Step 9
Go to Step 1
No
Go to Step 2
Clear inactive
codes
System OK
Repair complete
6254
3000 AND 4000 PRODUCT FAMILIES TROUBLESHOOTING MANUALALLISON 4th GENERATION CONTROLS
END VIEW OF
80-WAY CONNECTOR
END VIEW OF
20-WAY CONNECTOR
1
10
11
14
15
20
61
80
41
60
21
40
20
TRANSMISSION
TRANSID
TCM
20
HSD1
PCS4
PCS6
MAIN MOD
1
2
7
8
WIRE 176
WIRE 111
WIRE 155
WIRE 178
WIRE 174
76
11
TRANSID
HSD1
ANALOG
INTERFACE
55
78
V BATTERY
74
V09066.00.00
Circuit Description
Pressure control solenoid Main Mod solenoid is a normally closed solenoid used to modulate the transmission
main pressure schedule. The TCM commands the solenoid ON when specific transmission and engine conditions
are met. When the Main Mod solenoid is commanded ON, pressure is routed to the main regulator valve lowering
the main pressure schedule.
The TCM sends control current to the Main Mod solenoid from High Side Driver 1 (HSD1) via wire 111. HSD1 is
continuously ON unless the TCM detects a fault condition. The Transmission Control Module (TCM) regulates the
amount of current to the Main Mod solenoid by switching the Main Mod solenoids Low Side Driver ON and OFF.
Wire 174 completes the circuit between the Main Mod solenoid and its Low Side Driver (LSD). DTC P0960
indicates that the TCM has detected an open condition in the Main Mod solenoid electrical circuit. The open
condition may exist in the high side (wire 111) or low side (wire 174).
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).
TCM initialization is in process or engine speed is greater than 200 rpm and less than 7500 rpm for 5 seconds.
Copyright 2008 Allison Transmission, Inc.
6255
3000 AND 4000 PRODUCT FAMILIES TROUBLESHOOTING MANUALALLISON 4th GENERATION CONTROLS
You may have to drive the vehicle in order to experience a fault. Use the data obtained from failure records to
determine transmission range and/or certain vehicle operating variables such as temperature, run time etc. This
data can be useful in reproducing the failure mode when DTC was set.
Inspect the wiring for poor electrical connections at the TCM and transmission connector. Look for the
following conditions:
A bent terminal
A backed-out terminal
A damaged terminal
Poor terminal tension
A chafed wire
A broken wire inside the insulation
Inspect OEM wiring harness routing, look for possible contact points where chafing could occur leading to an
open or short circuit condition. Moving parts on the vehicle could be contacting the harness; this includes
parking brake drum, suspension components, etc.
When diagnosing for an intermittent short or open, massage the wiring harness while watching the test
equipment for a change.
Test Description
This DTC requires the use of the J 47275 TCM Breakout and J 47279 Transmission Breakout. The numbers below
refer to step numbers on the diagnostic table.
2. Tests for the proper ignition voltage.
3. Tests for an active DTC.
4. Tests the OEM harness for an excessive voltage drop caused by an open condition in either wire 111 or
wire 174 of the OEM chassis harness.
6. Tests for an open condition in the transmission internal harness.
7. Tests for the proper the Main Mod solenoid resistance.
6256
3000 AND 4000 PRODUCT FAMILIES TROUBLESHOOTING MANUALALLISON 4th GENERATION CONTROLS
Action
Value(s)
Yes
No
Go to Step 2
Go to Section 35,
Beginning the
Troubleshooting
Process
1. Install the Allison DOC For PCService Tool. 918V (12V TCM)
1832V (24V TCM)
2. Start the engine.
3. Record the failure records.
4. Monitor ignition voltage.
Is the voltage within the specified values?
Go to Step 3
Resolve voltage
problem
Go to Step 4
Go to
Diagnostic Aids
Go to Step 5
Go to Step 6
Go to Step 11
6257
3000 AND 4000 PRODUCT FAMILIES TROUBLESHOOTING MANUALALLISON 4th GENERATION CONTROLS
Action
Value(s)
Yes
No
Go to Step 11
Go to Step 5
Refer to Solenoid
Resistance Chart
(Appendix K)
Go to Step 10
Go to Step 7
Refer to Solenoid
Resistance Chart
(Appendix K)
Go to Step 8
Go to Step 9
Go to Step 11
Go to Step 8
Go to Step 11
Go to Step 9
Go to Step 11
Go to Step 10
Begin the
diagnosis again
System OK
10
11
6258
Go to Step 1
3000 AND 4000 PRODUCT FAMILIES TROUBLESHOOTING MANUALALLISON 4th GENERATION CONTROLS
END VIEW OF
20-WAY CONNECTOR
1
10
11
14
15
20
61
80
41
60
21
40
20
TRANSMISSION
TRANSID
HSD1
PCS4
PCS6
MAIN MOD
TCM
20
1
2
7
8
WIRE 176
WIRE 111
WIRE 155
WIRE 178
WIRE 174
76
11
TRANSID
HSD1
ANALOG
INTERFACE
55
78
V BATTERY
74
V09066.00.00
Circuit Description
Main Mod solenoid is a normally closed solenoid used to modulate the transmission main pressure schedule. The
TCM commands the solenoid ON when specific transmission and engine conditions are met. When the Main Mod
solenoid is commanded ON, pressure is routed to the main regulator valve lowering the main pressure schedule.
The TCM sends control current to the Main Mod solenoid from High Side Driver 1 (HSD1) via wire 111. HSD1 is
continuously ON unless the TCM detects a fault condition. The Transmission Control Module (TCM) regulates the
amount of current to the Main Mod solenoid by switching the Main Mod solenoids Low Side Driver (LSD) ON
and OFF. Wire 174 completes the circuit between the Main Mod solenoid and its LSD. DTC P0962 indicates that
the TCM has detected a short-to-ground condition in the low side of the Main Mod solenoid electrical circuit.
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).
TCM initialization is in process or engine speed is greater than 200 rpm and less than 7500 rpm for 5 seconds.
6259
3000 AND 4000 PRODUCT FAMILIES TROUBLESHOOTING MANUALALLISON 4th GENERATION CONTROLS
Hydraulic default (SOL OFF) is commanded. The shift selector position and hydraulic state of latch valves
determine the range attained.
DTC P0962 indicates a short-to-ground in the electrical circuit for the Main Mod solenoid.
You may have to drive the vehicle in order to experience a fault. Use the data obtained from failure records to
determine transmission range and/or certain vehicle operating variables such as temperature, run time etc. This
data can be useful in reproducing the failure mode when DTC was set.
Inspect the wiring for poor electrical connections at the TCM and transmission connector. Look for the
following conditions:
A bent terminal
A backed-out terminal
A damaged terminal
Poor terminal tension
A chafed wire
A broken wire inside the insulation
Inspect OEM wiring harness routing, look for possible contact points where chafing could occur leading to an
open or short circuit condition. Moving parts on the vehicle could be contacting the harness; this includes
parking brake drum, suspension components, etc.
When diagnosing for an intermittent short or open, massage the wiring harness while watching the test
equipment for a change.
6260
3000 AND 4000 PRODUCT FAMILIES TROUBLESHOOTING MANUALALLISON 4th GENERATION CONTROLS
DTC P0962 Pressure Control Solenoid Main Mod Control Circuit Low
Step
Yes
No
Action
Value(s)
Go to Step 2
Go to Section 35,
Beginning the
Troubleshooting
Process
1. Install the Allison DOC For PCService Tool. 918V (12V TCM)
1832V (24V TCM)
2. Start the engine.
3. Record the failure records.
4. Monitor ignition voltage.
Is the voltage within the specified values?
Go to Step 3
Resolve voltage
problem.
Go to Step 11
Go to Step 4
Go to
Diagnostic Aids
Go to Step 5
Go to Step 6
6261
3000 AND 4000 PRODUCT FAMILIES TROUBLESHOOTING MANUALALLISON 4th GENERATION CONTROLS
Action
Value(s)
Yes
No
Go to Step 11
Go to Step 5
Go to Step 7
Go to Step 10
Go to Step 8
Go to Step 9
Go to Step 11
Go to Step 8
Go to Step 11
Go to Step 9
Go to Step 11
Go to Step 10
Begin the
diagnosis again.
System OK
10
11
6262
Go to Step 1
3000 AND 4000 PRODUCT FAMILIES TROUBLESHOOTING MANUALALLISON 4th GENERATION CONTROLS
END VIEW OF
20-WAY CONNECTOR
1
10
11
14
15
20
61
80
41
60
21
40
20
TRANSMISSION
TRANSID
HSD1
PCS4
PCS6
MAIN MOD
TCM
20
1
2
7
8
WIRE 176
WIRE 111
WIRE 155
WIRE 178
WIRE 174
76
11
TRANSID
HSD1
ANALOG
INTERFACE
55
78
V BATTERY
74
V09066.00.00
Circuit Description
Main Modulation Solenoid (Main Mod) is a normally closed solenoid used to modulate the transmission main
pressure schedule. The TCM commands the solenoid ON when specific transmission and engine conditions are
met. When the Main Mod solenoid is commanded ON, pressure is routed to the main regulator valve lowering the
main pressure schedule.
The TCM sends control current to the Main Mod solenoid from High Side Driver 1 (HSD1) via wire 111. HSD1 is
continuously ON unless the TCM detects a fault condition. The Transmission Control Module (TCM) regulates the
amount of current to the Main Mod solenoid by switching the Main Mod solenoids Low Side Driver (LSD) ON
and OFF. Wire 174 completes the circuit between the Main Mod solenoid and its LSD. DTC P0963 indicates that
the TCM has detected a short-to-battery condition in the low side of the Main Mod solenoids electrical circuit.
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).
TCM initialization is in process or engine speed is greater than 200 rpm and less than 7500 rpm for 5 seconds.
6263
3000 AND 4000 PRODUCT FAMILIES TROUBLESHOOTING MANUALALLISON 4th GENERATION CONTROLS
DTC P0963 indicates a short-to-battery in the electrical circuit for the Main Mod solenoid.
You may have to drive the vehicle in order to experience a fault. Use the data obtained from failure records to
determine transmission range and/or certain vehicle operating variables such as temperature, run time etc. This
data can be useful in reproducing the failure mode when DTC was set.
Inspect the wiring for poor electrical connections at the TCM and transmission connector. Look for the
following conditions:
A bent terminal
A backed-out terminal
A damaged terminal
Poor terminal tension
A chafed wire
A broken wire inside the insulation
Inspect OEM wiring harness routing, look for possible contact points where chafing could occur leading to an
open or short circuit condition. Moving parts on the vehicle could be contacting the harness; this includes
parking brake drum, suspension components, etc.
When diagnosing for an intermittent short or open, massage the wiring harness while watching the test
equipment for a change.
6264
3000 AND 4000 PRODUCT FAMILIES TROUBLESHOOTING MANUALALLISON 4th GENERATION CONTROLS
DTC P0963 Pressure Control Solenoid Main Mod Control Circuit High
Step
Action
Value(s)
Yes
No
Go to Step 2
Go to Section 35,
Beginning the
Troubleshooting
Process
1. Install the Allison DOC For PCService Tool. 918V (12V TCM)
1832V (24V TCM)
2. Start the engine.
3. Record the failure records.
4. Monitor ignition voltage.
Is the voltage within the specified values?
Go to Step 3
Resolve voltage
problem.
Go to Step 4
Go to
Diagnostic Aids
Go to Step 5
Go to Step 6
Go to Step 11
6265
3000 AND 4000 PRODUCT FAMILIES TROUBLESHOOTING MANUALALLISON 4th GENERATION CONTROLS
Action
Value(s)
Yes
No
Go to Step 11
Go to Step 5
Go to Step 7
Go to Step 10
Go to Step 8
Go to Step 9
Go to Step 11
Go to Step 8
Go to Step 11
Go to Step 9
Go to Step 11
Go to Step 10
Begin the
diagnosis again
System OK
10
11
6266
Go to Step 1
3000 AND 4000 PRODUCT FAMILIES TROUBLESHOOTING MANUALALLISON 4th GENERATION CONTROLS
END VIEW OF
20-WAY CONNECTOR
1
10
11
14
15
20
61
80
41
60
21
40
20
TRANSMISSION
HSD2
PCS1
PCS2
PCS3
SS1
TCM
6
4
5
9
10
WIRE 171
WIRE 136
WIRE 152
WIRE 133
WIRE 151
71
HSD2
V BATTERY
36
52
33
51
V09067.00.00
Circuit Description
Pressure Control Solenoid 2 (PCS2) is a normally open solenoid used to apply the C2 clutch in fourth through sixth
range, and the C3 clutch in Reverse. The TCM commands the solenoid OFF to produce hydraulic pressure in the
clutch apply circuit. When PCS2 is commanded ON, the C2 clutch is released.
The TCM sends control current to PCS2 from High Side Driver 2 (HSD2) via wire 171. HSD2 is continuously ON
unless the TCM detects a fault condition. The Transmission Control Module (TCM) regulates the amount of
current to PCS2 by switching PCS2 Low Side Driver (LSD) ON and OFF. Wire 152 completes the circuit between
PCS2 and its LSD. DTC P0964 indicates that the TCM has detected an open condition in PCS2 electrical circuit.
The open condition may exist in the high side (wire 171) or low side (wire 152).
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).
TCM initialization is in process or engine speed is greater than 200 rpm and less than 7500 rpm for 5 seconds.
6267
3000 AND 4000 PRODUCT FAMILIES TROUBLESHOOTING MANUALALLISON 4th GENERATION CONTROLS
Hydraulic default (SOL OFF) is commanded. The shift selector position and hydraulic state of latch valves
determines the range attained.
You may have to drive the vehicle in order to experience a fault. Use the data obtained from failure records to
determine transmission range and/or certain vehicle operating variables such as temperature, run time etc. This
data can be useful in reproducing the failure mode when DTC was set.
Inspect the wiring for poor electrical connections at the TCM and transmission connector. Look for the
following conditions:
A bent terminal
A backed-out terminal
A damaged terminal
Poor terminal tension
A chafed wire
A broken wire inside the insulation
Inspect OEM wiring harness routing, look for possible contact points where chafing could occur leading to an
open or short circuit condition. Moving parts on the vehicle could be contacting the harness; this includes
parking brake drum, suspension components, etc.
When diagnosing for an intermittent short or open, massage the wiring harness while watching the test
equipment for a change.
Test Description
This DTC requires the use of the J 47275 TCM Breakout and J 47279 Transmission Breakout. The numbers below
refer to step numbers on the diagnostic table.
2. Tests for the proper ignition voltage.
3. Tests for an active DTC.
4. Tests the OEM harness for an excessive voltage drop caused by open condition in either wire 171 or wire
152 of the OEM chassis harness.
6. Tests for an open condition in the transmission internal harness.
7. Tests for the proper PCS2 resistance.
6268
3000 AND 4000 PRODUCT FAMILIES TROUBLESHOOTING MANUALALLISON 4th GENERATION CONTROLS
Action
Value(s)
Yes
No
Go to Step 2
Go to Section 35,
Beginning the
Troubleshooting
Process
1. Install the Allison DOC For PCService Tool. 918V (12V TCM)
1832V (24V TCM)
2. Start the engine.
3. Record the failure records.
4. Monitor ignition voltage.
Is the voltage within the specified values?
Go to Step 3
Resolve voltage
problem.
Go to Step 4
Go to
Diagnostic Aids
Go to Step 5
Go to Step 6
Go to Step 11
6269
3000 AND 4000 PRODUCT FAMILIES TROUBLESHOOTING MANUALALLISON 4th GENERATION CONTROLS
Action
Value(s)
Yes
No
Go to Step 11
Go to Step 5
Refer to Solenoid
Resistance Chart
(Appendix K)
Go to Step 10
Go to Step 7
Refer to Solenoid
Resistance Chart
(Appendix K)
Go to Step 8
Go to Step 9
Go to Step 11
Go to Step 8
Go to Step 11
Go to Step 9
Go to Step 11
Go to Step 10
Begin the
diagnosis again.
System OK
Replace PCS2.
Is the replacement complete?
10
11
6270
Go to Step 1
3000 AND 4000 PRODUCT FAMILIES TROUBLESHOOTING MANUALALLISON 4th GENERATION CONTROLS
END VIEW OF
20-WAY CONNECTOR
1
10
11
14
15
20
61
80
41
60
21
40
20
TRANSMISSION
HSD2
PCS1
PCS2
PCS3
SS1
TCM
6
4
5
9
10
WIRE 171
WIRE 136
WIRE 152
WIRE 133
WIRE 151
71
HSD2
V BATTERY
36
52
33
51
V09067.00.00
Circuit Description
Pressure Control Solenoid 2 (PCS2) is a normally open solenoid used to apply the C2 clutch in fourth through sixth
range and the C3 clutch in reverse. The TCM commands the solenoid OFF to produce hydraulic pressure in the
clutch apply circuit. When PCS2 is commanded ON, the C2 clutch is released.
The TCM sends control current to PCS2 from High Side Driver 2 (HSD2) via wire 171. HSD2 is continuously ON
unless the TCM detects a fault condition. The Transmission Control Module (TCM) regulates the amount of
current to PCS2 by switching PCS2 Low Side Driver (LSD) ON and OFF. Wire 152 completes the circuit between
PCS2 and its LSD. DTC P0966 indicates that the TCM has detected a short-to-ground condition in the low side of
PCS2 electrical circuit.
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).
TCM initialization is in process or engine speed is greater than 200 rpm and less than 7500 rpm for 5 seconds.
6271
3000 AND 4000 PRODUCT FAMILIES TROUBLESHOOTING MANUALALLISON 4th GENERATION CONTROLS
Hydraulic default (SOL OFF) is commanded. The shift selector position and hydraulic state of latch valves
determines the range attained.
DTC P0966 indicates a short-to-ground in the electrical circuit for the PCS2 solenoid.
You may have to drive the vehicle in order to experience a fault. Use the data obtained from failure records to
determine transmission range and/or certain vehicle operating variables such as temperature, run time etc. This
data can be useful in reproducing the failure mode when DTC was set.
Inspect the wiring for poor electrical connections at the TCM and transmission connector. Look for the
following conditions:
A bent terminal
A backed-out terminal
A damaged terminal
Poor terminal tension
A chafed wire
A broken wire inside the insulation
Inspect OEM wiring harness routing, look for possible contact points where chafing could occur leading to an
open or short circuit condition. Moving parts on the vehicle could be contacting the harness; this includes
parking brake drum, suspension components, etc.
When diagnosing for an intermittent short or open, massage the wiring harness while watching the test
equipment for a change.
6272
3000 AND 4000 PRODUCT FAMILIES TROUBLESHOOTING MANUALALLISON 4th GENERATION CONTROLS
Yes
No
Go to Step 2
Go to Section 35,
Beginning the
Troubleshooting
Process
1. Install the Allison DOC For PCService Tool. 918V (12V TCM)
1832V (24V TCM)
2. Start the engine.
3. Record the failure records.
4. Monitor ignition voltage.
Is the voltage within the specified values?
Go to Step 3
Resolve voltage
problem.
Go to Step 4
Go to
Diagnostic Aids
Go to Step 5
Go to Step 6
Action
Value(s)
Go to Step 11
6273
3000 AND 4000 PRODUCT FAMILIES TROUBLESHOOTING MANUALALLISON 4th GENERATION CONTROLS
Action
Value(s)
Yes
No
Go to Step 11
Go to Step 5
Go to Step 7
Go to Step 10
Go to Step 8
Go to Step 9
Go to Step 11
Go to Step 8
Go to Step 11
Go to Step 9
Go to Step 11
Go to Step 10
Begin the
diagnosis again.
System OK
Replace PCS2.
Is the replacement complete?
10
11
6274
Go to Step 1
3000 AND 4000 PRODUCT FAMILIES TROUBLESHOOTING MANUALALLISON 4th GENERATION CONTROLS
END VIEW OF
80-WAY CONNECTOR
END VIEW OF
20-WAY CONNECTOR
1
10
11
14
15
20
61
80
41
60
21
40
20
TRANSMISSION
HSD2
PCS1
PCS2
PCS3
SS1
TCM
6
4
5
9
10
WIRE 171
WIRE 136
WIRE 152
WIRE 133
WIRE 151
71
HSD2
V BATTERY
36
52
33
51
V09067.00.00
Circuit Description
Pressure Control Solenoid 2 (PCS2) is a normally open solenoid used to apply the C2 clutch in fourth through sixth
range and the C3 clutch in reverse. The TCM commands the solenoid OFF to produce hydraulic pressure in the
clutch apply circuit. When PCS2 is commanded ON, the C2 clutch is released.
The TCM sends control current to PCS2 from High Side Driver 2 (HSD2) via wire 171. HSD2 is continuously ON
unless the TCM detects a fault condition. The Transmission Control Module (TCM) regulates the amount of
current to PCS2 by switching PCS2 Low Side Driver (LSD) ON and OFF. Wire 152 completes the circuit between
PCS2 and its LSD. DTC P0967 indicates that the TCM has detected a short-to-battery condition in the low side of
PCS2 electrical circuit.
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).
TCM initialization is in process or engine speed is greater than 200 rpm and less than 7500 rpm for 5 seconds.
6275
3000 AND 4000 PRODUCT FAMILIES TROUBLESHOOTING MANUALALLISON 4th GENERATION CONTROLS
Hydraulic default (SOL OFF) is commanded. The shift selector position and hydraulic state of latch valves
determines the range attained.
DTC P0967 indicates a short-to-battery in the electrical circuit for the PCS2 solenoid.
You may have to drive the vehicle in order to experience a fault. Use the data obtained from failure records to
determine transmission range and/or certain vehicle operating variables such as temperature, run time etc. This
data can be useful in reproducing the failure mode when DTC was set.
Inspect the wiring for poor electrical connections at the TCM and transmission connector. Look for the
following conditions:
A bent terminal
A backed-out terminal
A damaged terminal
Poor terminal tension
A chafed wire
A broken wire inside the insulation
Inspect OEM wiring harness routing, look for possible contact points where chafing could occur leading to an
open or short circuit condition. Moving parts on the vehicle could be contacting the harness; this includes
parking brake drum, suspension components, etc.
When diagnosing for an intermittent short or open, massage the wiring harness while watching the test
equipment for a change.
6276
3000 AND 4000 PRODUCT FAMILIES TROUBLESHOOTING MANUALALLISON 4th GENERATION CONTROLS
Yes
No
Go to Step 2
Go to Section 35,
Beginning the
Troubleshooting
Process
1. Install the Allison DOC For PCService Tool. 918V (12V TCM)
1832V (24V TCM)
2. Start the engine.
3. Record the failure records.
4. Monitor ignition voltage.
Is the voltage within the specified values?
Go to Step 3
Resolve voltage
problem
Go to Step 4
Go to
Diagnostic Aids
Go to Step 5
Go to Step 6
Action
Value(s)
Go to Step 11
6277
3000 AND 4000 PRODUCT FAMILIES TROUBLESHOOTING MANUALALLISON 4th GENERATION CONTROLS
Action
Value(s)
Yes
No
Go to Step 11
Go to Step 5
Go to Step 7
Go to Step 10
Go to Step 8
Go to Step 9
Go to Step 11
Go to Step 8
Go to Step 11
Go to Step 9
Go to Step 11
Go to Step 10
Begin the
diagnosis again.
System OK
Refer to Solenoid
Resistance Chart
(Appendix K)
Replace PCS2.
Is the replacement complete?
10
11
6278
Go to Step 1
3000 AND 4000 PRODUCT FAMILIES TROUBLESHOOTING MANUALALLISON 4th GENERATION CONTROLS
END VIEW OF
80-WAY CONNECTOR
END VIEW OF
20-WAY CONNECTOR
1
10
11
14
15
20
61
80
41
60
21
40
20
TRANSMISSION
HSD2
PCS1
PCS2
PCS3
SS1
TCM
6
4
5
9
10
WIRE 171
WIRE 136
WIRE 152
WIRE 133
WIRE 151
71
HSD2
V BATTERY
36
52
33
51
V09067.00.00
Circuit Description
Pressure Control Solenoid 3 (PCS3) is a normally closed solenoid used to apply the C5 clutch in reverse, neutral
and first and to apply the C3 clutch in third and fifth ranges. The TCM commands the solenoid ON to produce
hydraulic pressure in the clutch apply circuit. When PCS3 is commanded OFF, the clutch pressure is released.
The TCM sends control current to PCS3 from High Side Driver 2 (HSD2) via wire 171. HSD2 is continuously ON
unless the TCM detects a fault condition. The Transmission Control Module (TCM) regulates the amount of
current to PCS3 by switching PCS3 Low Side Driver (LSD) ON and OFF. Wire 133 completes the circuit between
PCS3 and its LSD. DTC P0968 indicates that the TCM has detected an open condition in PCS3 electrical circuit.
The open condition may exist in the high side (wire 171) or low side (wire 133).
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).
TCM initialization is in process or engine speed is greater than 200 rpm and less than 7500 rpm for 5 seconds.
6279
3000 AND 4000 PRODUCT FAMILIES TROUBLESHOOTING MANUALALLISON 4th GENERATION CONTROLS
Hydraulic default (SOL OFF) is commanded. The shift selector position and hydraulic state of latch valves
determines the range attained.
You may have to drive the vehicle in order to experience a fault. Use the data obtained from failure records to
determine transmission range and/or certain vehicle operating variables such as temperature, run time etc. This
data can be useful in reproducing the failure mode when DTC was set.
Inspect the wiring for poor electrical connections at the TCM and transmission connector. Look for the
following conditions:
A bent terminal
A backed-out terminal
A damaged terminal
Poor terminal tension
A chafed wire
A broken wire inside the insulation
Inspect OEM wiring harness routing, look for possible contact points where chafing could occur leading to an
open or short circuit condition. Moving parts on the vehicle could be contacting the harness; this includes
parking brake drum, suspension components, etc.
When diagnosing for an intermittent short or open, massage the wiring harness while watching the test
equipment for a change.
Test Description
This DTC requires the use of the J 47275 TCM Breakout and J 47279 Transmission Breakout. The numbers below
refer to step numbers on the diagnostic table.
2. Tests for the proper ignition voltage.
3. Tests for an active DTC.
4. Tests the OEM harness for an excessive voltage drop caused by an open condition in either wire 171 or
wire 133 of the OEM chassis harness.
6. Tests for an open condition in the transmission internal harness.
7. Tests for the proper PCS3 resistance.
6280
3000 AND 4000 PRODUCT FAMILIES TROUBLESHOOTING MANUALALLISON 4th GENERATION CONTROLS
Action
Value(s)
Yes
No
Go to Step 2
Go to Section 35,
Beginning the
Troubleshooting
Process
Go to Step 3
Resolve voltage
problem.
Go to Step 11
Go to Step 4
Go to
Diagnostic Aids
Go to Step 5
Go to Step 6
6281
3000 AND 4000 PRODUCT FAMILIES TROUBLESHOOTING MANUALALLISON 4th GENERATION CONTROLS
Action
Value(s)
Yes
No
Go to Step 11
Go to Step 5
Refer to Solenoid
Resistance Chart
(Appendix K)
Go to Step 10
Go to Step 7
Refer to Solenoid
Resistance Chart
(Appendix K)
Go to Step 8
Go to Step 9
Go to Step 11
Go to Step 8
Go to Step 11
Go to Step 9
Go to Step 11
Go to Step 10
Begin the
diagnosis again
System OK
Replace PCS3.
Is the replacement complete?
10
11
6282
Go to Step 1
3000 AND 4000 PRODUCT FAMILIES TROUBLESHOOTING MANUALALLISON 4th GENERATION CONTROLS
END VIEW OF
80-WAY CONNECTOR
END VIEW OF
20-WAY CONNECTOR
1
10
11
14
15
20
61
80
41
60
21
40
20
TRANSMISSION
HSD2
PCS1
PCS2
PCS3
SS1
TCM
6
4
5
9
10
WIRE 171
WIRE 136
WIRE 152
WIRE 133
WIRE 151
71
HSD2
V BATTERY
36
52
33
51
V09067.00.00
Circuit Description
Pressure Control Solenoid 3 (PCS3) is a normally closed solenoid used to apply the C5 clutch in reverse, neutral
and first; and to apply the C3 clutch in third and fifth ranges. The TCM commands the solenoid ON to produce
hydraulic pressure in the clutch apply circuit. When PCS3 is commanded OFF, the clutch pressure is released.
The TCM sends control current to PCS3 from High Side Driver 2 (HSD2) via wire 171. HSD2 is continuously ON
unless the TCM detects a fault condition. The Transmission Control Module (TCM) regulates the amount of
current to PCS3 by switching PCS3 Low Side Driver (LSD) ON and OFF. Wire 133 completes the circuit between
PCS3 and its LSD. DTC P0970 indicates that the TCM has detected a short-to-ground condition in the low side of
PCS electrical circuit.
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).
TCM initialization is in process or engine speed is greater than 200 rpm and less than 7500 rpm for 5 seconds.
6283
3000 AND 4000 PRODUCT FAMILIES TROUBLESHOOTING MANUALALLISON 4th GENERATION CONTROLS
Hydraulic default (SOL OFF) is commanded. The shift selector position and hydraulic state of latch valves
determines the range attained.
DTC P0970 indicates a short-to-ground in the electrical circuit for the PCS3 solenoid.
You may have to drive the vehicle in order to experience a fault. Use the data obtained from failure records to
determine transmission range and/or certain vehicle operating variables such as temperature, run time etc. This
data can be useful in reproducing the failure mode when DTC was set.
Inspect the wiring for poor electrical connections at the TCM and transmission connector. Look for the
following conditions:
A bent terminal
A backed-out terminal
A damaged terminal
Poor terminal tension
A chafed wire
A broken wire inside the insulation
Inspect OEM wiring harness routing, look for possible contact points where chafing could occur leading to an
open or short circuit condition. Moving parts on the vehicle could be contacting the harness; this includes
parking brake drum, suspension components, etc.
When diagnosing for an intermittent short or open, massage the wiring harness while watching the test
equipment for a change.
6284
3000 AND 4000 PRODUCT FAMILIES TROUBLESHOOTING MANUALALLISON 4th GENERATION CONTROLS
Action
Value(s)
Yes
No
Go to Step 2
Go to Section 35,
Beginning the
Troubleshooting
Process
1. Install the Allison DOC For PCService Tool. 918V (12V TCM)
1832V (24V TCM)
2. Start the engine.
3. Record the failure records.
4. Monitor ignition voltage.
Is the voltage within the specified values?
Go to Step 3
Resolve voltage
problem.
Go to Step 11
Go to Step 4
Go to
Diagnostic Aids
Go to Step 5
Go to Step 6
6285
3000 AND 4000 PRODUCT FAMILIES TROUBLESHOOTING MANUALALLISON 4th GENERATION CONTROLS
Action
Value(s)
Yes
No
Go to Step 11
Go to Step 5
Go to Step 7
Go to Step 10
Go to Step 8
Go to Step 9
Go to Step 11
Go to Step 8
Go to Step 11
Go to Step 9
Go to Step 11
Go to Step 10
Begin the
diagnosis again.
System OK
Replace PCS3.
Is the replacement complete?
10
11
6286
Go to Step 1
3000 AND 4000 PRODUCT FAMILIES TROUBLESHOOTING MANUALALLISON 4th GENERATION CONTROLS
END VIEW OF
20-WAY CONNECTOR
1
10
11
14
15
20
61
80
41
60
21
40
20
TRANSMISSION
HSD2
PCS1
PCS2
PCS3
SS1
TCM
6
4
5
9
10
WIRE 171
WIRE 136
WIRE 152
WIRE 133
WIRE 151
71
HSD2
V BATTERY
36
52
33
51
V09067.00.00
Circuit Description
Pressure Control Solenoid 3 (PCS3) is a normally closed solenoid used to apply the C5 clutch in reverse, neutral
and first and to apply the C3 clutch in third and fifth ranges. The TCM commands the solenoid ON to produce
hydraulic pressure in the clutch apply circuit. When PCS3 is commanded OFF, the clutch pressure is released.
The TCM sends control current to PCS3 from High Side Driver 2 (HSD2) via wire 171. HSD2 is continuously ON
unless the TCM detects a fault condition. The Transmission Control Module (TCM) regulates the amount of
current to PCS3 by switching PCS3 Low Side Driver (LSD) ON and OFF. Wire 133 completes the circuit between
PCS3 and its LSD. DTC P0971 indicates that the TCM has detected a short-to-battery condition in the low side of
PCS electrical circuit.
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).
TCM initialization is in process or engine speed is greater than 200 rpm and less than 7500 rpm for 5 seconds.
6287
3000 AND 4000 PRODUCT FAMILIES TROUBLESHOOTING MANUALALLISON 4th GENERATION CONTROLS
Hydraulic default (SOL OFF) is commanded. The shift selector position and hydraulic state of latch valves
determines the range attained.
DTC P0971 indicates a short-to-battery in the electrical circuit for the PCS3 solenoid.
You may have to drive the vehicle in order to experience a fault. Use the data obtained from failure records to
determine transmission range and/or certain vehicle operating variables such as temperature, run time etc. This
data can be useful in reproducing the failure mode when DTC was set.
Inspect the wiring for poor electrical connections at the TCM and transmission connector. Look for the
following conditions:
A bent terminal
A backed-out terminal
A damaged terminal
Poor terminal tension
A chafed wire
A broken wire inside the insulation
Inspect OEM wiring harness routing, look for possible contact points where chafing could occur leading to an
open or short circuit condition. Moving parts on the vehicle could be contacting the harness; this includes
parking brake drum, suspension components, etc.
When diagnosing for an intermittent short or open, massage the wiring harness while watching the test
equipment for a change.
6288
3000 AND 4000 PRODUCT FAMILIES TROUBLESHOOTING MANUALALLISON 4th GENERATION CONTROLS
Action
Value(s)
Yes
No
Go to Step 2
Go to Section 35,
Beginning the
Troubleshooting
Process
1. Install the Allison DOC For PCService Tool. 918V (12V TCM)
1832V (24V TCM)
2. Start the engine.
3. Record the failure records.
4. Monitor ignition voltage.
Is the voltage within the specified values?
Go to Step 3
Resolve voltage
problem.
Go to Step 11
Go to Step 4
Go to
Diagnostic Aids
Go to Step 5
Go to Step 6
6289
3000 AND 4000 PRODUCT FAMILIES TROUBLESHOOTING MANUALALLISON 4th GENERATION CONTROLS
Action
Value(s)
Yes
No
Go to Step 11
Go to Step 5
Go to Step 7
Go to Step 10
Refer to Solenoid
Resistance Chart
(Appendix K)
Go to Step 8
Go to Step 9
Go to Step 11
Go to Step 8
Go to Step 11
Go to Step 9
Go to Step 11
Go to Step 10
Begin the
diagnosis again.
System OK
10
11
6290
Go to Step 1
3000 AND 4000 PRODUCT FAMILIES TROUBLESHOOTING MANUALALLISON 4th GENERATION CONTROLS
END VIEW OF
20-WAY CONNECTOR
1
10
11
14
15
20
61
80
41
60
21
40
20
TRANSMISSION
HSD2
PCS1
PCS2
PCS3
SS1
TCM
WIRE 171
WIRE 136
WIRE 152
WIRE 133
9
10
WIRE 151
71
HSD2
V BATTERY
36
52
33
51
V09067.00.00
Circuit Description
Shift Solenoid 1 (SS1) is a normally closed solenoid used to properly position the C1 and C2 latch valves in
forward ranges. The TCM commands the solenoid ON to supply control main pressure to the C1 and C2 latch
valves. When solenoid SS1 is commanded OFF, control main pressure is relieved from the C1 and C2 latch valves.
The TCM sends control current to solenoid SS1 from High Side Driver 2 (HSD2) via wire 171. HSD2 is
continuously ON unless the TCM detects a fault condition. The TCM energizes SS1 by switching the solenoids
Low Side Driver (LSD) ON. Wire 151 completes the circuit between SS1 and its LSD. DTC P0973 indicates that
the TCM has detected a short-to-ground or open circuit condition in the low side of SS1 electrical circuit.
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).
TCM initialization is in process or engine speed is greater than 200 rpm and less than 7500 rpm for 5 seconds.
6291
3000 AND 4000 PRODUCT FAMILIES TROUBLESHOOTING MANUALALLISON 4th GENERATION CONTROLS
Hydraulic default (SOL OFF) is commanded. The shift selector position and hydraulic state of latch valves
determines the range attained.
You may have to drive the vehicle in order to experience a fault. Use the data obtained from failure records to
determine transmission range and/or certain vehicle operating variables such as temperature, run time etc. This
data can be useful in reproducing the failure mode when DTC was set.
Inspect the wiring for poor electrical connections at the TCM and transmission connector. Look for the
following conditions:
A bent terminal
A backed-out terminal
A damaged terminal
Poor terminal tension
A chafed wire
A broken wire inside the insulation
Inspect OEM wiring harness routing, look for possible contact points where chafing could occur leading to an
open or short circuit condition. Moving parts on the vehicle could be contacting the harness; this includes
parking brake drum, suspension components, etc.
When diagnosing for an intermittent short or open, massage the wiring harness while watching the test
equipment for a change.
6292
3000 AND 4000 PRODUCT FAMILIES TROUBLESHOOTING MANUALALLISON 4th GENERATION CONTROLS
Yes
No
Action
Value(s)
Go to Step 2
Go to Section 35,
Beginning the
Troubleshooting
Process
1. Install the Allison DOC For PCService Tool. 918V (12V TCM)
1832V (24V TCM)
2. Start the engine.
3. Record the failure records.
4. Monitor ignition voltage.
Is the voltage within the specified values?
Go to Step 3
Resolve voltage
problem.
Go to Step 12
Go to Step 4
Go to
Diagnostic Aids
6293
3000 AND 4000 PRODUCT FAMILIES TROUBLESHOOTING MANUALALLISON 4th GENERATION CONTROLS
Action
Value(s)
Yes
No
Go to Step 6
Go to Step 5
Go to Step 6
Go to Step 7
6294
3000 AND 4000 PRODUCT FAMILIES TROUBLESHOOTING MANUALALLISON 4th GENERATION CONTROLS
Action
Value(s)
Yes
No
Go to Step 12
Go to Step 6
Go to Step 8
Go to Step 11
Refer to Solenoid
Resistance Chart
(Appendix K)
Go to Step 9
Go to Step 10
Go to Step 12
Go to Step 9
Go to Step 12
Go to Step 10
Go to Step 12
Go to Step 11
Begin the
diagnosis again.
System OK
Replace SS1.
Is the replacement complete?
11
12
Go to Step 1
6295
3000 AND 4000 PRODUCT FAMILIES TROUBLESHOOTING MANUALALLISON 4th GENERATION CONTROLS
END VIEW OF
80-WAY CONNECTOR
END VIEW OF
20-WAY CONNECTOR
1
10
11
14
15
20
61
80
41
60
21
40
20
TRANSMISSION
HSD2
PCS1
PCS2
PCS3
SS1
TCM
6
4
5
9
10
WIRE 171
WIRE 136
WIRE 152
WIRE 133
WIRE 151
71
HSD2
V BATTERY
36
52
33
51
V09067.00.00
Circuit Description
Shift Solenoid 1 (SS1) is a normally closed solenoid used to properly position the C1 and C2 logic latch valves in
forward ranges. The TCM commands the solenoid ON to supply control main pressure to the C1 and C2 logic latch
valves. When SS1 is commanded OFF, control main pressure is relieved from the C1 and C2 latch valves.
The TCM sends control current to SS1 from High Side Driver 2 (HSD2) via wire 171. HSD2 is continuously
ON unless the TCM detects a fault condition. The TCM energizes SS1 by switching the solenoids Low Side
Driver (LSD) ON. Wire 151 completes the circuit between SS1 and its LSD. DTC P0974 indicates that the TCM
has detected a short-to-battery condition in the low side of SS1 electrical circuit.
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).
TCM initialization is in process or engine speed is greater than 200 rpm and less than 7500 rpm for 5 seconds.
3000 AND 4000 PRODUCT FAMILIES TROUBLESHOOTING MANUALALLISON 4th GENERATION CONTROLS
Hydraulic default (SOL OFF) is commanded. The shift selector position and hydraulic state of latch valves
determines the range attained.
You may have to drive the vehicle in order to experience a fault. Use the data obtained from failure records to
determine transmission range and/or certain vehicle operating variables such as temperature, run time etc. This
data can be useful in reproducing the failure mode when DTC was set.
Inspect the wiring for poor electrical connections at the TCM and transmission connector. Look for the
following conditions:
A bent terminal
A backed-out terminal
A damaged terminal
Poor terminal tension
A chafed wire
A broken wire inside the insulation
Inspect OEM wiring harness routing, look for possible contact points where chafing could occur leading to an
open or short circuit condition. Moving parts on the vehicle could be contacting the harness; this includes
parking brake drum, suspension components, etc.
When diagnosing for an intermittent short or open, massage the wiring harness while watching the test
equipment for a change.
6297
3000 AND 4000 PRODUCT FAMILIES TROUBLESHOOTING MANUALALLISON 4th GENERATION CONTROLS
Yes
No
Action
Value(s)
Go to Step 2
Go to Section 35,
Beginning the
Troubleshooting
Process
1. Install the Allison DOC For PCService Tool. 918V (12V TCM)
1832V (24V TCM)
2. Start the engine.
3. Record the failure records.
4. Monitor ignition voltage.
Is the voltage within the specified values?
Go to Step 3
Resolve voltage
problem.
Go to Step 11
Go to Step 4
Go to
Diagnostic Aids
Go to Step 5
Go to Step 6
6298
3000 AND 4000 PRODUCT FAMILIES TROUBLESHOOTING MANUALALLISON 4th GENERATION CONTROLS
Action
Value(s)
Yes
No
Go to Step 11
Go to Step 5
Go to Step 7
Go to Step 10
Refer to Solenoid
Resistance Chart
(Appendix K)
Go to Step 8
Go to Step 9
Go to Step 11
Go to Step 8
Go to Step 11
Go to Step 9
Go to Step 11
Go to Step 10
Begin the
diagnosis again
System OK
Replace SS1.
Is the replacement complete?
10
11
Go to Step 1
6299
3000 AND 4000 PRODUCT FAMILIES TROUBLESHOOTING MANUALALLISON 4th GENERATION CONTROLS
END VIEW OF
20-WAY CONNECTOR
END VIEW OF
80-WAY CONNECTOR
10
11
14
15
20
61
80
41
60
21
40
20
TRANSMISSION
HSD3
TCC
SS2
TCM
11
12
17
WIRE 131
WIRE 137
WIRE 119
(7-SPEED MODELS)
31
HSD3
V BATTERY
37
19
15
RTDR ACCUM
HSD3
SS2
B
A
WIRE 131
WIRE 119
RTDR OR
DIFF LOCK (T-CASE)
HSD3
PCS5
B
A
WIRE 131
WIRE 115
V09068.00.00
6300
3000 AND 4000 PRODUCT FAMILIES TROUBLESHOOTING MANUALALLISON 4th GENERATION CONTROLS
TCM initialization is in process or engine speed is greater than 200 rpm and less than 7500 rpm for 5 seconds.
6301
3000 AND 4000 PRODUCT FAMILIES TROUBLESHOOTING MANUALALLISON 4th GENERATION CONTROLS
Inspect OEM wiring harness routing, look for possible contact points where chafing could occur leading to an
open or short circuit condition. Moving parts on the vehicle could be contacting the harness; this includes
parking brake drum, suspension components, etc.
When diagnosing for an intermittent short or open, massage the wiring harness while watching the test
equipment for a change.
Test Description
This DTC requires the use of the J 47275 TCM Breakout and J 47279 Transmission Breakout. The numbers below
refer to step numbers on the diagnostic table.
2. Tests for the proper ignition voltage.
3. Tests for an active DTC.
4. Tests the OEM harness for an excessive voltage drop caused by an open condition in either wire 131 or
wire 115 of the OEM chassis harness.
6. Tests for an open condition in the transmission internal harness or retarder accumulator solenoid harness.
7. Tests for the proper SS2 resistance (7-speed models only).
Action
Value(s)
Yes
No
Go to Step 2
Go to Section 35,
Beginning the
Troubleshooting
Process
1. Install the Allison DOC For PCService Tool. 918V (12V TCM)
1832V (24V TCM)
2. Start the engine.
3. Record the failure records.
4. Monitor ignition voltage.
Is the voltage within the specified values?
Go to Step 3
Resolve voltage
problem.
Go to Step 11
Go to Step 4
Go to
Diagnostic Aids
6302
3000 AND 4000 PRODUCT FAMILIES TROUBLESHOOTING MANUALALLISON 4th GENERATION CONTROLS
Action
Value(s)
Yes
No
Go to Step 5
Go to Step 6
Go to Step 11
Go to Step 5
6303
3000 AND 4000 PRODUCT FAMILIES TROUBLESHOOTING MANUALALLISON 4th GENERATION CONTROLS
Action
For 7-speed transmissions:
1. Turn ignition OFF.
2. Disconnect the OEM 20-way connector from
J 47279 Transmission Breakout. Leave the
transmission-side connected.
3. Using a DVOM, measure the resistance between
pin 11 and pin 17 of the transmission 20-way
connector.
For retarder units:
Value(s)
Yes
No
Refer to Solenoid
Resistance Chart
(Appendix K)
Go to Step 10
7-speed
transmissions, go
to Step 7.
Retarder equipped
transmissions, go
to Step 9.
Refer to Solenoid
Resistance Chart
(Appendix K)
Go to Step 8
Go to Step 9
Go to Step 11
Go to Step 8
Go to Step 11
Go to Step 9
Go to Step 11
Go to Step 10
Begin the
diagnosis again.
System OK
Replace SS2.
Is the replacement complete?
10
11
6304
Go to Step 1
3000 AND 4000 PRODUCT FAMILIES TROUBLESHOOTING MANUALALLISON 4th GENERATION CONTROLS
END VIEW OF
80-WAY CONNECTOR
10
11
14
15
20
61
80
41
60
21
40
20
TRANSMISSION
HSD3
TCC
SS2
TCM
11
12
17
WIRE 131
WIRE 137
WIRE 119
(7-SPEED MODELS)
31
HSD3
V BATTERY
37
19
15
RTDR ACCUM
HSD3
SS2
B
A
WIRE 131
WIRE 119
RTDR OR
DIFF LOCK (T-CASE)
HSD3
PCS5
B
A
WIRE 131
WIRE 115
V09068.00.00
Circuit Description
Shift Solenoid 2 (SS2) is a normally closed solenoid used to either activate the retarder accumulator air solenoid
(retarder models) or the C6 enable solenoid (7-speed models).
The TCM sends control current to SS2 from High Side Driver 3 (HSD3) via wire 131. HSD3 is continuously
ON unless the TCM detects a fault condition. The TCM energizes SS2 by switching the solenoids Low Side
Driver (LSD) ON. Wire 119 completes the circuit between SS2 and its LSD. DTC P0976 indicates that the TCM
has detected a short-to-ground condition in the low side of SS2 electrical circuit.
6305
3000 AND 4000 PRODUCT FAMILIES TROUBLESHOOTING MANUALALLISON 4th GENERATION CONTROLS
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).
TCM initialization is in process or engine speed is greater than 200 rpm and less than 7500 rpm for 5 seconds.
The TCM allows operation in second range through sixth range and in Neutral and Reverse.
DTC P0976 indicates a short-to-ground in the electrical circuit for the SS2 solenoid.
You may have to drive the vehicle in order to experience a fault. Use the data obtained from failure records to
determine transmission range and/or certain vehicle operating variables such as temperature, run time etc. This
data can be useful in reproducing the failure mode when DTC was set.
Inspect the wiring for poor electrical connections at the TCM and transmission connector. Look for the
following conditions:
A bent terminal
A backed-out terminal
A damaged terminal
Poor terminal tension
A chafed wire
A broken wire inside the insulation
Inspect OEM wiring harness routing, look for possible contact points where chafing could occur leading to an
open or short circuit condition. Moving parts on the vehicle could be contacting the harness; this includes
parking brake drum, suspension components, etc.
When diagnosing for an intermittent short or open, massage the wiring harness while watching the test
equipment for a change.
6306
3000 AND 4000 PRODUCT FAMILIES TROUBLESHOOTING MANUALALLISON 4th GENERATION CONTROLS
Test Description
This DTC requires the use of the J 47275 TCM Breakout and J 47279 Transmission Breakout. The numbers below
refer to step numbers on the diagnostic table.
2.
3.
4.
6.
Action
Value(s)
Yes
No
Go to Step 2
Go to Section 35,
Beginning the
Troubleshooting
Process
1. Install the Allison DOC For PCService Tool. 918V (12V TCM)
1832V (24V TCM)
2. Start the engine.
3. Record the failure records.
4. Monitor ignition voltage.
Is the voltage within the specified values?
Go to Step 3
Resolve voltage
problem.
Go to Step 11
Go to Step 4
Go to
Diagnostic Aids
6307
3000 AND 4000 PRODUCT FAMILIES TROUBLESHOOTING MANUALALLISON 4th GENERATION CONTROLS
Action
Value(s)
Yes
No
Go to Step 5
Go to Step 6
Go to Step 11
Go to Step 5
6308
3000 AND 4000 PRODUCT FAMILIES TROUBLESHOOTING MANUALALLISON 4th GENERATION CONTROLS
Action
Value(s)
Yes
No
7-speed
transmissions go to
Step 7.
Go to Step 10
Retarder equipped
transmission go to
Step 9.
Go to Step 8
Go to Step 9
Go to Step 11
Go to Step 8
Go to Step 11
Go to Step 9
Go to Step 11
Go to Step 10
Replace SS2.
Is the replacement complete?
10
6309
3000 AND 4000 PRODUCT FAMILIES TROUBLESHOOTING MANUALALLISON 4th GENERATION CONTROLS
Action
Value(s)
6310
Yes
No
Begin the
diagnosis again.
System OK
Go to Step 1
3000 AND 4000 PRODUCT FAMILIES TROUBLESHOOTING MANUALALLISON 4th GENERATION CONTROLS
END VIEW OF
80-WAY CONNECTOR
10
11
14
15
20
61
80
41
60
21
40
20
TRANSMISSION
HSD3
TCC
SS2
TCM
11
12
17
WIRE 131
WIRE 137
WIRE 119
(7-SPEED MODELS)
31
HSD3
V BATTERY
37
19
15
RTDR ACCUM
HSD3
SS2
B
A
WIRE 131
WIRE 119
RTDR OR
DIFF LOCK (T-CASE)
HSD3
PCS5
B
A
WIRE 131
WIRE 115
V09068.00.00
Circuit Description
Shift Solenoid 2 (SS2) is a normally closed solenoid used to either activate the retarder accumulator air solenoid
(retarder models) or the C6 enable solenoid (7-speed models). The TCM commands the solenoid ON to supply
control main pressure to SS2. When SS2 is commanded OFF, the retarder accumulator air solenoid closes in
retarder units or the C6 enable valve closes in 7-speed transmissions.
The TCM sends control current to SS2 from High Side Driver 3 (HSD3) via wire 131. HSD3 is continuously
ON unless the TCM detects a fault condition. The TCM energizes SS2 by switching the solenoids Low Side
Driver (LSD) ON. Wire 119 completes the circuit between SS2 and its LSD. DTC P0977 indicates that the TCM
has detected a short-to-battery condition in the low side of SS2 electrical circuit.
Copyright 2008 Allison Transmission, Inc.
6311
3000 AND 4000 PRODUCT FAMILIES TROUBLESHOOTING MANUALALLISON 4th GENERATION CONTROLS
TCM initialization is in process or engine speed is greater than 200 rpm and less than 7500 rpm for 5 seconds.
The TCM allows operation in second range through sixth range and in Neutral and Reverse.
You may have to drive the vehicle in order to experience a fault. Use the data obtained from failure records to
determine transmission range and/or certain vehicle operating variables such as temperature, run time etc. This
data can be useful in reproducing the failure mode when DTC was set.
Inspect the wiring for poor electrical connections at the TCM and transmission connector. Look for the
following conditions:
A bent terminal
A backed-out terminal
A damaged terminal
Poor terminal tension
A chafed wire
A broken wire inside the insulation
Inspect OEM wiring harness routing, look for possible contact points where chafing could occur leading to an
open or short circuit condition. Moving parts on the vehicle could be contacting the harness; this includes
parking brake drum, suspension components, etc.
When diagnosing for an intermittent short or open, massage the wiring harness while watching the test
equipment for a change.
6312
3000 AND 4000 PRODUCT FAMILIES TROUBLESHOOTING MANUALALLISON 4th GENERATION CONTROLS
Yes
No
Action
Value(s)
Go to Step 2
Go to Section 35,
Beginning the
Troubleshooting
Process
1. Install the Allison DOC For PCService Tool. 918V (12V TCM)
1832V (24V TCM)
2. Start the engine.
3. Record the failure records.
4. Monitor ignition voltage.
Is the voltage within the specified values?
Go to Step 3
Resolve voltage
problem.
Go to Step 11
Go to Step 4
Go to
Diagnostic Aids
6313
3000 AND 4000 PRODUCT FAMILIES TROUBLESHOOTING MANUALALLISON 4th GENERATION CONTROLS
Action
Value(s)
Yes
No
Go to Step 5
Go to Step 6
Go to Step 11
Go to Step 5
7-speed
transmissions go to
Step 7.
Go to Step 10
6314
Retarder equipped
transmission go to
Step 9.
3000 AND 4000 PRODUCT FAMILIES TROUBLESHOOTING MANUALALLISON 4th GENERATION CONTROLS
Action
Value(s)
Yes
No
Go to Step 8
Go to Step 9
Go to Step 11
Go to Step 8
Go to Step 11
Go to Step 9
Go to Step 11
Go to Step 10
Begin the
diagnosis again.
System OK
Replace SS2.
Is the replacement complete?
10
11
Go to Step 1
6315
3000 AND 4000 PRODUCT FAMILIES TROUBLESHOOTING MANUALALLISON 4th GENERATION CONTROLS
END VIEW OF
80-WAY CONNECTOR
10
11
14
15
20
61
80
41
60
21
40
20
TO RETARDER
CONTROL DEVICES
RETARDER
REQUEST SENSOR
(RESISTANCE
MODULE)
A
PWM
THROTTLE
SOURCE
TCM
THROTTLE
POSITION
SENSOR (TPS)
OR
ELECTRONIC
BRAKING (EBS)
RTDR PRESSURE
SENSOR
WIRE 156
WIRE 112
WIRE 144
WIRE 158
A
RETARDER TEMP
ENGINE TEMP
TRANSMISSION
ANALOG RETURN
OIL LEVEL
HALL
A
C
EFFECT
B
SUMP TEMP
19
16
15
18
PS1
PS2 NC*
NC*
3
17
WIRE 175
WIRE 135
56
12
5V SENSOR VOLTAGE
44
THROTTLE POSITION OR
RTDR PRESSURE SIGNAL
58
ANALOG RETURN
75
RETARDER TEMP
35
16
54
SUMP TEMP
77
WIRE 158
WIRE 112
WIRE 116
WIRE 154
WIRE 177
WIRE 118
18
* NORMALLY CLOSED
V11114.00.00
6316
3000 AND 4000 PRODUCT FAMILIES TROUBLESHOOTING MANUALALLISON 4th GENERATION CONTROLS
When the TCM commands more retardation, pressure in the retarder charge pressure circuit increases resulting in a
larger voltage signal from the retarder pressure transducer.
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).
Engine speed is greater than 200 rpm and less than 7500 rpm for 5 seconds.
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 and operate the retarder in order to experience a fault.
Copyright 2008 Allison Transmission, Inc.
6317
3000 AND 4000 PRODUCT FAMILIES TROUBLESHOOTING MANUALALLISON 4th GENERATION CONTROLS
DTC P0989 can be caused by an open or short-to-ground in either the 5V reference wire 112 or retarder
pressure sensor signal wire 144. The retarder pressure sensor 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 shortto-ground on wire 144 will cause DTC P0989 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 active DTCs.
3. Tests for wire-to-wire shorts, opens, or shorts-to-ground on wires 112 and 144.
5. This step verifies the TCM is supplying proper 5V reference voltage.
Yes
No
Action
Value(s)
Go to Step 2
Go to Section 35,
Beginning the
Troubleshooting
Process
1.
2.
3.
4.
Go to Step 3
Go to
Diagnostic Aids
Go to Step 4
Go to Step 5
6318
3000 AND 4000 PRODUCT FAMILIES TROUBLESHOOTING MANUALALLISON 4th GENERATION CONTROLS
Action
Value(s)
Yes
No
Go to Step 8
Go to Step 4
Go to Step 6
Go to Step 7
Go to Step 8
Go to Step 6
Go to Step 8
Go to Step 7
Begin the
diagnosis again.
System OK
4.755.0V
Go to Step 1
6319
3000 AND 4000 PRODUCT FAMILIES TROUBLESHOOTING MANUALALLISON 4th GENERATION CONTROLS
END VIEW OF
80-WAY CONNECTOR
10
11
14
15
20
61
80
41
60
21
40
20
TO RETARDER
CONTROL DEVICES
RETARDER
REQUEST SENSOR
(RESISTANCE
MODULE)
A
PWM
THROTTLE
SOURCE
TCM
THROTTLE
POSITION
SENSOR (TPS)
OR
ELECTRONIC
BRAKING (EBS)
RTDR PRESSURE
SENSOR
WIRE 156
WIRE 112
WIRE 144
WIRE 158
A
RETARDER TEMP
ENGINE TEMP
TRANSMISSION
ANALOG RETURN
OIL LEVEL
HALL
A
C
EFFECT
B
SUMP TEMP
19
16
15
18
PS1
PS2 NC*
NC*
3
17
WIRE 175
WIRE 135
56
12
5V SENSOR VOLTAGE
44
THROTTLE POSITION OR
RTDR PRESSURE SIGNAL
58
ANALOG RETURN
75
RETARDER TEMP
35
16
54
SUMP TEMP
77
WIRE 158
WIRE 112
WIRE 116
WIRE 154
WIRE 177
WIRE 118
18
* NORMALLY CLOSED
V11114.00.00
6320
3000 AND 4000 PRODUCT FAMILIES TROUBLESHOOTING MANUALALLISON 4th GENERATION CONTROLS
When the TCM commands more retardation, pressure in the retarder charge pressure circuit increases resulting in a
larger voltage signal from the retarder pressure transducer.
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).
Engine speed is greater than 200 rpm and less than 7500 rpm for 5 seconds.
Inspect the wiring for poor electrical connections at the TCM and retarder pressure sensor. 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 and operate the retarder in order to experience a fault.
Copyright 2008 Allison Transmission, Inc.
6321
3000 AND 4000 PRODUCT FAMILIES TROUBLESHOOTING MANUALALLISON 4th GENERATION CONTROLS
DTC P0990 can be caused by a short-to-battery in the 5V reference wire 112 or retarder pressure sensor
wire 144. DTC P0990 can also be caused by an open in analog return wire 158. The retarder pressure sensor
shares a common 5V reference voltage wire 112 with the optional transmission oil level sensor (OLS) and
retarder request sensor. A short-to-battery in the 5V reference wire 112 or open in analog return wire 158
causes a Sensor Failed High code for these other devices as well. A short-to-battery in retarder pressure sensor
signal wire 144 will produce DTC P0990 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 active DTCs.
3. Tests for wire-to-wire shorts or shorts-to-battery on wires 112 and 144, and opens in wire 158.
5. This step verifies the TCM is supplying proper 5V reference voltage.
Action
Value(s)
Yes
No
Go to Step 2
Go to Section 35,
Beginning the
Troubleshooting
Process
1.
2.
3.
4.
Go to Step 3
Go to
Diagnostic Aids
Go to Step 4
Go to Step 5
6322
3000 AND 4000 PRODUCT FAMILIES TROUBLESHOOTING MANUALALLISON 4th GENERATION CONTROLS
Action
Value(s)
Yes
No
Go to Step 8
Go to Step 4
Go to Step 6
Go to Step 7
Go to Step 8
Go to Step 6
Go to Step 8
Go to Step 7
Begin the
diagnosis again.
System OK
4.755.0V
Go to Step 1
6323
3000 AND 4000 PRODUCT FAMILIES TROUBLESHOOTING MANUALALLISON 4th GENERATION CONTROLS
No shift in progress.
The TCM commands second range and allows operation in second range through sixth range, and in neutral
and reverse.
You may have to clear the DTC and drive the vehicle in order to experience a fault. Use the data obtained from
failure records to determine transmission range and/or certain vehicle operating variables such as temperature,
run time, etc. This data can be useful in reproducing failures mode where DTC was set.
Incorrect ratio codes typically indicate mechanical problems with specific clutches for range indicated, i.e. C3
and C6 (3000 7-speed model) or C1 and C6 (4000 7-speed model) for Low range.
An incorrect ratio DTC may indicate a mechanically failed clutch control solenoid. Check the DTC
information for the specific solenoid.
Output speed or turbine speed tone wheel damage may cause erratic speed sensor input allowing this code to
set.
6324
3000 AND 4000 PRODUCT FAMILIES TROUBLESHOOTING MANUALALLISON 4th GENERATION CONTROLS
Action
Value(s)
Yes
No
Go to Step 2
Go to Section 35,
Beginning the
Troubleshooting
Process
Go to Step 3
Go to Step 4
Go to General
Troubleshooting,
Section 8
Go to appropriate
speed sensor DTC
Go to Step 5
6325
3000 AND 4000 PRODUCT FAMILIES TROUBLESHOOTING MANUALALLISON 4th GENERATION CONTROLS
Action
Value(s)
5
WARNING: To avoid injury or property
damage caused by sudden and unexpected
vehicle movement, do not start a stationary
stall test until you do all of the following:
Put the transmission in N (Neutral).
Apply the parking and service brakes.
Chock the wheels and take any other steps
necessary to prevent the vehicle from
moving.
Warn personnel to keep clear of the
vehicle. and its path.
Yes
No
Go to
Diagnostic Aids
Go to Step 6
Go to Step 7
Go to Step 8
Go to Step 10
Go to
Diagnostic Aids
Go to Step 11
Go to Step 9
Refer to Main
Clutch Pressure
specifications in
Appendix B
6326
3000 AND 4000 PRODUCT FAMILIES TROUBLESHOOTING MANUALALLISON 4th GENERATION CONTROLS
Action
Value(s)
Yes
No
Go to Step 11
Go to Step 9
Go to Step 11
Go to Step 10
Begin the
diagnosis again.
System OK
11
Go to Step 1
6327
3000 AND 4000 PRODUCT FAMILIES TROUBLESHOOTING MANUALALLISON 4th GENERATION CONTROLS
END VIEW OF
80-WAY CONNECTOR
10
11
14
15
20
61
80
41
60
21
40
20
TO RETARDER
CONTROL DEVICES
RETARDER
REQUEST SENSOR
(RESISTANCE
MODULE)
A
PWM
THROTTLE
SOURCE
TCM
THROTTLE
POSITION
SENSOR (TPS)
OR
ELECTRONIC
BRAKING (EBS)
RTDR PRESSURE
SENSOR
WIRE 156
WIRE 112
WIRE 144
WIRE 158
A
RETARDER TEMP
ENGINE TEMP
TRANSMISSION
ANALOG RETURN
OIL LEVEL
HALL
A
C
EFFECT
B
SUMP TEMP
19
16
15
18
PS1
PS2 NC*
NC*
3
17
WIRE 175
WIRE 135
56
12
5V SENSOR VOLTAGE
44
THROTTLE POSITION OR
RTDR PRESSURE SIGNAL
58
ANALOG RETURN
75
RETARDER TEMP
35
16
54
SUMP TEMP
77
WIRE 158
WIRE 112
WIRE 116
WIRE 154
WIRE 177
WIRE 118
18
* NORMALLY CLOSED
V11114.00.00
6328
3000 AND 4000 PRODUCT FAMILIES TROUBLESHOOTING MANUALALLISON 4th GENERATION CONTROLS
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).
Engine speed is greater than 200 rpm and less than 7500 rpm for 5 seconds.
The TCM detects the throttle source automatically during the initial series of engine starts. The TCM may have
auto-detected the wrong throttle source type. Use the Allison DOC For PCService Tool to reset auto-detect
or select the appropriate throttle source if PWM-type sensor is not being used.
Inspect the wiring for poor electrical connections at the TCM and PWM throttle sensor. 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.
Advanced troubleshootingmonitor frequency on pin 44 as throttle is increased from closed throttle to wide
open throttle. If frequency does not vary, the signal is bad. Have the vehicle manufacturer replace the PWM
device.
Copyright 2008 Allison Transmission, Inc.
6329
3000 AND 4000 PRODUCT FAMILIES TROUBLESHOOTING MANUALALLISON 4th GENERATION CONTROLS
Action
Value(s)
Yes
No
Go to Step 2
Go to Section 35,
Beginning the
Troubleshooting
Process
1.
2.
3.
4.
Go to Step 3
Resolve voltage
problem (refer to
DTC P0882 and
DTC P0883)
Go to
Diagnostic Aids.
Go to Step 4
Go to Step 5
Go to Step 6
Go to Step 10
Go to Step 5
Go to Step 7
Go to Step 8
Go to Step 10
Go to Step 7
Install the Allison DOC For PCService Tool. 918V (12V TCM)
1832V (24V
Start the engine.
TCM)
Record the failure records.
Using Allison DOC For PCService Tool,
measure ignition voltage.
Is ignition voltage within the specified value?
6330
3000 AND 4000 PRODUCT FAMILIES TROUBLESHOOTING MANUALALLISON 4th GENERATION CONTROLS
Action
Value(s)
Yes
No
Go to Step 10
Go to Step 9
Go to Step 10
Go to Step 9
Begin the
diagnosis again.
System OK
10
Go to Step 1
6331
3000 AND 4000 PRODUCT FAMILIES TROUBLESHOOTING MANUALALLISON 4th GENERATION CONTROLS
END VIEW OF
80-WAY CONNECTOR
10
11
14
15
20
61
80
41
60
21
40
20
TO RETARDER
CONTROL DEVICES
RETARDER
REQUEST SENSOR
(RESISTANCE
MODULE)
A
PWM
THROTTLE
SOURCE
TCM
THROTTLE
POSITION
SENSOR (TPS)
OR
ELECTRONIC
BRAKING (EBS)
RTDR PRESSURE
SENSOR
WIRE 156
WIRE 112
WIRE 144
WIRE 158
A
RETARDER TEMP
ENGINE TEMP
TRANSMISSION
ANALOG RETURN
OIL LEVEL
HALL
A
C
EFFECT
B
SUMP TEMP
19
16
15
18
PS1
PS2 NC*
NC*
3
17
WIRE 175
WIRE 135
56
12
5V SENSOR VOLTAGE
44
THROTTLE POSITION OR
RTDR PRESSURE SIGNAL
58
ANALOG RETURN
75
RETARDER TEMP
35
16
54
SUMP TEMP
77
WIRE 158
WIRE 112
WIRE 116
WIRE 154
WIRE 177
WIRE 118
18
* NORMALLY CLOSED
V11114.00.00
6332
3000 AND 4000 PRODUCT FAMILIES TROUBLESHOOTING MANUALALLISON 4th GENERATION CONTROLS
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).
Engine speed is greater than 200 rpm and less than 7500 rpm for 5 seconds.
The TCM detects the throttle source automatically during the initial series of engine starts. The TCM may have
auto-detected the wrong throttle source type. Use the Allison DOC For PCService Tool to reset auto-detect
or select the appropriate throttle source if PWM-type sensor is not being used.
Inspect the wiring for poor electrical connections at the TCM and PWM throttle sensor. 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.
Advanced troubleshootingmonitor frequency on pin 44 as throttle is increased from closed throttle to wide
open throttle. if frequency does not vary, the signal is bad. Have the vehicle manufacturer replace the PWM
device.
Copyright 2008 Allison Transmission, Inc.
6333
3000 AND 4000 PRODUCT FAMILIES TROUBLESHOOTING MANUALALLISON 4th GENERATION CONTROLS
Action
Value(s)
Yes
No
Go to Step 2
Go to Section 35,
Beginning the
Troubleshooting
Process
1.
2.
3.
4.
Go to Step 3
Resolve voltage
problem (refer to
DTC P0882 and
DTC P0883)
Go to
Diagnostic Aids
Go to Step 4
Go to Step 5
Go to Step 6
Go to Step 10
Go to Step 5
Go to Step 7
Go to Step 8
Install the Allison DOC For PCService Tool. 918V (12V TCM)
1832V (24V TCM)
Start the engine.
Record the failure records.
Using Allison DOC For PCService Tool,
measure ignition voltage.
Is ignition voltage within the specified value?
6334
3000 AND 4000 PRODUCT FAMILIES TROUBLESHOOTING MANUALALLISON 4th GENERATION CONTROLS
Action
Value(s)
Yes
No
Go to Step 10
Go to Step 7
Go to Step 10
Go to Step 9
Go to Step 10
Go to Step 9
Begin the
diagnosis again.
System OK
10
Go to Step 1
6335
3000 AND 4000 PRODUCT FAMILIES TROUBLESHOOTING MANUALALLISON 4th GENERATION CONTROLS
END VIEW OF
80-WAY CONNECTOR
10
11
14
15
20
61
80
41
60
21
40
20
TO RETARDER
CONTROL DEVICES
RETARDER
REQUEST SENSOR
(RESISTANCE
MODULE)
A
PWM
THROTTLE
SOURCE
TCM
THROTTLE
POSITION
SENSOR (TPS)
OR
ELECTRONIC
BRAKING (EBS)
RTDR PRESSURE
SENSOR
WIRE 156
WIRE 112
WIRE 144
WIRE 158
A
RETARDER TEMP
ENGINE TEMP
TRANSMISSION
ANALOG RETURN
OIL LEVEL
HALL
A
C
EFFECT
B
SUMP TEMP
19
16
15
18
PS1
PS2 NC*
NC*
3
17
WIRE 175
WIRE 135
56
12
5V SENSOR VOLTAGE
44
THROTTLE POSITION OR
RTDR PRESSURE SIGNAL
58
ANALOG RETURN
75
RETARDER TEMP
35
16
54
SUMP TEMP
77
WIRE 158
WIRE 112
WIRE 116
WIRE 154
WIRE 177
WIRE 118
18
* NORMALLY CLOSED
V11114.00.00
6336
3000 AND 4000 PRODUCT FAMILIES TROUBLESHOOTING MANUALALLISON 4th GENERATION CONTROLS
Engine speed is greater than 200 rpm and less than 7500 rpm for 5 seconds.
The Retarder reduction and preselect based on engine coolant temperature feature is enabled in the
calibration.
Inspect the wiring for poor electrical connections at the TCM and engine coolant temp sensor. 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
Copyright 2008 Allison Transmission, Inc.
6337
3000 AND 4000 PRODUCT FAMILIES TROUBLESHOOTING MANUALALLISON 4th GENERATION CONTROLS
When diagnosing for an intermittent short or open, massage the wiring harness while watching the test
equipment for a change.
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 proper ignition voltage.
3. This step verifies which condition has set the DTC P2184.
4. Tests for the proper 5V reference voltage at TCM.
5. Tests for wire-to-wire shorts, shorts-to-ground, or an open in wires 135 (engine coolant temp) and wire
112 (5V reference).
Yes
No
Go to Step 2
Go to Section 35,
Beginning the
Troubleshooting
Process
1.
2.
3.
4.
Install the Allison DOC For PCService Tool. 918V (12V TCM)
1832V (24V TCM)
Start the engine.
Record failure record.
Using Allison DOC For PCService Tool,
measure ignition voltage.
Is ignition voltage within the specified value?
Go to Step 3
Resolve voltage
problem (refer to
DTC P0882 and
DTC P0883)
>174.11C
(345.4F)
Go to Step 4
Go to
Diagnostic Aids
4.75 to 5.0V
Go to Step 7
Go to Step 5
6338
Action
Value(s)
3000 AND 4000 PRODUCT FAMILIES TROUBLESHOOTING MANUALALLISON 4th GENERATION CONTROLS
Action
Value(s)
Yes
No
Go to Step 6
Go to Step 8
Go to Step 9
Go to Step 6
Go to Step 9
Go to Step 7
Go to Step 9
Go to Step 8
Begin the
diagnosis again.
System OK
Go to Step 1
6339
3000 AND 4000 PRODUCT FAMILIES TROUBLESHOOTING MANUALALLISON 4th GENERATION CONTROLS
END VIEW OF
80-WAY CONNECTOR
10
11
14
15
20
61
80
41
60
21
40
20
TO RETARDER
CONTROL DEVICES
RETARDER
REQUEST SENSOR
(RESISTANCE
MODULE)
A
PWM
THROTTLE
SOURCE
TCM
THROTTLE
POSITION
SENSOR (TPS)
OR
ELECTRONIC
BRAKING (EBS)
RTDR PRESSURE
SENSOR
WIRE 156
WIRE 112
WIRE 144
WIRE 158
A
RETARDER TEMP
ENGINE TEMP
TRANSMISSION
ANALOG RETURN
OIL LEVEL
HALL
A
C
EFFECT
B
SUMP TEMP
19
16
15
18
PS1
PS2 NC*
NC*
3
17
WIRE 175
WIRE 135
56
12
5V SENSOR VOLTAGE
44
THROTTLE POSITION OR
RTDR PRESSURE SIGNAL
58
ANALOG RETURN
75
RETARDER TEMP
35
16
54
SUMP TEMP
77
WIRE 158
WIRE 112
WIRE 116
WIRE 154
WIRE 177
WIRE 118
18
* NORMALLY CLOSED
V11114.00.00
6340
3000 AND 4000 PRODUCT FAMILIES TROUBLESHOOTING MANUALALLISON 4th GENERATION CONTROLS
The Retarder reduction and preselect based on engine coolant temperature feature is enabled in the
calibration.
6341
3000 AND 4000 PRODUCT FAMILIES TROUBLESHOOTING MANUALALLISON 4th GENERATION CONTROLS
When diagnosing for an intermittent short or open, massage the wiring harness while watching the test
equipment for a change.
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 proper ignition voltage.
3. Verifies which condition has set the DTC P2185.
4. Tests for the proper 5V reference voltage at TCM.
5. Tests for wiring defects in the OEM chassis harness.
Action
Value(s)
Yes
No
Go to Step 2
Go to Section 35,
Beginning the
Troubleshooting
Process
1.
2.
3.
4.
Install the Allison DOC For PCService Tool. 918V (12V TCM)
1832V (24V TCM)
Start the engine.
Record failure record.
Using Allison DOC For PCService Tool,
measure ignition voltage.
Is ignition voltage within the specified value?
Go to Step 3
Resolve voltage
problem (refer to
DTC P0882 and
DTC P0883)
42C (43.6F)
Go to Step 4
Go to
Diagnostic Aids
4.75 to 5.0V
Go to Step 7
Go to Step 5
6342
3000 AND 4000 PRODUCT FAMILIES TROUBLESHOOTING MANUALALLISON 4th GENERATION CONTROLS
Action
Value(s)
Yes
No
Go to Step 6
Go to Step 8
Go to Step 9
Go to Step 6
Go to Step 9
Go to Step 7
Go to Step 9
Go to Step 8
Begin the
diagnosis again.
System OK
Go to Step 1
6343
3000 AND 4000 PRODUCT FAMILIES TROUBLESHOOTING MANUALALLISON 4th GENERATION CONTROLS
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).
Engine speed is greater than 200 rpm but less than 7500 rpm for 5 seconds.
Engine ECM is not responding to SEM torque reduction signal request from the TCM.
A non-approved J1939 device is interfering with the SEM torque reduction signal request.
3000 AND 4000 PRODUCT FAMILIES TROUBLESHOOTING MANUALALLISON 4th GENERATION CONTROLS
Action
Value(s)
Yes
No
Go to Step 2
Go to Section 35,
Beginning the
Troubleshooting
Process
Go to DTC P0614
and resolve before
proceeding to
Step 3
Go to Step 3
Allison DOC
1. Install the Allison DOC For PCService Tool.
For PCService
2. Turn ignition ON.
3. Refer to the SEM torque reduction status in SEM/
Tool indicates
LRTP AUTODECT INFO display of Allison
correct response or
DOC For PCService Tool.
incorrect response
Does Allison DOC For PCService Tool indicate
the ECM response to SEM torque reduction as
INCORRECT?
Go to Step 6
Go to Step 4
Go to Step 6
Go to Step 5
Go to Step 7
Go to Step 5
Go to Step 7
Go to Step 6
Allison DOC
For PCService
Tool shows the
actual device at
fault
6345
3000 AND 4000 PRODUCT FAMILIES TROUBLESHOOTING MANUALALLISON 4th GENERATION CONTROLS
Action
6346
Value(s)
Yes
No
Begin the
diagnosis again.
System OK
Go to Step 1
3000 AND 4000 PRODUCT FAMILIES TROUBLESHOOTING MANUALALLISON 4th GENERATION CONTROLS
Engine speed is greater than 200 rpm but less than 7500 rpm for 5 seconds.
Engine ECM is not responding to LRTP torque reduction signal request from the TCM.
A non-approved J1939 device is interfering with the LRTP torque reduction signal request.
6347
3000 AND 4000 PRODUCT FAMILIES TROUBLESHOOTING MANUALALLISON 4th GENERATION CONTROLS
Action
Value(s)
Yes
No
Go to Step 2
Go to Section 35,
Beginning the
Troubleshooting
Process
Go to DTC P0614
and resolve before
proceeding to
Step 3
Go to Step 3
Allison DOC
For PCService
Tool indicates
correct response or
incorrect response
Go to Step 6
Go to Step 4
Allison DOC
For PCService
Tool shows the
Go to Step6
Go to Step 5
Go to Step 7
Go to Step 5
Go to Step 7
Go to Step 6
actual device at
fault
6348
3000 AND 4000 PRODUCT FAMILIES TROUBLESHOOTING MANUALALLISON 4th GENERATION CONTROLS
Action
Value(s)
Yes
No
Begin the
diagnosis again.
System OK
Go to Step 1
6349
3000 AND 4000 PRODUCT FAMILIES TROUBLESHOOTING MANUALALLISON 4th GENERATION CONTROLS
END VIEW OF
20-WAY CONNECTOR
1
10
11
14
15
20
61
80
41
60
21
40
20
TRANSMISSION
HSD2
PCS1
PCS2
PCS3
SS1
TCM
WIRE 171
WIRE 136
WIRE 152
WIRE 133
WIRE 151
10
71
HSD2
V BATTERY
36
52
33
51
V09067.00.00
Circuit Description
High Side Driver 2 (HSD2) supplies battery voltage to the PCS1, PCS2, PCS3, and SS1 solenoids via wire 171. HSD2 is
continuously ON during normal operation except during brief circuit tests. The Transmission Module Control (TCM) regulates
control current to the solenoids by switching the appropriate low side driver ON and OFF. DTC P2669 indicates the TCM has
detected multiple low side circuits are open while having HSD2 voltage of over 6 volts. DTC P2669 could be caused by open
condition in the high side wiring attached to HSD2 (wire 171).
Hydraulic default (SOL OFF) is commanded. The shift selector position and hydraulic state of latch valves determines
6350
3000 AND 4000 PRODUCT FAMILIES TROUBLESHOOTING MANUALALLISON 4th GENERATION CONTROLS
The TCM automatically clears the DTC from the TCM history if the vehicle completes 40 engine starts
without reoccurrence of the DTC.
Diagnostic Aids
HSD2 supplies power to Pressure Control Solenoids 1 (PCS1), PCS2, PCS3, and SS1. Other codes related to
these solenoids and solenoid circuits may need to be resolved if no cause is found for the active DTC P2669,
HSD2 Open.
If there are other vehicle DTCs, then consider that the cause for transmission-related DTCs might be external
to the transmission and those vehicle systems must be corrected in order for the transmission DTCs to be
resolved.
A transmission DTC must be active during the troubleshooting process to determine what caused the DTC. Use
the Snapshot feature of Allison DOC For PCService Tool while the vehicle is operated in the same
conditions listed in the failure record available in the Allison DOC For PCService Tool Reports Menu for
the specific DTC that was active.
Manipulating the chassis harness and data link wiring may reveal intermittent shorts to ground, shorts to
another circuit, and open circuits causing a DTC.
Out of specification driveline components can damage transmission components and cause some transmission
DTCs.
NOTE: Allison Transmission components that are damaged because the driveline exceeded Allison
Transmission driveline specifications are not covered under Allison Transmission Warranty.
NOTE: OEM vehicle harness repairs are not covered under Allison Transmission warranty.
NOTE: OEM repairs necessary for transmission DTCs to go inactive are not covered under Allison
Transmission warranty.
The following wiring and connector issues can cause transmission DTCs:
Expanded female terminals in a connector. Use a mating pin or terminal to check for a light drag feel when
the mating terminal or pin is inserted and slowly removed. There should be some slight friction between
the matching terminal and pin combination. Expanded terminals have no feel of drag when the matching
pin or terminal is inserted and removed.
Broken terminal locks allow the pins or terminals to push back into the connector resulting in poor
connection or pin to pin shorts in the connector. Inspect for broken locks and displaced terminals in
connections. Never use paper clips or other devices to back probe a connector while doing Allison service
work.
Poor pin crimps. Pin crimps should be pull-tested by the technician to verify the crimp is secure to the wire.
If the pin crimp is loose, the pin easily moves or even comes off the wire with a slight tug on the terminal
by the technician. This situation may not reveal itself as an active DTC but instead may exhibit other
symptoms like shift quality issues.
Connector and pin corrosion caused by moisture in connectors. Empty wire locations in connectors must
always have a plug to keep moisture from finding a path into the connector.
Copyright 2008 Allison Transmission, Inc.
6351
3000 AND 4000 PRODUCT FAMILIES TROUBLESHOOTING MANUALALLISON 4th GENERATION CONTROLS
then always use heat-shrinkable butt splices. Never use wire ties inside the transmission, to hold connector
components together in the place of a connector lock, or in the place of the correct strain relief components
and clips used to fasten harnesses to the vehicle or to retain vehicle connectors unless OEM approved for
the location and vehicle component being repaired.
The following procedures are not documented in any Allison service procedures or in any Allison
Troubleshooting Manual or Service Manual and therefore should not be used as a method to diagnose any
transmission DTC(s), function, or shift quality concern:
Back probing any connectors used for transmission features or functions may damage and/or unlock the
terminals from the back-probed connector creating permanent or intermittent shorts and/or open circuits. If
possible, use the Breakout Box J 39700, appropriate harness adapters, and appropriate magnetic overlays
to troubleshoot the vehicle.
Load-testing any transmission-related circuits with any other electrical devices such as vehicle lamps or
relays, especially with the TCM connected to the harness. Use Breakout Box J 39700 and appropriate
harnesses with Allison DOC For PCService Tool to monitor the circuit performance in question unless
otherwise specified in the various Troubleshooting Manuals to use a digital volt-Ohm meter (DVOM) with
the Breakout.
Piercing a wire to check for voltages, shorts-to-grounds or other wires anywhere in the circuit but
especially at the TCM. This creates a leak path for moisture and damages the wire and insulation.
If needed, call for local distributor and/or factory support before downtime and expense of repair effect the
Allison Customer Experience. The phone number for the Technical Assistance Center in the United States is 1800-252-5283
Always use tools that are in good condition. Refer to the Allison Essential Tools list on the Allison Extranet to
complete any service procedure listed in an Allison publication. Also see appropriate Service Manuals and
Troubleshooting Manuals for service tools information.
Test Description
1. Review of general troubleshooting procedures and DTC service tips
2. Check for active DTC.
3. Check internal transmission harness.
4. Check OEM harness.
5. Check for other active codes.
6. Check TCM.
6352
3000 AND 4000 PRODUCT FAMILIES TROUBLESHOOTING MANUALALLISON 4th GENERATION CONTROLS
Action
Value(s)
Yes
No
Go to Step 2
Review the
information in
Section 3-5,
Section 6-6, and
Diagnostic Aids
listed for this DTC
Go to Step 1
Go to Step 3
Go to Step 7
Refer to
appropriate
transmission
service manual and
repair or replace
the internal
transmission
harness.
Go to Step 4
Go to Step 7
Go to Step 5
NOTE: OEM
repairs necessary
for transmission
DTCs to go
inactive are not
covered under
Allison
Transmission
warranty
Go to Step 7
6353
3000 AND 4000 PRODUCT FAMILIES TROUBLESHOOTING MANUALALLISON 4th GENERATION CONTROLS
Action
Value(s)
Yes
No
Troubleshoot all
other active codes
Go to Step 6
Go to Step 1
Go to Step 7
Go to Step 1
System OK
6354
Clear inactive
codes from history
Repair complete
3000 AND 4000 PRODUCT FAMILIES TROUBLESHOOTING MANUALALLISON 4th GENERATION CONTROLS
END VIEW OF
20-WAY CONNECTOR
1
10
11
14
15
20
61
80
41
60
21
40
20
TRANSMISSION
HSD2
PCS1
PCS2
PCS3
SS1
TCM
6
4
5
9
10
WIRE 171
WIRE 136
WIRE 152
WIRE 133
WIRE 151
71
HSD2
V BATTERY
36
52
33
51
V09067.00.00
Circuit Description
High Side Driver 2 (HSD2) supplies battery voltage to the PCS1, PCS2, PCS3, and SS1 solenoids via wire 171.
HSD2 is continuously ON during normal operation except during brief circuit tests. The Transmission Control
Module (TCM) regulates control current to the solenoids by switching the appropriate Low Side Driver (LSD) ON
and OFF. DTC P2670 indicates the TCM has detected a supply voltage in the HSD2 circuit of 6 volts or less. DTC
P2670 could be caused by a short-to-ground in the high side wiring attached to HSD2 (wire 171).
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).
HSD2 is commanded ON.
Engine speed greater than 200 rpm.
Conditions for Setting the DTC
DTC P2670 sets when the TCM detects a low voltage condition (less than 6 volts) in three solenoids in the HSD2
circuit.
Actions Taken When the DTC Sets
When DTC P2670 is active, the following conditions occur:
6355
3000 AND 4000 PRODUCT FAMILIES TROUBLESHOOTING MANUALALLISON 4th GENERATION CONTROLS
You may have to drive the vehicle in order to experience a fault. Use the data obtained from failure records to
determine transmission range and/or certain vehicle operating variables such as temperature, run time etc. This
data can be useful in reproducing the failure mode when DTC was set.
Inspect the wiring for poor electrical connections at the TCM and transmission connector. Look for the
following conditions:
A bent terminal
A backed-out terminal
A damaged terminal
Poor terminal tension
A chafed wire
A broken wire inside the insulation
Inspect OEM wiring harness routing, look for possible contact points where chafing could occur leading to an
open or short circuit condition. Moving parts on the vehicle could be contacting the harness; this includes
parking brake drum, suspension components, etc.
When diagnosing for an intermittent short or open, massage the wiring harness while watching the test
equipment for a change.
Test Description
This DTC requires the use of the J 47275 TCM Breakout and J 47279 Transmission Breakout. The numbers below
refer to step numbers on the diagnostic table.
2. Tests for the proper ignition voltage.
3. Tests for an active DTC.
4. Tests for a wire-to-wire short, or short-to-ground in the wire 171 of the OEM chassis harness.
6. Tests for wiring defects in the transmission internal harness.
Action
Value(s)
Yes
No
Go to Step 2
Go to Section 35,
Beginning the
Troubleshooting
Process
1. Install the Allison DOC For PCService Tool. 918V (12V TCM)
1832V (24V TCM)
2. Start the engine.
3. Record the failure records.
4. Monitor ignition voltage.
Is voltage within the specified values?
Go to Step 3
Resolve voltage
problems
6356
3000 AND 4000 PRODUCT FAMILIES TROUBLESHOOTING MANUALALLISON 4th GENERATION CONTROLS
Action
Value(s)
Yes
No
Go to Step 4
Go to
Diagnostic Aids
Go to Step 5
Go to Step 6
Go to Step 9
Go to Step 5
Go to Step 7
Go to Step 8
6357
3000 AND 4000 PRODUCT FAMILIES TROUBLESHOOTING MANUALALLISON 4th GENERATION CONTROLS
Action
Value(s)
Yes
No
Go to Step 9
Go to Step 7
Go to Step 9
Go to Step 8
Begin the
diagnosis again.
System OK
6358
Go to Step 1
3000 AND 4000 PRODUCT FAMILIES TROUBLESHOOTING MANUALALLISON 4th GENERATION CONTROLS
END VIEW OF
80-WAY CONNECTOR
END VIEW OF
20-WAY CONNECTOR
1
10
11
14
15
20
61
80
41
60
21
40
20
TRANSMISSION
HSD2
PCS1
PCS2
PCS3
SS1
TCM
WIRE 171
WIRE 136
WIRE 152
WIRE 133
WIRE 151
10
71
HSD2
V BATTERY
36
52
33
51
V09067.00.00
Circuit Description
High Side Driver 2 (HSD2) supplies battery voltage to the PCS1, PCS2, PCS3, and SS1 solenoids via wire 171.
HSD2 is continuously ON during normal operation except during brief circuit tests. The Transmission Control
Module (TCM) regulates control current to the solenoids by switching the appropriate Low Side Driver (LSD) ON
and OFF. DTC P2671 indicates the TCM has detected greater than or equal to 6 volts in the HSD2 circuit when
HSD2 is OFF during TCM initialization. DTC P2671 could be caused by an open or short to battery in the high
side wiring attached to HSD2 (wire 171).
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).
6359
3000 AND 4000 PRODUCT FAMILIES TROUBLESHOOTING MANUALALLISON 4th GENERATION CONTROLS
Hydraulic default (SOL OFF) is commanded. The shift selector position and hydraulic state of latch valves
determines the range attained.
You may have to drive the vehicle in order to experience a fault. Use the data obtained from failure records to
determine transmission range and/or certain vehicle operating variables such as temperature, run time etc. This
data can be useful in reproducing the failure mode when DTC was set.
Inspect the wiring for poor electrical connections at the TCM and transmission connector. Look for the
following conditions:
A bent terminal
A backed-out terminal
A damaged terminal
Poor terminal tension
A chafed wire
A broken wire inside the insulation
Inspect OEM wiring harness routing, look for possible contact points where chafing could occur leading to an
open or short circuit condition. Moving parts on the vehicle could be contacting the harness; this includes
parking brake drum, suspension components, etc.
When diagnosing for an intermittent short or open, massage the wiring harness while watching the test
equipment for a change.
Test Description
This DTC requires the use of the J 47275 TCM Breakout and J 47279 Transmission Breakout. The numbers below
refer to step numbers on the diagnostic table.
2. Tests for the proper igni.tion voltage.
3. Tests for an active DTC.
4. Tests for an open in wire 171 of OEM chassis harness.
5. Tests for a wire-to-wire short, or short-to-battery in the wire 171 of the OEM chassis harness.
7. Tests for wiring defects in the transmission internal harness.
6360
3000 AND 4000 PRODUCT FAMILIES TROUBLESHOOTING MANUALALLISON 4th GENERATION CONTROLS
Action
Value(s)
Yes
No
Go to Step 2
Go to Section 35,
Beginning the
Troubleshooting
Process
1. Install the Allison DOC For PCService Tool. 918V (12V TCM)
1832V (24V TCM)
2. Start the engine.
3. Record the failure records.
4. Monitor ignition voltage.
Is voltage within the specified values?
Go to Step 3
Resolve voltage
problems
Go to Step 4
Go to
Diagnostic Aids
Go to Step 6
Go to Step 5
NOTE: This DTC detects an open or short-tobattery condition in the HSD2 electrical
circuit.
Did DTC P2671 return?
4
6361
3000 AND 4000 PRODUCT FAMILIES TROUBLESHOOTING MANUALALLISON 4th GENERATION CONTROLS
Action
Value(s)
Yes
No
Go to Step 6
Go to Step 7
Go to Step 10
Go to Step 6
Go to Step 8
Go to Step 9
Go to Step 10
Go to Step 8
Go to Step 10
Go to Step 9
Begin the
diagnosis again.
System OK
6362
Go to Step 1
3000 AND 4000 PRODUCT FAMILIES TROUBLESHOOTING MANUALALLISON 4th GENERATION CONTROLS
END VIEW OF
80-WAY CONNECTOR
10
11
14
15
20
61
80
41
60
21
40
20
TRANSMISSION
HSD3
TCC
SS2
TCM
11
12
17
WIRE 131
WIRE 137
WIRE 119
(7-SPEED MODELS)
31
HSD3
V BATTERY
37
19
15
RTDR ACCUM
HSD3
SS2
B
A
WIRE 131
WIRE 119
RTDR OR
DIFF LOCK (T-CASE)
HSD3
PCS5
B
A
WIRE 131
WIRE 115
V09068.00.00
Circuit Description
High Side Driver 3 (HSD3) supplies battery voltage to the Torque Convertor Clutch (TCC), PCS5 (retarder and 7speed models) and SS2 (also, retarder and 7-speed models) solenoids via wire 131. HSD3 is continuously ON
during normal operation except during brief circuit tests. The Transmission Control Module (TCM) regulates
control current to the solenoids by switching the appropriate low side driver ON and OFF. DTC P2684 indicates
the TCM has detected multiple low side circuits are open while having HSD3 voltage of over 6 volts. DTC P2684
could be caused by open condition in the high side wiring attached to HSD3 (wire 131).
6363
3000 AND 4000 PRODUCT FAMILIES TROUBLESHOOTING MANUALALLISON 4th GENERATION CONTROLS
If there are other vehicle DTCs, the cause for transmission-related DTCs might be external to the transmission
and those vehicle systems must be corrected in order for the transmission DTCs to be resolved.
A transmission DTC must be active during the troubleshooting process to determine what caused the DTC. Use
the Snapshot feature of Allison DOC For PCService Tool while operating the vehicle in the same
conditions listed in the failure record, available in the Allison DOC For PCService Tool Reports Menu.
Manipulating the chassis harness and data link wiring may reveal intermittent shorts to ground, shorts to
another circuit, and open circuits causing a DTC.
Out of specification driveline components can damage transmission components and cause some transmission
DTCs.
NOTE: Allison Transmission components that are damaged because the driveline exceeded Allison
Transmission driveline specifications are not covered under Allison Transmission Warranty.
NOTE: OEM vehicle harness repairs are not covered under Allison Transmission warranty.
NOTE: OEM repairs necessary for transmission DTCs to go inactive are not covered under Allison
Transmission warranty.
The following wiring and connector issues can cause transmission DTCs:
6364
3000 AND 4000 PRODUCT FAMILIES TROUBLESHOOTING MANUALALLISON 4th GENERATION CONTROLS
the mating terminal or pin is inserted and slowly removed. There should be some slight friction between
the matching terminal and pin combination. Expanded terminals have no feel of drag when the matching
pin or terminal is inserted and removed.
Broken terminal locks allow the pins or terminals to push back into the connector resulting in poor
connection or pin to pin shorts in the connector. Inspect for broken locks and displaced terminals in
connections. Never use paper clips or other devices to back probe a connector while doing Allison service
work.
Poor pin crimps. Pin crimps should be pull-tested by the technician to verify the crimp is secure to the wire.
If the pin crimp is loose, the pin easily moves or even comes off the wire with a slight tug on the terminal
by the technician. This situation may not reveal itself as an active DTC but instead may exhibit other
symptoms like shift quality issues.
Connector and pin corrosion caused by moisture in connectors. Empty wire locations in connectors must
always have a plug to keep moisture from finding a path into the connector.
Poor harness routing and improper strain relief may cause damage resulting in electrical open and/or short
then always use heat-shrinkable butt splices. Never use wire ties inside the transmission, to hold connector
components together in the place of a connector lock, or in the place of the correct strain relief components
and clips used to fasten harnesses to the vehicle or to retain vehicle connectors unless OEM approved for
the location and vehicle component being repaired.
The following procedures are not documented in any Allison service procedures or in any Allison
Troubleshooting Manual or Service Manual and therefore should not be used as a method to diagnose any
transmission DTC(s), function, or shift quality concern:
Back probing any connectors used for transmission features or functions may damage and/or unlock the
terminals from the back-probed connector creating permanent or intermittent shorts and/or open circuits. If
possible, use the Breakout Box J 39700, appropriate harness adapters, and appropriate magnetic overlays
to troubleshoot the vehicle.
Load-testing any transmission-related circuits with any other electrical devices such as vehicle lamps or
relays, especially with the TCM connected to the harness. Use Breakout Box J 39700 and appropriate
harnesses with Allison DOC For PCService Tool to monitor the circuit performance in question unless
otherwise specified in the various Troubleshooting Manuals to use a digital volt-Ohm meter (DVOM) with
the Breakout.
Piercing a wire to check for voltages, shorts-to-grounds or other wires anywhere in the circuit but
especially at the TCM. This creates a leak path for moisture and damages the wire and insulation.
If needed, call for local distributor and/or factory support before downtime and expense of repair effect the
Allison Customer Experience. The phone number for the Technical Assistance Center in the United States is 1800-252-5283
Always use tools that are in good condition. Refer to the Allison Essential Tools list on the Allison Extranet to
complete any service procedure listed in an Allison publication. Also see appropriate Service Manuals and
Troubleshooting Manuals for service tools information
Copyright 2008 Allison Transmission, Inc.
6365
3000 AND 4000 PRODUCT FAMILIES TROUBLESHOOTING MANUALALLISON 4th GENERATION CONTROLS
Test Description
1. Review of general troubleshooting procedures and DTC service tips.
2. Check for active DTC.
3. Check internal transmission harness.
4. Check OEM harness.
5. Check for other active codes.
6. Check TCM.
7. Confirm repair is successful.
Action
Value(s)
Yes
No
Go to Step 2
Review the
information in
Section 3-5,
Section 6-6, and
Diagnostic Aids
listed for this DTC
Go to Step 1
6366
Go to Step 3
Go to Step 7
3000 AND 4000 PRODUCT FAMILIES TROUBLESHOOTING MANUALALLISON 4th GENERATION CONTROLS
Action
Value(s)
Yes
No
Refer to
appropriate
transmission
service manual and
repair or replace
the internal
transmission
harness.
Go to Step 4
Go to Step 7
Go to Step 5
NOTE:
OEM repairs
necessary for
transmission
DTCs to go
inactive are not
covered under
Allison
Transmission
warranty
Go to Step 7
Troubleshoot all
other active codes
Go to Step 6
6367
3000 AND 4000 PRODUCT FAMILIES TROUBLESHOOTING MANUALALLISON 4th GENERATION CONTROLS
Action
Value(s)
Yes
No
Go to Step 1
Go to Step 7
Go to Step 1
System OK
6368
Clear inactive
codes from history
Repair complete
3000 AND 4000 PRODUCT FAMILIES TROUBLESHOOTING MANUALALLISON 4th GENERATION CONTROLS
END VIEW OF
80-WAY CONNECTOR
10
11
14
15
20
61
80
41
60
21
40
20
TRANSMISSION
HSD3
TCC
SS2
TCM
11
12
17
WIRE 131
WIRE 137
WIRE 119
(7-SPEED MODELS)
31
HSD3
V BATTERY
37
19
15
RTDR ACCUM
HSD3
SS2
B
A
WIRE 131
WIRE 119
RTDR OR
DIFF LOCK (T-CASE)
HSD3
PCS5
B
A
WIRE 131
WIRE 115
V09068.00.00
Circuit Description
High Side Driver 3 (HSD3) supplies battery voltage to the TCC, PCS5, and SS2 (retarder and 7-speed models)
solenoids via wire 131. HSD3 is continuously ON during normal operation except during brief circuit tests. The
Transmission Control Module (TCM) regulates control current to the solenoids by switching the appropriate Low
Side Driver (LSD) ON and OFF. DTC P2685 indicates the TCM has detected a supply voltage in the HSD3 circuit
of 6V or less. DTC P2685 could be caused by a short-to-ground in the high side wiring attached to HSD3 (wire
131).
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).
HSD3 is commanded ON.
6369
3000 AND 4000 PRODUCT FAMILIES TROUBLESHOOTING MANUALALLISON 4th GENERATION CONTROLS
Hydraulic default (SOL OFF) is commanded. The shift selector position and hydraulic state of latch valves
determines the range attained.
You may have to drive the vehicle in order to experience a fault. Use the data obtained from failure records to
determine transmission range and/or certain vehicle operating variables such as temperature, run time etc. This
data can be useful in reproducing the failure mode when DTC was set.
Inspect the wiring for poor electrical connections at the TCM and transmission connector. Look for the
following conditions:
A bent terminal
A backed-out terminal
A damaged terminal
Poor terminal tension
A chafed wire
A broken wire inside the insulation
Inspect OEM wiring harness routing, look for possible contact points where chafing could occur leading to an
open or short circuit condition. Moving parts on the vehicle could be contacting the harness; this includes
parking brake drum, suspension components, etc.
When diagnosing for an intermittent short or open, massage the wiring harness while watching the test
equipment for a change.
Test Description
This DTC requires the use of the J 47275 TCM Breakout and J 47279 Transmission Breakout. The numbers below
refer to step numbers on the diagnostic table.
2. Tests for the proper ignition voltage.
3. Tests for an active DTC.
4. Tests for a wire-to-wire short, or short-to-ground in the wire 131 of the OEM chassis harness.
6. Tests for wiring defects in the transmission internal harness.
6370
3000 AND 4000 PRODUCT FAMILIES TROUBLESHOOTING MANUALALLISON 4th GENERATION CONTROLS
Action
Value(s)
Yes
No
Go to Step 2
Go to Section 35,
Beginning the
Troubleshooting
Process
1. Install the Allison DOC For PCService Tool. 918V (12V TCM)
1832V (24V TCM)
2. Start the engine.
3. Record the failure records.
4. Monitor ignition voltage.
Is voltage within the specified values?
Go to Step 3
Resolve voltage
problems
Go to Step 4
Go to
Diagnostic Aids
Go to Step 5
Go to Step 6
Go to Step 9
Go to Step 5
6371
3000 AND 4000 PRODUCT FAMILIES TROUBLESHOOTING MANUALALLISON 4th GENERATION CONTROLS
Action
Value(s)
Yes
No
Go to Step 7
Go to Step 8
Go to Step 9
Go to Step 7
Go to Step 9
Go to Step 8
Begin the
diagnosis again.
System OK
6372
Go to Step 1
3000 AND 4000 PRODUCT FAMILIES TROUBLESHOOTING MANUALALLISON 4th GENERATION CONTROLS
END VIEW OF
80-WAY CONNECTOR
10
11
14
15
20
61
80
41
60
21
40
20
TRANSMISSION
HSD3
TCC
SS2
TCM
11
12
17
WIRE 131
WIRE 137
WIRE 119
(7-SPEED MODELS)
31
HSD3
V BATTERY
37
19
15
RTDR ACCUM
HSD3
SS2
B
A
WIRE 131
WIRE 119
RTDR OR
DIFF LOCK (T-CASE)
HSD3
PCS5
B
A
WIRE 131
WIRE 115
V09068.00.00
Circuit Description
High Side Driver 3 (HSD3) supplies battery voltage to the TCC, PCS5, and SS2 solenoids (retarder and 7-speed
models) via wire 131. HSD3 is continuously ON during normal operation except during brief circuit tests. The
Transmission Control Module (TCM) regulates control current to the solenoids by switching the appropriate Low
Side Driver (LSD) ON and OFF. DTC P2686 indicates the TCM has detected greater than or equal to 6V in the
HSD3 circuit when HSD3 is OFF during TCM initialization. DTC P2686 could be caused by an open or short-tobattery in the high side wiring attached to HSD3 (wire 131).
Conditions for Running the DTC
The components are powered and ignition voltage is greater than 9 volts and less than 18V (12V TCM) or
greater than 9 volts and less than 32 volts (24V TCM).
HSD3 is commanded ON.
Engine speed greater than 200 rpm.
Copyright 2008 Allison Transmission, Inc.
6373
3000 AND 4000 PRODUCT FAMILIES TROUBLESHOOTING MANUALALLISON 4th GENERATION CONTROLS
Hydraulic default (SOL OFF) is commanded. The shift selector position and hydraulic state of latch valves
determines the range attained.
Inspect the wiring for poor electrical connections at the TCM and transmission connector. Look for the
following conditions:
A bent terminal
A backed-out terminal
A damaged terminal
Poor terminal tension
A chafed wire
A broken wire inside the insulation
Inspect OEM wiring harness routing, look for possible contact points where chafing could occur leading to an
open or short circuit condition. Moving parts on the vehicle could be contacting the harness; this includes
parking brake drum, suspension components, etc.
When diagnosing for an intermittent short or open, massage the wiring harness while watching the test
equipment for a change.
Test Description
This DTC requires the use of the J 47275 TCM Breakout and J 47279 Transmission Breakout. The numbers below
refer to step numbers on the diagnostic table.
2. Tests for the proper ignition voltage.
3. Tests for an active DTC.
4. Tests for an open in wire 131 of the OEM chassis harness.
5. Tests for wire-to-wire short, or short-to-battery in wire 131 of the OEM chassis harness.
7. Tests for wiring defects in the transmission internal harness.
6374
3000 AND 4000 PRODUCT FAMILIES TROUBLESHOOTING MANUALALLISON 4th GENERATION CONTROLS
Action
Value(s)
Yes
No
Go to Step 2
Go to Section 35,
Beginning the
Troubleshooting
Process
1. Install the Allison DOC For PCService Tool. 918V (12V TCM)
1832V (24V TCM)
2. Start the engine.
3. Record the failure records.
4. Monitor ignition voltage.
Is voltage within the specified values?
Go to Step 3
Resolve voltage
problems
Go to Step 4
Go to
Diagnostic Aids
Go to Step 6
Go to Step 5
NOTE: This DTC detects an open or short-tobattery condition in the HSD3 electrical
circuit.
Did DTC P2686 return?
4
6375
3000 AND 4000 PRODUCT FAMILIES TROUBLESHOOTING MANUALALLISON 4th GENERATION CONTROLS
Action
Value(s)
Yes
No
Go to Step 6
Go to Step 7
Go to Step 10
Go to Step 6
Go to Step 8
Go to Step 9
Go to Step 10
Go to Step 8
Go to Step 10
Go to Step 9
Begin the
diagnosis again.
System OK
6376
Go to Step 1
3000 AND 4000 PRODUCT FAMILIES TROUBLESHOOTING MANUALALLISON 4th GENERATION CONTROLS
When DTC P2714 occurs, the TCM will command previous range.
While Diagnostic Response is active, the TCM ignores shift selector inputs.
This DTC indicates the oncoming clutch being controlled by PCS4 is not applied or applied too slowly.
Common causes include:
Erratic turbine or output speed signals.
A leak or obstruction in the C4 clutch apply circuit.
A defective solenoid.
A stuck PCS4 regulator valve.
PCS4 supplies hydraulic pressure to C4 clutch in second and sixth ranges. To determine which clutch circuit is
suspect, check the Allison DOC For PCService Tool failure record data for previous or current range
information when the DTC was set.
Copyright 2008 Allison Transmission, Inc.
6377
3000 AND 4000 PRODUCT FAMILIES TROUBLESHOOTING MANUALALLISON 4th GENERATION CONTROLS
If the condition is intermittent, connect Allison DOC For PCService Tool and observe the speed sensor
indicated by the code. If the signal is erratic, investigate and eliminate the following:
Intermittent wiring connection
Excessive vibration (driveline or engine torsionals)
Irregular sensor gap (loose sensor, loose tone wheel, or damaged tone wheel)
Test Description
The numbers below refer to step numbers on the diagnostic table.
2. Tests for proper transmission fluid level.
3. Tests for active DTCs.
4. Tests ignition voltage.
5. Tests speed sensor readings.
6. Tests for C4 clutch pressure from PCS4.
7. Tests for evidence of clutch failure.
8. Tests for stuck or sticking valves and damaged valve body gaskets.
Yes
No
Action
Value(s)
Go to Step 2
Go to Section 35,
Beginning the
Troubleshooting
Process
Go to Step 3
1.
2.
3.
4.
5.
Go to Step 4
Go to
Diagnostic Aids
Go to Step 5
Go to Section 8,
General
Troubleshooting,
6378
1.
2.
3.
4.
Install the Allison DOC For PCService Tool. 918V (12V TCM)
Start the engine.
1832V (24V TCM)
Record the DTC failure record data.
Using the Allison DOC For PCService Tool,
measure ignition voltage.
Is the voltage within the specified value?
Copyright 2008 Allison Transmission, Inc.
3000 AND 4000 PRODUCT FAMILIES TROUBLESHOOTING MANUALALLISON 4th GENERATION CONTROLS
Action
Value(s)
Yes
No
Go to appropriate
speed sensor DTC
Go to Step 6
Go to Step 7
Go to Step 8
Go to Step 10
Go to
Diagnostic Aids
Go to Step 11
Go to Step 9
Replace PCS4.
Go to Step 11
Go to Step 9
Go to Step 11
Go to Step 10
6379
3000 AND 4000 PRODUCT FAMILIES TROUBLESHOOTING MANUALALLISON 4th GENERATION CONTROLS
Action
Value(s)
6380
Yes
No
Begin the
diagnosis again.
System OK
Go to Step 1
3000 AND 4000 PRODUCT FAMILIES TROUBLESHOOTING MANUALALLISON 4th GENERATION CONTROLS
While Diagnostic Response is active, the TCM ignores shift selector inputs.
PCS4 supplies hydraulic pressure to C4 clutch in second and sixth ranges. To determine which clutch circuit is
suspect, check the Allison DOC For PCService Tool failure record data for previous or current range
information when the DTC was set.
If the condition is intermittent, connect Allison DOC For PCService Tool and observe the speed sensor
indicated by the code. If the signal is erratic, investigate and eliminate the following:
Intermittent wiring connection
Excessive vibration (driveline or engine torsionals)
Copyright 2008 Allison Transmission, Inc.
6381
3000 AND 4000 PRODUCT FAMILIES TROUBLESHOOTING MANUALALLISON 4th GENERATION CONTROLS
Test Description
The numbers below refer to step numbers on the diagnostic table.
2. Tests for proper transmission fluid level.
3. Tests for active DTCs.
4. Tests ignition voltage.
5. Tests speed sensor readings.
6. Tests for C4 clutch pressure from PCS4.
7. Tests for evidence of clutch failure.
8. Tests for stuck or sticking valves and damaged valve body gaskets.
Action
Value(s)
Yes
No
Go to Step 2
Go to Section 35,
Beginning the
Troubleshooting
Process
Go to Step 3
Go to Step 4
Go to
Diagnostic Aids
Go to Step 5
Go to General
Troubleshooting,
Section 8
6382
3000 AND 4000 PRODUCT FAMILIES TROUBLESHOOTING MANUALALLISON 4th GENERATION CONTROLS
Action
Value(s)
Yes
No
Go to appropriate
speed sensor DTC
Go to Step 6
Go to Step 7
Go to Step 8
Go to Step 10
Go to
Diagnostic Aids
Go to Step 11
Go to Step 9
Replace PCS4.
Go to Step 11
Go to Step 9
Go to Step 11
Go to Step 10
Begin the
diagnosis again.
System OK
11
Go to Step 1
6383
3000 AND 4000 PRODUCT FAMILIES TROUBLESHOOTING MANUALALLISON 4th GENERATION CONTROLS
END VIEW OF
20-WAY CONNECTOR
1
10
11
14
15
20
61
80
41
60
21
40
20
TRANSMISSION
TRANSID
HSD1
PCS4
PCS6
MAIN MOD
TCM
20
1
2
7
8
WIRE 176
WIRE 111
WIRE 155
WIRE 178
WIRE 174
76
11
TRANSID
HSD1
ANALOG
INTERFACE
55
78
V BATTERY
74
V09066.00.00
Circuit Description
Pressure Control Solenoid 4 (PCS4) is a normally closed solenoid used to apply the C4 clutch in second and sixth
ranges. The TCM commands the solenoid ON to produce hydraulic pressure in the clutch apply circuit. When
PCS4 is commanded OFF, the clutch pressure is released.
The TCM sends control current to PCS4 from High Side Driver 1 (HSD1) via wire 111. HSD1 is continuously ON
unless the TCM detects a fault condition. The Transmission Control Module (TCM) regulates the amount of
current to PCS4 by switching PCS4 Low Side Driver (LSD) ON and OFF. Wire 155 completes the circuit between
PCS4 and its LSD. DTC P2718 indicates that the TCM has detected an open condition in PCS4 electrical circuit.
The open condition may exist in the high side (wire 111) or low side (wire 155).
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).
TCM initialization is in process or engine speed is greater than 200 rpm and less than 7500 rpm for 5 seconds.
3000 AND 4000 PRODUCT FAMILIES TROUBLESHOOTING MANUALALLISON 4th GENERATION CONTROLS
Hydraulic default (SOL OFF) is commanded. The shift selector position and hydraulic state of latch valves
determines the range attained.
You may have to drive the vehicle in order to experience a fault. Use the data obtained from failure records to
determine transmission range and/or certain vehicle operating variables such as temperature, run time etc. This
data can be useful in reproducing the failure mode when DTC was set.
Inspect the wiring for poor electrical connections at the TCM and transmission connector. Look for the
following conditions:
A bent terminal
A backed-out terminal
A damaged terminal
Poor terminal tension
A chafed wire
A broken wire inside the insulation
Inspect OEM wiring harness routing, look for possible contact points where chafing could occur leading to an
open or short circuit condition. Moving parts on the vehicle could be contacting the harness; this includes
parking brake drum, suspension components, etc.
When diagnosing for an intermittent short or open, massage the wiring harness while watching the test
equipment for a change.
Test Description
This DTC requires the use of the J 47275 TCM Breakout and J 47279 Transmission Breakout. The numbers below
refer to step numbers on the diagnostic table.
2. Tests for the proper ignition voltage.
3. Tests for an active DTC.
4. Tests the OEM harness for an excessive voltage drop caused by an open condition in either wire 111 or
wire 155 of the OEM chassis harness.
6. Tests for an open condition in the transmission internal harness.
7. Tests for the proper PCS4 resistance.
Copyright 2008 Allison Transmission, Inc.
6385
3000 AND 4000 PRODUCT FAMILIES TROUBLESHOOTING MANUALALLISON 4th GENERATION CONTROLS
Action
Value(s)
Yes
No
Go to Step 2
Go to Section 35,
Beginning the
Troubleshooting
Process
1. Install the Allison DOC For PCService Tool. 918V (12V TCM)
2. Start the engine.
1832V (24V TCM)
3. Record the failure records.
4. Monitor ignition voltage.
Is the voltage within the specified values?
Go to Step 3
Resolve voltage
problem
Go to Step 4
Go to
Diagnostic Aids
Go to Step 5
Go to Step 6
6386
3000 AND 4000 PRODUCT FAMILIES TROUBLESHOOTING MANUALALLISON 4th GENERATION CONTROLS
Action
Value(s)
Yes
No
Go to Step 11
Go to Step 5
Refer to Solenoid
Resistance Chart
(Appendix K)
Go to Step 10
Go to Step 7
Refer to Solenoid
Resistance Chart
(Appendix K)
Go to Step 8
Go to Step 9
Go to Step 11
Go to Step 8
Go to Step 11
Go to Step 9
Go to Step 11
Go to Step 10
Begin the
diagnosis again.
System OK
Replace PCS4.
Is the replacement complete?
10
11
Go to Step 1
6387
3000 AND 4000 PRODUCT FAMILIES TROUBLESHOOTING MANUALALLISON 4th GENERATION CONTROLS
END VIEW OF
20-WAY CONNECTOR
1
10
11
14
15
20
61
80
41
60
21
40
20
TRANSMISSION
TRANSID
HSD1
PCS4
PCS6
MAIN MOD
TCM
20
1
2
7
8
WIRE 176
WIRE 111
WIRE 155
WIRE 178
WIRE 174
76
11
TRANSID
HSD1
ANALOG
INTERFACE
55
78
V BATTERY
74
V09066.00.00
Circuit Description
Pressure Control Solenoid 4 (PCS4) is a normally closed solenoid used to apply the C4 clutch in second and sixth
ranges. The TCM commands the solenoid ON to produce hydraulic pressure in the clutch apply circuit. When
PCS4 is commanded OFF, the clutch pressure is released.
The TCM sends control current to PCS4 from High Side Driver 1 (HSD1) via wire 111. HSD1 is continuously ON
unless the TCM detects a fault condition. The Transmission Control Module (TCM) regulates the amount of
current to PCS4 by switching PCS4 Low Side Driver (LSD) ON and OFF. Wire 155 completes the circuit between
PCS4 and its LSD. DTC P2720 indicates that the TCM has detected a short-to-ground condition in the low side of
PCS4 electrical circuit.
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).
TCM initialization is in process or engine speed is greater than 200 rpm and less than 7500 rpm for 5 seconds.
3000 AND 4000 PRODUCT FAMILIES TROUBLESHOOTING MANUALALLISON 4th GENERATION CONTROLS
Hydraulic default (SOL OFF) is commanded. The shift selector position and hydraulic state of latch valves
determines the range attained.
You may have to drive the vehicle in order to experience a fault. Use the data obtained from failure records to
determine transmission range and/or certain vehicle operating variables such as temperature, run time etc. This
data can be useful in reproducing the failure mode when DTC was set.
Inspect the wiring for poor electrical connections at the TCM and transmission connector. Look for the
following conditions:
A bent terminal
A backed-out terminal
A damaged terminal
Poor terminal tension
A chafed wire
A broken wire inside the insulation
Inspect OEM wiring harness routing, look for possible contact points where chafing could occur leading to an
open or short circuit condition. Moving parts on the vehicle could be contacting the harness; this includes
parking brake drum, suspension components, etc.
When diagnosing for an intermittent short or open, massage the wiring harness while watching the test
equipment for a change.
6389
3000 AND 4000 PRODUCT FAMILIES TROUBLESHOOTING MANUALALLISON 4th GENERATION CONTROLS
Action
Value(s)
Yes
No
Go to Step 2
Go to Section 35,
Beginning the
Troubleshooting
Process
1. Install the Allison DOC For PCService Tool. 918V (12V TCM)
1832V (24V TCM)
2. Start the engine.
3. Record the failure records.
4. Monitor ignition voltage.
Is the voltage within the specified values?
Go to Step 3
Resolve voltage
problem
Go to Step 4
Go to
Diagnostic Aids
Go to Step 5
Go to Step 6
6390
3000 AND 4000 PRODUCT FAMILIES TROUBLESHOOTING MANUALALLISON 4th GENERATION CONTROLS
Action
Value(s)
Yes
No
Go to Step 11
Go to Step 5
Go to Step 7
Go to Step 10
Refer to Solenoid
Resistance Chart
(Appendix K)
Go to Step 8
Go to Step 9
Go to Step 11
Go to Step 8
Go to Step 11
Go to Step 9
Go to Step 11
Go to Step 10
Begin the
diagnosis again.
System OK
Replace PCS4.
Is the replacement complete?
10
11
Go to Step 1
6391
3000 AND 4000 PRODUCT FAMILIES TROUBLESHOOTING MANUALALLISON 4th GENERATION CONTROLS
END VIEW OF
20-WAY CONNECTOR
1
10
11
14
15
20
61
80
41
60
21
40
20
TRANSMISSION
TRANSID
HSD1
PCS4
PCS6
MAIN MOD
TCM
20
1
2
7
8
WIRE 176
WIRE 111
WIRE 155
WIRE 178
WIRE 174
76
11
TRANSID
HSD1
ANALOG
INTERFACE
55
78
V BATTERY
74
V09066.00.00
Circuit Description
Pressure Control Solenoid 4 (PCS4) is a normally closed solenoid used to apply the C4 clutch in second and sixth
ranges. The TCM commands the solenoid ON to produce hydraulic pressure in the clutch apply circuit. When
PCS4 is commanded OFF, the clutch pressure is released.
The TCM sends control current to PCS4 from High Side Driver 1 (HSD1) via wire 111. HSD1 is continuously ON
unless the TCM detects a fault condition. The Transmission Control Module (TCM) regulates the amount of
current to PCS4 by switching PCS4 Low Side Driver (LSD) ON and OFF. Wire 155 completes the circuit between
PCS4 and its LSD. DTC P2721 indicates that the TCM has detected a short-to-battery condition in the low side of
PCS4 electrical circuit.
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).
TCM initialization is in process or engine speed is greater than 200 rpm and less than 7500 rpm for 5 seconds.
3000 AND 4000 PRODUCT FAMILIES TROUBLESHOOTING MANUALALLISON 4th GENERATION CONTROLS
Hydraulic default (SOL OFF) is commanded. The shift selector position and hydraulic state of latch valves
determines the range attained.
DTC P2721 indicates a short-to-battery in the electrical circuit for the PCS4 solenoid.
You may have to drive the vehicle in order to experience a fault. Use the data obtained from failure records to
determine transmission range and/or certain vehicle operating variables such as temperature, run time etc. This
data can be useful in reproducing the failure mode when DTC was set.
Inspect the wiring for poor electrical connections at the TCM and transmission connector. Look for the
following conditions:
A bent terminal
A backed-out terminal
A damaged terminal
Poor terminal tension
A chafed wire
A broken wire inside the insulation
Inspect OEM wiring harness routing, look for possible contact points where chafing could occur leading to an
open or short circuit condition. Moving parts on the vehicle could be contacting the harness; this includes
parking brake drum, suspension components, etc.
When diagnosing for an intermittent short or open, massage the wiring harness while watching the test
equipment for a change.
6393
3000 AND 4000 PRODUCT FAMILIES TROUBLESHOOTING MANUALALLISON 4th GENERATION CONTROLS
Yes
No
Action
Value(s)
Go to Step 2
Go to Section 35,
Beginning the
Troubleshooting
Process
1. Install the Allison DOC For PCService Tool. 918V (12V TCM)
1832V (24V TCM)
2. Start the engine.
3. Record the failure records.
4. Monitor ignition voltage.
Is voltage within specified values?
Go to Step 3
Resolve voltage
problem
Go to Step 4
Go to
Diagnostic Aids
Go to Step 5
Go to Step 6
6394
3000 AND 4000 PRODUCT FAMILIES TROUBLESHOOTING MANUALALLISON 4th GENERATION CONTROLS
Action
Value(s)
Yes
No
Go to Step 11
Go to Step 5
Go to Step 7
Go to Step 10
Refer to Solenoid
Resistance Chart
(Appendix K)
Go to Step 8
Go to Step 9
Go to Step 11
Go to Step 8
Go to Step 11
Go to Step 9
Go to Step 11
Go to Step 10
Begin the
diagnosis again.
System OK
Replace PCS4.
Is the replacement complete?
10
11
Go to Step 1
6395
3000 AND 4000 PRODUCT FAMILIES TROUBLESHOOTING MANUALALLISON 4th GENERATION CONTROLS
PCS1 supplies hydraulic pressure to C1 clutch in first range through fourth ranges. To determine which clutch
circuit is suspect, check the Allison DOC For PCService Tool failure record data for previous or current
range information when the DTC was set.
If the condition is intermittent, connect Allison DOC For PCService Tool and observe the speed sensor
indicated by the DTC. If the signal is erratic, investigate and eliminate the following:
Intermittent wiring connection
Excessive vibration (driveline or engine torsionals)
Irregular sensor gap (loose sensor, loose tone wheel, or damaged tone wheel)
6396
3000 AND 4000 PRODUCT FAMILIES TROUBLESHOOTING MANUALALLISON 4th GENERATION CONTROLS
Value(s)
Yes
Go to Step 2
Go to Step 3
No
Go to Section 35,
Beginning the
Troubleshooting
Process
Put in the correct
fluid level
Go to Step 11
Go to Step 4
Go to
Diagnostic Aids
Go to General
Troubleshooting,
Section 8
Go to Step 6
6397
3000 AND 4000 PRODUCT FAMILIES TROUBLESHOOTING MANUALALLISON 4th GENERATION CONTROLS
10
Value(s)
Refer to Main and
Clutch Pressure
specifications in
Appendix B
6398
Yes
Go to Step 7
No
Go to Step 8
Go to Step 10
Go to
Diagnostic Aids
Go to Step 11
Go to Step 9
Go to Step 11
Go to Step 9
Go to Step 11
Go to Step 10
3000 AND 4000 PRODUCT FAMILIES TROUBLESHOOTING MANUALALLISON 4th GENERATION CONTROLS
Value(s)
Yes
Begin the
diagnosis again.
No
System OK
Go to Step 1
6399
3000 AND 4000 PRODUCT FAMILIES TROUBLESHOOTING MANUALALLISON 4th GENERATION CONTROLS
While Diagnostic Response is active, the TCM ignores shift selector inputs.
PCS1 supplies hydraulic pressure to C1 clutch in first range through fourth ranges. To determine which clutch
circuit is suspect, check the Allison DOC For PCService Tool failure record data for previous or current
range information when the DTC was set.
PCS1 and PCS2 are normally high solenoids. PCS1 and PCS2 supply full hydraulic pressure when their coils
are de-energized, and no output pressure when receiving maximum current from the TCM.
If the condition is intermittent, connect Allison DOC For PCService Tool and observe the speed sensor
indicated by the code. If the signal is erratic, investigate and eliminate the following:
Intermittent wiring connection
6400
3000 AND 4000 PRODUCT FAMILIES TROUBLESHOOTING MANUALALLISON 4th GENERATION CONTROLS
Test Description
The numbers below refer to step numbers on the diagnostic table.
2. Tests for proper transmission fluid level.
3. Tests for active DTCs.
4. Tests ignition voltage.
5. Tests speed sensor readings.
6. Tests for C1 clutch pressure from PCS1.
7. Tests for evidence of clutch failure.
8. Tests for stuck or sticking valves and damaged valve body gaskets.
Action
Was Section 35, Beginning The Troubleshooting
Process, performed?
Value(s)
Yes
Go to Step 2
Go to Step 3
No
Go to Section 35,
Beginning the
Troubleshooting
Process
Put in the correct
fluid level
Go to Step 11
Go to Step 4
Go to
Diagnostic Aids
Go to General
Troubleshooting,
Section 8
Go to Step 6
6401
3000 AND 4000 PRODUCT FAMILIES TROUBLESHOOTING MANUALALLISON 4th GENERATION CONTROLS
9
10
Action
1. Turn ignition OFF.
2. Install 2000 kPa (290 psi) pressure gauges in
main and C1 pressure taps.
3. Start the engine.
4. Using Allison DOC For PCService Tool,
select the clutch test mode.
5. With brakes applied, select and attain the range
where the DTC occurred as indicated in the
failure records.
6. Read and record Main and C1 clutch pressures.
Are the pressure readings within specified values in
Appendix B?
Remove the dipstick and inspect the transmission
fluid for clutch debris or burnt odor. If necessary,
drain a small amount of fluid for this inspection.
Value(s)
Refer to main and
clutch pressure
specifications in
Appendix B
Yes
Go to Step 7
No
Go to Step 8
Go to Step 10
Go to
Diagnostic Aids
Go to Step 11
Go to Step 9
Go to Step 11
Go to Step 9
Go to Step 11
Go to Step 10
Begin the
diagnosis again.
System OK
6402
Go to Step 1
3000 AND 4000 PRODUCT FAMILIES TROUBLESHOOTING MANUALALLISON 4th GENERATION CONTROLS
END VIEW OF
20-WAY CONNECTOR
1
10
11
14
15
20
61
80
41
60
21
40
20
TRANSMISSION
HSD2
PCS1
PCS2
PCS3
SS1
TCM
6
4
5
9
10
WIRE 171
WIRE 136
WIRE 152
WIRE 133
WIRE 151
71
HSD2
V BATTERY
36
52
33
51
V09067.00.00
Circuit Description
Pressure Control Solenoid 1 (PCS1) is a normally open solenoid used to apply the C1 clutch in first through fourth
range. The TCM commands the solenoid OFF to produce hydraulic pressure in the clutch apply circuit. When
PCS1 is commanded ON, the C1 clutch is released.
The TCM sends control current to PCS1 from High Side Driver 2 (HSD2) via wire 171. HSD2 is continuously ON
unless the TCM detects a fault condition. The Transmission Control Module (TCM) regulates the amount of
current to PCS1 by switching PCS1 Low Side Driver (LSD) ON and OFF. Wire 136 completes the circuit between
PCS1 and its LSD. DTC P2727 indicates that the TCM has detected an open condition in PCS1 electrical circuit.
The open condition may exist in the high side (wire 171) or low side (wire 136).
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).
TCM initialization is in process or engine speed is greater than 200 rpm and less than 7500 rpm for 5 seconds.
6403
3000 AND 4000 PRODUCT FAMILIES TROUBLESHOOTING MANUALALLISON 4th GENERATION CONTROLS
Hydraulic default (SOL OFF) is commanded. The shift selector position and hydraulic state of latch valves
determines the range attained.
You may have to drive the vehicle in order to experience a fault. Use the data obtained from failure records to
determine transmission range and/or certain vehicle operating variables such as temperature, run time etc. This
data can be useful in reproducing the failure mode when DTC was set.
Inspect the wiring for poor electrical connections at the TCM and transmission connector. Look for the
following conditions:
A bent terminal
A backed-out terminal
A damaged terminal
Poor terminal tension
A chafed wire
A broken wire inside the insulation
Inspect OEM wiring harness routing, look for possible contact points where chafing could occur leading to an
open or short circuit condition. Moving parts on the vehicle could be contacting the harness; this includes
parking brake drum, suspension components, etc.
When diagnosing for an intermittent short or open, massage the wiring harness while watching the test
equipment for a change.
Test Description
This DTC requires the use of the J 47275 TCM Breakout and J 47279 Transmission Breakout. The numbers below
refer to step numbers on the diagnostic table.
2. Tests for the proper ignition voltage.
3. Tests for an active DTC.
4. Tests the OEM harness for an excessive voltage drop caused by an open condition in either wire 171 or
wire 136 of the OEM chassis harness.
6. Tests for an open condition in the transmission internal harness.
7. Tests for the proper PCS1 resistance.
6404
3000 AND 4000 PRODUCT FAMILIES TROUBLESHOOTING MANUALALLISON 4th GENERATION CONTROLS
Action
Value(s)
Yes
No
Go to Step 2
Go to Section 35,
Beginning the
Troubleshooting
Process
1. Install the Allison DOC For PCService Tool. 918V (12V TCM)
1832V (24V TCM)
2. Start the engine.
3. Record the failure records.
4. Monitor ignition voltage.
Is the voltage within the specified values?
Go to Step 3
Resolve voltage
problem
Go to Step 4
Go to
Diagnostic Aids
Go to Step 5
Go to Step 6
6405
3000 AND 4000 PRODUCT FAMILIES TROUBLESHOOTING MANUALALLISON 4th GENERATION CONTROLS
Action
Value(s)
Yes
No
Go to Step 11
Go to Step 5
Refer to Solenoid
Resistance Chart
(Appendix K)
Go to Step 10
Go to Step 7
Refer to Solenoid
Resistance Chart
(Appendix K)
Go to Step 8
Go to Step 9
Go to Step 11
Go to Step 8
Go to Step 11
Go to Step 9
Go to Step 11
Go to Step 10
Begin the
diagnosis again.
System OK
Replace PCS1.
Is the replacement complete?
10
11
6406
Go to Step 1
3000 AND 4000 PRODUCT FAMILIES TROUBLESHOOTING MANUALALLISON 4th GENERATION CONTROLS
END VIEW OF
20-WAY CONNECTOR
1
10
11
14
15
20
61
80
41
60
21
40
20
TRANSMISSION
HSD2
PCS1
PCS2
PCS3
SS1
TCM
6
4
5
9
10
WIRE 171
WIRE 136
WIRE 152
WIRE 133
WIRE 151
71
HSD2
V BATTERY
36
52
33
51
V09067.00.00
Circuit Description
Pressure Control Solenoid 1 (PCS1) is a normally open solenoid used to apply the C1 clutch in first through fourth
range. The TCM commands the solenoid OFF to produce hydraulic pressure in the clutch apply circuit. When
PCS1 is commanded ON, the C1 clutch is released.
The TCM sends control current to PCS1 from High Side Driver 2 (HSD2) via wire 171. HSD2 is continuously ON
unless the TCM detects a fault condition. The Transmission Control Module (TCM) regulates the amount of
current to PCS1 by switching PCS1 Low Side Driver (LSD) ON and OFF. Wire 136 completes the circuit between
PCS1 and its LSD. DTC P2729 indicates that the TCM has detected a short-to-ground condition in the low side of
PCS1 electrical circuit.
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).
TCM initialization is in process or engine speed is greater than 200 rpm and less than 7500 rpm for 5 seconds.
Conditions for Setting the DTC
DTC P2729 sets when the TCM detects a short-to-ground in the PCS1 return circuit for more than 2 seconds.
Actions Taken When the DTC Sets
When DTC P2729 is active, the following conditions occur:
The CHECK TRANS light illuminates.
DTC is stored in TCM history.
Hydraulic default (SOL OFF) is commanded. The shift selector position and hydraulic state of latch valves
determines the range attained.
Copyright 2008 Allison Transmission, Inc.
6407
3000 AND 4000 PRODUCT FAMILIES TROUBLESHOOTING MANUALALLISON 4th GENERATION CONTROLS
You may have to drive the vehicle in order to experience a fault. Use the data obtained from failure records to
determine transmission range and/or certain vehicle operating variables such as temperature, run time etc. This
data can be useful in reproducing the failure mode when DTC was set.
Inspect the wiring for poor electrical connections at the TCM and transmission connector. Look for the
following conditions:
A bent terminal
A backed-out terminal
A damaged terminal
Poor terminal tension
A chafed wire
A broken wire inside the insulation
Inspect OEM wiring harness routing, look for possible contact points where chafing could occur leading to an
open or short circuit condition. Moving parts on the vehicle could be contacting the harness; this includes
parking brake drum, suspension components, etc.
When diagnosing for an intermittent short or open, massage the wiring harness while watching the test
equipment for a change.
Test Description
This DTC requires the use of the J 47275 TCM Breakout and J 47279 Transmission Breakout. The numbers below
refer to step numbers on the diagnostic table.
2. Tests for the proper ignition voltage.
3. Tests for an active DTC.
4. Tests for wire-to-wire shorts or a short-to-ground condition in wire 136.
6. Tests for the wire-to-wire shorts or a short-to-ground in the internal transmission harness.
6408
3000 AND 4000 PRODUCT FAMILIES TROUBLESHOOTING MANUALALLISON 4th GENERATION CONTROLS
Action
Value(s)
Yes
No
Go to Step 2
Go to Section 35,
Beginning the
Troubleshooting
Process
1. Install the Allison DOC For PCService Tool. 918V (12V TCM)
1832V (24V TCM)
2. Start the engine.
3. Record the failure records.
4. Monitor ignition voltage.
Is the voltage within the specified values?
Go to Step 3
Resolve voltage
problem.
Go to Step 4
Go to
Diagnostic Aids
Go to Step 5
Go to Step 6
Go to Step 11
Go to Step 5
6409
3000 AND 4000 PRODUCT FAMILIES TROUBLESHOOTING MANUALALLISON 4th GENERATION CONTROLS
Action
Value(s)
Yes
No
Go to Step 7
Go to Step 10
Go to Step 8
Go to Step 9
Go to Step 11
Go to Step 8
Go to Step 11
Go to Step 9
Go to Step 11
Go to Step 10
Begin the
diagnosis again.
System OK
Replace PCS1.
Is the replacement complete?
10
11
6410
Go to Step 1
3000 AND 4000 PRODUCT FAMILIES TROUBLESHOOTING MANUALALLISON 4th GENERATION CONTROLS
END VIEW OF
20-WAY CONNECTOR
1
10
11
14
15
20
61
80
41
60
21
40
20
TRANSMISSION
HSD2
PCS1
PCS2
PCS3
SS1
TCM
6
4
5
9
10
WIRE 171
WIRE 136
WIRE 152
WIRE 133
WIRE 151
71
HSD2
V BATTERY
36
52
33
51
V09067.00.00
Circuit Description
Pressure Control Solenoid 1 (PCS1) is a normally open solenoid used to apply the C1 clutch in first through fourth
range. The TCM commands the solenoid OFF to produce hydraulic pressure in the clutch apply circuit. When
PCS1 is commanded ON, the C1 clutch is released.
The TCM sends control current to PCS1 from High Side Driver 2 (HSD2) via wire 171. HSD2 is continuously ON
unless the TCM detects a fault condition. The Transmission Control Module (TCM) regulates the amount of
current to PCS1 by switching PCS1 Low Side Driver (LSD) ON and OFF. Wire 136 completes the circuit between
PCS1 and its LSD. DTC P2730 indicates that the TCM has detected a short-to-battery condition in the low side of
PCS1 electrical circuit.
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).
TCM initialization is in process or engine speed is greater than 200 rpm and less than 7500 rpm for 5 seconds.
Conditions for Setting the DTC
DTC P2730 sets when the TCM detects a short-to-battery in the PCS1 return circuit for more than 2 seconds.
Actions Taken When the DTC Sets
When DTC P2730 is active, the following conditions occur:
The CHECK TRANS light illuminates.
DTC is stored in TCM history.
Hydraulic default (SOL OFF) is commanded. The shift selector position and hydraulic state of latch valves
determines the range attained.
Copyright 2008 Allison Transmission, Inc.
6411
3000 AND 4000 PRODUCT FAMILIES TROUBLESHOOTING MANUALALLISON 4th GENERATION CONTROLS
You may have to drive the vehicle in order to experience a fault. Use the data obtained from failure records to
determine transmission range and/or certain vehicle operating variables such as temperature, run time etc. This
data can be useful in reproducing the failure mode when DTC was set.
Inspect the wiring for poor electrical connections at the TCM and transmission connector. Look for the
following conditions:
A bent terminal
A backed-out terminal
A damaged terminal
Poor terminal tension
A chafed wire
A broken wire inside the insulation
Inspect OEM wiring harness routing, look for possible contact points where chafing could occur leading to an
open or short circuit condition. Moving parts on the vehicle could be contacting the harness; this includes
parking brake drum, suspension components, etc.
When diagnosing for an intermittent short or open, massage the wiring harness while watching the test
equipment for a change.
Test Description
This DTC requires the use of the J 47275 TCM Breakout and J 47279 Transmission Breakout. The numbers below
refer to step numbers on the diagnostic table.
2. Tests for the proper ignition voltage.
3. Tests for an active DTC.
4. Tests for wire-to-wire shorts between wire 136 and other wires in the OEM chassis harness.
6. Tests for the wire-to-wire shorts in the transmission internal harness.
6412
3000 AND 4000 PRODUCT FAMILIES TROUBLESHOOTING MANUALALLISON 4th GENERATION CONTROLS
Action
Value(s)
Yes
No
Go to Step 2
Go to Section 35,
Beginning the
Troubleshooting
Process
1. Install the Allison DOC For PCService Tool. 918V (12V TCM)
1832V (24V TCM)
2. Start the engine.
3. Record the failure records.
4. Monitor ignition voltage.
Is the voltage within the specified values?
Go to Step 3
Resolve voltage
problem.
Go to Step 4
Go to
Diagnostic Aids
Go to Step 5
Go to Step 6
Go to Step 11
Go to Step 5
6413
3000 AND 4000 PRODUCT FAMILIES TROUBLESHOOTING MANUALALLISON 4th GENERATION CONTROLS
Action
Value(s)
Yes
No
Go to Step 7
Go to Step 10
Go to Step 8
Go to Step 9
Go to Step 11
Go to Step 8
Go to Step 11
Go to Step 9
Go to Step 11
Go to Step 10
Begin the
diagnosis again.
System OK
Refer to Solenoid
Resistance Chart
(Appendix K)
Replace PCS1.
Is the replacement complete?
10
11
6414
Go to Step 1
3000 AND 4000 PRODUCT FAMILIES TROUBLESHOOTING MANUALALLISON 4th GENERATION CONTROLS
END VIEW OF
80-WAY CONNECTOR
10
11
14
15
20
61
80
41
60
21
40
20
TRANSMISSION
HSD3
TCC
SS2
TCM
11
12
17
WIRE 131
WIRE 137
WIRE 119
(7-SPEED MODELS)
31
HSD3
V BATTERY
37
19
15
RTDR ACCUM
HSD3
SS2
B
A
WIRE 131
WIRE 119
RTDR OR
DIFF LOCK (T-CASE)
HSD3
PCS5
B
A
WIRE 131
WIRE 115
V09068.00.00
Circuit Description
Pressure Control Solenoid 5 (PCS5) is a normally closed solenoid used to apply the retarder solenoid (retarder
units) or differential lock solenoid (3000 7-speed only). The TCM commands the solenoid ON to produce
hydraulic pressure in the control circuit. When PCS5 is commanded OFF, the control circuit is deactivated.
The TCM sends control current to PCS5 from High Side Driver 3 (HSD3) via wire 131. HSD3 is continuously ON
unless the TCM detects a fault condition. The Transmission Control Module (TCM) regulates the amount of
current to PCS5 by switching PCS5 Low Side Driver (LSD) ON and OFF. Wire 115 completes the circuit between
PCS5 and its LSD. DTC P2736 indicates that the TCM has detected an open condition in PCS5 electrical circuit.
The open condition may exist in the high side (wire 131) or low side (wire 115).
Copyright 2008 Allison Transmission, Inc.
6415
3000 AND 4000 PRODUCT FAMILIES TROUBLESHOOTING MANUALALLISON 4th GENERATION CONTROLS
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).
TCM initialization is in process or engine speed is greater than 200 rpm and less than 7500 rpm for 5 seconds.
DTC P2736 indicates an open in the electrical circuit for PCS5. In addition to PCS5, HSD3 also supplies
power to solenoids torque converter clutch (TCC) and SS2. If DTC P2736 is accompanied by DTC P0975 and
P2761, the open is most likely in the high side of the circuit.
You may have to drive the vehicle in order to experience a fault. Use the data obtained from failure records to
determine transmission range and/or certain vehicle operating variables such as temperature, run time etc. This
data can be useful in reproducing the failure mode when DTC was set.
Inspect the wiring for poor electrical connections at the TCM and transmission connector. Look for the
following conditions:
A bent terminal
A backed-out terminal
A damaged terminal
Poor terminal tension
A chafed wire
A broken wire inside the insulation
Inspect OEM wiring harness routing, look for possible contact points where chafing could occur leading to an
open or short circuit condition. Moving parts on the vehicle could be contacting the harness; this includes
parking brake drum, suspension components, etc.
When diagnosing for an intermittent short or open, massage the wiring harness while watching the test
equipment for a change.
6416
3000 AND 4000 PRODUCT FAMILIES TROUBLESHOOTING MANUALALLISON 4th GENERATION CONTROLS
Action
Value(s)
Yes
No
Go to Step 2
Go to Section 35,
Beginning the
Troubleshooting
Process
1. Install the Allison DOC For PCService Tool. 918V (12V TCM)
1832V (24V TCM)
2. Start the engine.
3. Record the failure records.
4. Monitor ignition voltage.
Is the voltage within the specified values?
Go to Step 3
Resolve voltage
problem
Go to Step 4
Go to
Diagnostic Aids
6417
3000 AND 4000 PRODUCT FAMILIES TROUBLESHOOTING MANUALALLISON 4th GENERATION CONTROLS
Action
Value(s)
6418
Yes
No
Go to Step 5
Go to Step 6
3000 AND 4000 PRODUCT FAMILIES TROUBLESHOOTING MANUALALLISON 4th GENERATION CONTROLS
Action
Value(s)
Yes
No
Go to Step 9
Go to Step 5
Go to Step 8
Go to Step 7
Refer to Solenoid
Resistance Chart
(Appendix K)
Go to Step 9
Go to Step 7
Go to Step 9
Go to Step 8
Begin the
diagnosis again.
System OK
Go to Step 1
6419
3000 AND 4000 PRODUCT FAMILIES TROUBLESHOOTING MANUALALLISON 4th GENERATION CONTROLS
END VIEW OF
20-WAY CONNECTOR
END VIEW OF
80-WAY CONNECTOR
10
11
14
15
20
61
80
41
60
21
40
20
TRANSMISSION
HSD3
TCC
SS2
TCM
11
12
17
WIRE 131
WIRE 137
WIRE 119
(7-SPEED MODELS)
31
HSD3
V BATTERY
37
19
15
RTDR ACCUM
HSD3
SS2
B
A
WIRE 131
WIRE 119
RTDR OR
DIFF LOCK (T-CASE)
HSD3
PCS5
B
A
WIRE 131
WIRE 115
V09068.00.00
Circuit Description
Pressure Control Solenoid 5 (PCS5) is a normally closed solenoid used to apply the retarder solenoid (retarder
units) or differential lock solenoid (3000 7-speed only). The TCM commands the solenoid ON to produce hydraulic
pressure in the control circuit. When PCS5 is commanded OFF, the control circuit is deactivated.
The TCM sends control current to PCS5 from High Side Driver 3 (HSD3) via wire 131. HSD3 is continuously ON
unless the TCM detects a fault condition. The Transmission Control Module (TCM) regulates the amount of
current to PCS5 by switching PCS5 Low Side Driver (LSD) ON and OFF. Wire 115 completes the circuit between
PCS5 and its LSD. DTC P2738 indicates that the TCM has detected a short-to-ground condition in the low side of
PCS5 electrical circuit.
6420
3000 AND 4000 PRODUCT FAMILIES TROUBLESHOOTING MANUALALLISON 4th GENERATION CONTROLS
TCM initialization is in process or engine speed is greater than 200 rpm and less than 7500 rpm for 5 seconds.
The TCM allows operation in second through sixth range, and in Neutral and Reverse.
Inspect OEM wiring harness routing, look for possible contact points where chafing could occur leading to an
open or short circuit condition. Moving parts on the vehicle could be contacting the harness; this includes
parking brake drum, suspension components, etc.
When diagnosing for an intermittent short or open, massage the wiring harness while watching the test
equipment for a change.
6421
3000 AND 4000 PRODUCT FAMILIES TROUBLESHOOTING MANUALALLISON 4th GENERATION CONTROLS
Action
Value(s)
Yes
No
Go to Step 2
Go to Section 35,
Beginning the
Troubleshooting
Process
1. Install the Allison DOC For PCService Tool. 918V (12V TCM)
1832V (24V TCM)
2. Start the engine.
3. Record the failure records.
4. Monitor ignition voltage.
Is the voltage within the specified values?
Go to Step 3
Resolve voltage
problem
Go to Step 4
Go to
Diagnostic Aids
6422
3000 AND 4000 PRODUCT FAMILIES TROUBLESHOOTING MANUALALLISON 4th GENERATION CONTROLS
Action
Value(s)
Yes
No
Go to Step 5
Go to Step 6
Go to Step 9
Go to Step 5
Go to Step 7
Go to Step 8
Go to Step 9
Go to Step 7
Go to Step 9
Go to Step 8
Begin the
diagnosis again.
System OK
Go to Step 1
6423
3000 AND 4000 PRODUCT FAMILIES TROUBLESHOOTING MANUALALLISON 4th GENERATION CONTROLS
END VIEW OF
80-WAY CONNECTOR
10
11
14
15
20
61
80
41
60
21
40
20
TRANSMISSION
HSD3
TCC
SS2
TCM
11
12
17
WIRE 131
WIRE 137
WIRE 119
(7-SPEED MODELS)
31
HSD3
V BATTERY
37
19
15
RTDR ACCUM
HSD3
SS2
B
A
WIRE 131
WIRE 119
RTDR OR
DIFF LOCK (T-CASE)
HSD3
PCS5
B
A
WIRE 131
WIRE 115
V09068.00.00
Circuit Description
Pressure Control Solenoid 5 (PCS5) is a normally closed solenoid used to apply the retarder solenoid (retarder
units) or differential lock solenoid (3000 7-speed only). The TCM commands the solenoid ON to produce
hydraulic pressure in the control circuit. When PCS5 is commanded OFF, the control circuit is deactivated.
The TCM sends control current to PCS5 from High Side Driver 3 (HSD3) via wire 131. HSD3 is continuously ON
unless the TCM detects a fault condition. The Transmission Control Module (TCM) regulates the amount of
current to PCS5 by switching PCS5 Low Side Driver (LSD) ON and OFF. Wire 115 completes the circuit between
PCS5 and its LSD. DTC P2739 indicates that the TCM has detected a short-to-battery condition in the low side of
PCS5 electrical circuit.
6424
3000 AND 4000 PRODUCT FAMILIES TROUBLESHOOTING MANUALALLISON 4th GENERATION CONTROLS
TCM initialization is in process or engine speed is greater than 200 rpm and less than 7500 rpm for 5 seconds.
You may have to drive the vehicle in order to experience a fault. Use the data obtained from failure records to
determine transmission range and/or certain vehicle operating variables such as temperature, run time etc. This
data can be useful in reproducing the failure mode when DTC was set.
Inspect the wiring for poor electrical connections at the TCM and transmission connector. Look for the
following conditions:
A bent terminal
A backed-out terminal
A damaged terminal
Poor terminal tension
A chafed wire
A broken wire inside the insulation
Inspect OEM wiring harness routing, look for possible contact points where chafing could occur leading to an
open or short circuit condition. Moving parts on the vehicle could be contacting the harness; this includes
parking brake drum, suspension components, etc.
When diagnosing for an intermittent short or open, massage the wiring harness while watching the test
equipment for a change.
6425
3000 AND 4000 PRODUCT FAMILIES TROUBLESHOOTING MANUALALLISON 4th GENERATION CONTROLS
Yes
No
Action
Value(s)
Go to Step 2
Go to Section 35,
Beginning the
Troubleshooting
Process
1. Install the Allison DOC For PCService Tool. 918V (12V TCM)
1832V (24V TCM)
2. Start the engine.
3. Record the failure records.
4. Monitor ignition voltage.
Is the voltage within the specified values?
Go to Step 3
Resolve voltage
problem
Go to Step 4
Go to
Diagnostic Aids
Go to Step 5
Go to Step 6
6426
3000 AND 4000 PRODUCT FAMILIES TROUBLESHOOTING MANUALALLISON 4th GENERATION CONTROLS
Action
Value(s)
Yes
No
Go to Step 9
Go to Step 5
Go to Step 8
Go to Step 7
Refer to Solenoid
Resistance Chart
(Appendix K)
Go to Step 9
Go to Step 7
Go to Step 9
Go to Step 8
Begin the
diagnosis again.
System OK
Go to Step 1
6427
3000 AND 4000 PRODUCT FAMILIES TROUBLESHOOTING MANUALALLISON 4th GENERATION CONTROLS
Use the Allison DOC For PCService 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.
The TCM cancels the DTC default actions when the fault no longer exists and the DTC passes test.
Diagnostic Aids
The Allison DOC For PCService Tool retarder oil temperature should rise steadily during retarder
operation and drop to near sump temp when the retarder is deactivated.
A stuck autoflow valve can cause overheating in retarder-equipped transmissions. Refer to Section 8 for
general troubleshooting of performance complaints.
6428
3000 AND 4000 PRODUCT FAMILIES TROUBLESHOOTING MANUALALLISON 4th GENERATION CONTROLS
Yes
No
Action
Value(s)
Go to Step 2
Go to Section 35,
Beginning the
Troubleshooting
Process
Go to Step 3
Go to Step 4
Go to
Diagnostic Aids
Go to Step 10
Go to Step 5
6429
3000 AND 4000 PRODUCT FAMILIES TROUBLESHOOTING MANUALALLISON 4th GENERATION CONTROLS
Action
Value(s)
Yes
No
Refer to
Appendix Q
Go to Step 9
Go to Step 6
Refer to
Appendix Q
Go to Step 7
Go to Step 8
Go to Step 14
Go to Step 7
Go to Step 14
Go to Step 8
Go to Step 14
Go to Step 9
6430
3000 AND 4000 PRODUCT FAMILIES TROUBLESHOOTING MANUALALLISON 4th GENERATION CONTROLS
Action
Value(s)
10
11
Refer to
1. Install pressure gauges in the TO and FROM
cooler lines.
Table 618 or 619
2. Start the engine.
3. Subtract the from cooler pressure from the to
cooler pressure to obtain pressure drop across the
transmission oil cooler.
4. Verify cooler pressure drop satisfies limits of
Table 616 (4000 Product Family) or Table 617
(3000 Product Family).
Is cooler pressure drop within specified values?
12
Yes
No
Go to Step 14
Go to Step 11
Go to
Diagnostic Aids
Go to Step 12
Go to Step 13
Go to
Diagnostic Aids
Go to Step 14
Go to
Diagnostic Aids
Begin the
diagnosis again.
System OK
14
Go to Step 1
6431
3000 AND 4000 PRODUCT FAMILIES TROUBLESHOOTING MANUALALLISON 4th GENERATION CONTROLS
Pressure Drop
Input rpm
L/s
GPM
kPa
psi
600
0.22
3.4
900
0.38
6.1
1200
0.55
8.7
1500
0.80
12.7
1800
1.03
16.4
2100
1.13
18.0
2300
1.20
19.0
CONVERTER OPERATION
COOLER FLOW AT MAXIMUM ALLOWABLE PRESSURE DROP
600
0.20
3.2
31.0
4.5
900
0.37
5.8
63.0
9.1
1200
0.55
8.7
108.0
15.7
1500
0.77
12.2
167.0
24.2
1800
0.92
14.5
231.0
33.5
2100
0.97
15.3
238.0
34.5
2300
1.00
15.9
250.0
36.3
6432
Pressure Drop
Input rpm
L/s
GPM
kPa
psi
600
0.10
1.6
800
0.23
3.7
1200
0.47
7.4
1400
0.61
9.7
1600
0.74
11.7
2000
0.94
14.9
3000 AND 4000 PRODUCT FAMILIES TROUBLESHOOTING MANUALALLISON 4th GENERATION CONTROLS
1.19
18.9
3200
1.28
20.3
CONVERTER OPERATION
MAXIMUM ALLOWABLE PRESSURE DROP
Flow
Pressure Drop
Input rpm
L/s
GPM
kPa
psi
600
0.10
1.6
10.0
1.5
800
0.23
3.5
40.0
5.8
1200
0.45
7.1
159.0
23.1
1400
0.57
9.0
252.0
36.6
1600
0.67
10.6
338.0
49.0
2000
0.80
12.7
481.0
69.8
2400
0.85
13.5
549.0
79.6
3200
0.85
13.5
549.0
79.6
LOCKUP OPERATION
MAXIMUM COOLER FLOW AT MINIMUM PRESSURE DROP
600
0.10
1.6
800
0.23
3.7
1200
0.50
7.9
1400
0.63
10.0
1600
0.77
12.2
2000
0.95
15.1
2400
1.12
17.8
2800
1.22
19.3
3200
1.28
20.3
LOCKUP OPERATION
MAXIMUM ALLOWABLE PRESSURE DROP
600
0.10
1.6
5.0
0.7
800
0.23
3.7
46.0
6.7
1200
0.48
7.6
148.0
21.5
1400
0.62
9.8
247.0
35.8
1600
0.73
11.6
346.0
50.2
2000
0.90
14.3
561.0
81.4
2400
1.07
17.0
737.0
106.9
2800
1.10
17.4
770.0
111.7
3200
1.10
17.4
791.0
114.7
6433
3000 AND 4000 PRODUCT FAMILIES TROUBLESHOOTING MANUALALLISON 4th GENERATION CONTROLS
END VIEW OF
80-WAY CONNECTOR
10
11
14
15
20
61
80
41
60
21
40
20
TO RETARDER
CONTROL DEVICES
RETARDER
REQUEST SENSOR
(RESISTANCE
MODULE)
A
PWM
THROTTLE
SOURCE
TCM
THROTTLE
POSITION
SENSOR (TPS)
OR
ELECTRONIC
BRAKING (EBS)
RTDR PRESSURE
SENSOR
WIRE 156
WIRE 112
WIRE 144
WIRE 158
A
RETARDER TEMP
ENGINE TEMP
TRANSMISSION
ANALOG RETURN
OIL LEVEL
HALL
A
C
EFFECT
B
SUMP TEMP
19
16
15
18
PS1
PS2 NC*
NC*
3
17
WIRE 175
WIRE 135
56
12
5V SENSOR VOLTAGE
44
THROTTLE POSITION OR
RTDR PRESSURE SIGNAL
58
ANALOG RETURN
75
RETARDER TEMP
35
16
54
SUMP TEMP
77
WIRE 158
WIRE 112
WIRE 116
WIRE 154
WIRE 177
WIRE 118
18
* NORMALLY CLOSED
V11114.00.00
6434
3000 AND 4000 PRODUCT FAMILIES TROUBLESHOOTING MANUALALLISON 4th GENERATION CONTROLS
The TCM is detecting voltage. An unusually low input voltage implies low thermistor resistance, which
corresponds to an illogically high retarder oil temperature measurement.
Inspect the wiring for poor electrical connections at the TCM and retarder temperature sensor. 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
Copyright 2008 Allison Transmission, Inc.
6435
3000 AND 4000 PRODUCT FAMILIES TROUBLESHOOTING MANUALALLISON 4th GENERATION CONTROLS
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 and operate the retarder in order to experience a fault.
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.
3.
4.
5.
6.
7.
Action
Value(s)
Yes
No
Go to Step 2
Go to Section 35,
Beginning the
Troubleshooting
Process
Go to Step 3
1.
2.
3.
4.
5.
6436
>178C (352F)
Go to Step 4
Go to
Diagnostic Aids
4.75 to 5.0V
Go to Step 6
Go to Step 5
3000 AND 4000 PRODUCT FAMILIES TROUBLESHOOTING MANUALALLISON 4th GENERATION CONTROLS
Action
Value(s)
Yes
No
Go to Step 8
Go to Step 10
Refer to
Appendix Q
Go to
Diagnostic Aids
Go to Step 7
Refer to
Appendix Q
Go to Step 8
Go to Step 9
Go to Step 11
Go to Step 8
Go to Step 11
Go to Step 9
Go to Step 11
Go to Step 10
Begin the
diagnosis again.
System OK
10
11
Go to Step 1
6437
3000 AND 4000 PRODUCT FAMILIES TROUBLESHOOTING MANUALALLISON 4th GENERATION CONTROLS
END VIEW OF
80-WAY CONNECTOR
10
11
14
15
20
61
80
41
60
21
40
20
TO RETARDER
CONTROL DEVICES
RETARDER
REQUEST SENSOR
(RESISTANCE
MODULE)
A
PWM
THROTTLE
SOURCE
TCM
THROTTLE
POSITION
SENSOR (TPS)
OR
ELECTRONIC
BRAKING (EBS)
RTDR PRESSURE
SENSOR
WIRE 156
WIRE 112
WIRE 144
WIRE 158
A
RETARDER TEMP
ENGINE TEMP
TRANSMISSION
ANALOG RETURN
OIL LEVEL
HALL
A
C
EFFECT
B
SUMP TEMP
19
16
15
18
PS1
PS2 NC*
NC*
3
17
WIRE 175
WIRE 135
56
12
5V SENSOR VOLTAGE
44
THROTTLE POSITION OR
RTDR PRESSURE SIGNAL
58
ANALOG RETURN
75
RETARDER TEMP
35
16
54
SUMP TEMP
77
WIRE 158
WIRE 112
WIRE 116
WIRE 154
WIRE 177
WIRE 118
18
* NORMALLY CLOSED
V11114.00.00
6438
3000 AND 4000 PRODUCT FAMILIES TROUBLESHOOTING MANUALALLISON 4th GENERATION CONTROLS
6439
3000 AND 4000 PRODUCT FAMILIES TROUBLESHOOTING MANUALALLISON 4th GENERATION CONTROLS
When diagnosing for an intermittent short or open, massage the wiring harness while watching the test
equipment for a change.
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 proper transmission fluid level.
3. This step verifies which condition has set the DTC P2743.
4. Tests for the proper 5V reference voltage at TCM.
5. Tests for wire-to-wire shorts, shorts-to-ground, or an open on wire 175.
6. Tests for proper system circuit resistance value.
7. Tests the resistance value of the retarder temp sensor.
Action
Value(s)
Yes
No
Go to Step 2
Go to Section 35,
Beginning the
Troubleshooting
Process
Go to Step 3
6440
<45 C (49 F)
Go to Step 4
Go to
Diagnostic Aids
3000 AND 4000 PRODUCT FAMILIES TROUBLESHOOTING MANUALALLISON 4th GENERATION CONTROLS
Action
Turn ignition OFF.
Install J 47275 TCM Breakout at the TCM.
Disconnect the retarder temp sensor connector.
Turn ignition ON.
At J 47275-1 TCM Overlay connect a DVOM
and select the volts-DC scale.
6. Measure voltage between pin 75 and an isolated
ground.
Is the voltage within the specified value?
Value(s)
Yes
No
4.75 to 5.0V
Go to Step 6
Go to Step 5
Go to Step 8
Go to Step 10
1.
2.
3.
4.
5.
Refer to
Appendix Q
Go to
Diagnostic Aids
Go to Step 7
Refer to
Appendix Q
Go to Step 8
Go to Step 9
Go to Step 11
Go to Step 8
Go to Step 11
Go to Step 9
Go to Step 11
Go to Step 10
10
6441
3000 AND 4000 PRODUCT FAMILIES TROUBLESHOOTING MANUALALLISON 4th GENERATION CONTROLS
Action
Value(s)
6442
Yes
No
Begin the
diagnosis again.
System OK
Go to Step 1
3000 AND 4000 PRODUCT FAMILIES TROUBLESHOOTING MANUALALLISON 4th GENERATION CONTROLS
END VIEW OF
80-WAY CONNECTOR
10
11
14
15
20
61
80
41
60
21
40
20
TRANSMISSION
HSD3
TCC
SS2
TCM
11
12
17
WIRE 131
WIRE 137
WIRE 119
(7-SPEED MODELS)
31
HSD3
V BATTERY
37
19
15
RTDR ACCUM
HSD3
SS2
B
A
WIRE 131
WIRE 119
RTDR OR
DIFF LOCK (T-CASE)
HSD3
PCS5
B
A
WIRE 131
WIRE 115
V09068.00.00
Circuit Description
Torque Converter Clutch Pressure Control Solenoid (TCC) is a normally closed solenoid used to apply the torque
converter clutch when specific engine and turbine speed conditions are met. The TCM commands the solenoid ON
to produce hydraulic pressure in the torque converter clutch apply circuit. When solenoid TCC is commanded OFF,
torque converter clutch pressure is released.
The TCM sends control current to solenoid TCC from High Side Driver 3 (HSD3) via wire 131. HSD3 is
continuously ON unless the TCM detects a fault condition. The Transmission Control Module (TCM) regulates the
amount of current to TCC by switching TCCs Low Side Driver (LSD) ON and OFF. Wire 137 completes the
circuit between TCC and its LSD. DTC P2761 indicates that the TCM has detected an open condition in solenoid
TCCs electrical circuit. The open condition may exist in the high side (wire 131) or low side (wire 137).
Copyright 2008 Allison Transmission, Inc.
6443
3000 AND 4000 PRODUCT FAMILIES TROUBLESHOOTING MANUALALLISON 4th GENERATION CONTROLS
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).
TCM initialization is in process or engine speed is greater than 200 rpm and less than 7500 rpm for 5 seconds.
DTC P2761 indicates an open in the electrical circuit for the TCC solenoid. In addition to TCC, HSD3 also
supplies power to PCS5 and SS2. If DTC P2761 is accompanied by DTCs P0975 and P2736, the open is most
likely in the high side of the circuit.
You may have to drive the vehicle in order to experience a fault. Use the data obtained from failure records to
determine transmission range and/or certain vehicle operating variables such as temperature, run time etc. This
data can be useful in reproducing the failure mode when DTC was set.
Inspect the wiring for poor electrical connections at the TCM and transmission connector. Look for the
following conditions:
A bent terminal
A backed-out terminal
A damaged terminal
Poor terminal tension
A chafed wire
A broken wire inside the insulation
Inspect OEM wiring harness routing, look for possible contact points where chafing could occur leading to an
open or short circuit condition. Moving parts on the vehicle could be contacting the harness; this includes
parking brake drum, suspension components, etc.
When diagnosing for an intermittent short or open, massage the wiring harness while watching the test
equipment for a change.
6444
3000 AND 4000 PRODUCT FAMILIES TROUBLESHOOTING MANUALALLISON 4th GENERATION CONTROLS
Yes
No
Action
Value(s)
Go to Step 2
Go to Section 35,
Beginning the
Troubleshooting
Process
1. Install the Allison DOC For PCService Tool. 918V (12V TCM)
1832V (24V TCM)
2. Start the engine.
3. Record the failure records.
4. Monitor ignition voltage.
Is the voltage within the specified values?
Go to Step 3
Resolve voltage
problem
Go to Step 4
Go to
Diagnostic Aids
6445
3000 AND 4000 PRODUCT FAMILIES TROUBLESHOOTING MANUALALLISON 4th GENERATION CONTROLS
Action
Value(s)
Yes
No
Go to Step 5
Go to Step 6
Go to Step 11
Go to Step 5
Go to Step 10
Go to Step 7
6446
Refer to Solenoid
Resistance Chart
(Appendix K)
3000 AND 4000 PRODUCT FAMILIES TROUBLESHOOTING MANUALALLISON 4th GENERATION CONTROLS
Action
Value(s)
Yes
No
Refer to Solenoid
Resistance Chart
(Appendix K)
Go to Step 8
Go to Step 9
Go to Step 11
Go to Step 8
Go to Step 11
Go to Step 9
Go to Step 11
Go to Step 10
Begin the
diagnosis again.
System OK
10
11
Go to Step 1
6447
3000 AND 4000 PRODUCT FAMILIES TROUBLESHOOTING MANUALALLISON 4th GENERATION CONTROLS
END VIEW OF
80-WAY CONNECTOR
10
11
14
15
20
61
80
41
60
21
40
20
TRANSMISSION
HSD3
TCC
SS2
TCM
11
12
17
WIRE 131
WIRE 137
WIRE 119
(7-SPEED MODELS)
31
HSD3
V BATTERY
37
19
15
RTDR ACCUM
HSD3
SS2
B
A
WIRE 131
WIRE 119
RTDR OR
DIFF LOCK (T-CASE)
HSD3
PCS5
B
A
WIRE 131
WIRE 115
V09068.00.00
Circuit Description
Torque Converter Clutch Pressure Control Solenoid (TCC) is a normally closed solenoid used to apply the torque
converter clutch when specific engine and turbine speed conditions are met. The TCM commands the solenoid ON
to produce hydraulic pressure in the torque converter clutch apply circuit. When solenoid TCC is commanded OFF,
torque converter clutch pressure is released.
The TCM sends control current to solenoid TCC from High Side Driver 3 (HSD3) via wire 131. HSD3 is
continuously ON unless the TCM detects a fault condition. The Transmission Control Module (TCM) regulates the
amount of current to TCC by switching TCCs Low Side Driver (LSD) ON and OFF. Wire 137 completes the
circuit between TCC and its LSD. DTC P2763 indicates that the TCM has detected a short-to-battery condition in
the low side of solenoid TCCs electrical circuit.
6448
3000 AND 4000 PRODUCT FAMILIES TROUBLESHOOTING MANUALALLISON 4th GENERATION CONTROLS
TCM initialization is in process or engine speed is greater than 200 rpm and less than 7500 rpm for 5 seconds.
You may have to drive the vehicle in order to experience a fault. Use the data obtained from failure records to
determine transmission range and/or certain vehicle operating variables such as temperature, run time etc. This
data can be useful in reproducing the failure mode when DTC was set.
Inspect the wiring for poor electrical connections at the TCM and transmission connector. Look for the
following conditions:
A bent terminal
A backed-out terminal
A damaged terminal
Poor terminal tension
A chafed wire
A broken wire inside the insulation
Inspect OEM wiring harness routing, look for possible contact points where chafing could occur leading to an
open or short circuit condition. Moving parts on the vehicle could be contacting the harness; this includes
parking brake drum, suspension components, etc.
When diagnosing for an intermittent short or open, massage the wiring harness while watching the test
equipment for a change.
6449
3000 AND 4000 PRODUCT FAMILIES TROUBLESHOOTING MANUALALLISON 4th GENERATION CONTROLS
Yes
No
Action
Value(s)
Go to Step 2
Go to Section 35,
Beginning the
Troubleshooting
Process
1. Install the Allison DOC For PCService Tool. 918V (12V TCM)
1832V (24V TCM)
2. Start the engine.
3. Record the failure records.
4. Monitor ignition voltage.
Is the voltage within the specified values?
Go to Step 3
Resolve voltage
problem
Go to Step 4
Go to
Diagnostic Aids
6450
3000 AND 4000 PRODUCT FAMILIES TROUBLESHOOTING MANUALALLISON 4th GENERATION CONTROLS
Action
Value(s)
Yes
No
Go to Step 5
Go to Step 6
Go to Step 11
Go to Step 5
Go to Step 7
Go to Step 10
Go to Step 8
Go to Step 9
Go to Step 11
Go to Step 8
Go to Step 11
Go to Step 9
6451
3000 AND 4000 PRODUCT FAMILIES TROUBLESHOOTING MANUALALLISON 4th GENERATION CONTROLS
Action
Value(s)
10
Yes
No
Go to Step 11
Go to Step 10
Begin the
diagnosis again.
System OK
6452
Go to Step 1
3000 AND 4000 PRODUCT FAMILIES TROUBLESHOOTING MANUALALLISON 4th GENERATION CONTROLS
END VIEW OF
80-WAY CONNECTOR
10
11
14
15
20
61
80
41
60
21
40
20
TRANSMISSION
HSD3
TCC
SS2
TCM
11
12
17
WIRE 131
WIRE 137
WIRE 119
(7-SPEED MODELS)
31
HSD3
V BATTERY
37
19
15
RTDR ACCUM
HSD3
SS2
B
A
WIRE 131
WIRE 119
RTDR OR
DIFF LOCK (T-CASE)
HSD3
PCS5
B
A
WIRE 131
WIRE 115
V09068.00.00
Circuit Description
Torque Converter Clutch Pressure Control Solenoid (TCC) is a normally closed solenoid used to apply the torque
converter clutch when specific engine and turbine speed conditions are met. The TCM commands the solenoid ON
to produce hydraulic pressure in the torque converter clutch apply circuit. When solenoid TCC is commanded OFF,
torque converter clutch pressure is released.
The TCM sends control current to solenoid TCC from High Side Driver 3 (HSD3) via wire 131. HSD3 is
continuously ON unless the TCM detects a fault condition. The Transmission Control Module (TCM) regulates the
amount of current to TCC by switching TCCs Low Side Driver (LSD) ON and OFF. Wire 137 completes the
circuit between TCC and its LSD. DTC P2764 indicates that the TCM has detected a short-to-ground condition in
the low side of solenoid TCCs electrical circuit.
Copyright 2008 Allison Transmission, Inc.
6453
3000 AND 4000 PRODUCT FAMILIES TROUBLESHOOTING MANUALALLISON 4th GENERATION CONTROLS
TCM initialization is in process or engine speed is greater than 200 rpm and less than 7500 rpm for 5 seconds.
You may have to drive the vehicle in order to experience a fault. Use the data obtained from failure records to
determine transmission range and/or certain vehicle operating variables such as temperature, run time etc. This
data can be useful in reproducing the failure mode when DTC was set.
Inspect the wiring for poor electrical connections at the TCM and transmission connector. Look for the
following conditions:
A bent terminal
A backed-out terminal
A damaged terminal
Poor terminal tension
A chafed wire
A broken wire inside the insulation
Inspect OEM wiring harness routing, look for possible contact points where chafing could occur leading to an
open or short circuit condition. Moving parts on the vehicle could be contacting the harness; this includes
parking brake drum, suspension components, etc.
When diagnosing for an intermittent short or open, massage the wiring harness while watching the test
equipment for a change.
6454
3000 AND 4000 PRODUCT FAMILIES TROUBLESHOOTING MANUALALLISON 4th GENERATION CONTROLS
Action
Value(s)
Yes
No
Go to Step 2
Go to Section 35,
Beginning the
Troubleshooting
Process
1. Install the Allison DOC For PCService Tool. 918V (12V TCM)
1832V (24V TCM)
2. Start the engine.
3. Record the failure records.
4. Monitor ignition voltage.
Is the voltage within the specified values?
Go to Step 3
Resolve voltage
problem
Go to Step 4
Go to
Diagnostic Aids
6455
3000 AND 4000 PRODUCT FAMILIES TROUBLESHOOTING MANUALALLISON 4th GENERATION CONTROLS
Action
Value(s)
Yes
No
Go to Step 5
Go to Step 6
Go to Step 11
Go to Step 5
Go to Step 7
Go to Step 10
Go to Step 8
Go to Step 9
Go to Step 11
Go to Step 8
Refer to Solenoid
Resistance Chart
(Appendix K)
6456
3000 AND 4000 PRODUCT FAMILIES TROUBLESHOOTING MANUALALLISON 4th GENERATION CONTROLS
Action
Value(s)
Yes
No
Go to Step 11
Go to Step 9
Go to Step 11
Go to Step 10
Begin the
diagnosis again.
System OK
11
Go to Step 1
6457
3000 AND 4000 PRODUCT FAMILIES TROUBLESHOOTING MANUALALLISON 4th GENERATION CONTROLS
This DTC goes inactive when percent clutch life remaining is predicted to be more than approximately 20%.
Use the Allison DOC For PCService Tool to Reset Transmission Health Indicator by specific clutch(es)
through the Action Request screen. The DTC may also be cleared from TCM history using Allison DOC For
PCService Tool.
Diagnostic Aids
Ask the OEM for support in troubleshooting and repairing all non-Allison TRANS SERVICE indicator issues,
such as OEM selectors or dash lamps that remain illuminated due to chassis wiring issues but Allison DOC
For PCService Tool indicates clutches are OK.
6458
3000 AND 4000 PRODUCT FAMILIES TROUBLESHOOTING MANUALALLISON 4th GENERATION CONTROLS
Low oil level can cause adaptive learning at limit notification. Always verify oil level is correct before
removing any filters for inspection, removing the control module for inspection, or removing the transmission
from the vehicle.
Inspect for signs of clutch wear by looking for signs of excessive debris plugging the main filter or suction
filter in the control module before removing the transmission for service. Check the following if no clutch
debris is noted in the main filter or suction filter:
Speed signal issues can cause adaptive learning at limit notification. Check speed signal integrity
especially if other DTC(s) are in history.
Solenoid issues can cause adaptive learning at limit notification. Check for solenoid issues especially if
there are solenoid or ratio DTC(s) in history.
Low main pressure or control main pressure. Always check pressures to verify they are within service
limits. Check that the Filter Life Indicator is not active also indicating that filter restriction has reduced
main pressure.
TCM issues can cause adaptive learning at limit notification. Check for full TCM functionality especially
if other DTC(s) are in history to indicate a possible TCM issue.
When transmission clutches are replaced, reset the TCM to unadapted shifts. The TM function may also be
reset at this time using Allison DOC For PCService Tool in action requests instead of waiting on the
function to recalculate its values and reset itself.
NOTE: OEM vehicle harness repairs are not covered under Allison Transmission warranty.
NOTE: OEM repairs necessary for transmission DTCs to go inactive are not covered under Allison
Transmission warranty.
The following wiring and connector issues can cause transmission DTCs:
Expanded female terminals in a connector. Use a mating pin or terminal to check for a light drag feel when
the mating terminal or pin is inserted and slowly removed. There should be some slight friction between
the matching terminal and pin combination. Expanded terminals have no feel of drag when the matching
pin or terminal is inserted and removed.
Broken terminal locks allow the pins or terminals to push back into the connector resulting in poor
connection or pin to pin shorts in the connector. Inspect for broken locks and displaced terminals in
connections. Never use paper clips or other devices to back probe a connector while doing Allison service
work.
Poor pin crimps. Pin crimps should be pull-tested by the technician to verify the crimp is secure to the wire.
If the pin crimp is loose, the pin easily moves or even comes off the wire with a slight tug on the terminal
by the technician. This situation may not reveal itself as an active DTC but instead may exhibit other
symptoms like shift quality issues.
Connector and pin corrosion caused by moisture in connectors. Empty wire locations in connectors must
always have a plug to keep moisture from finding a path into the connector.
Poor harness routing and improper strain relief may cause damage resulting in electrical open and/or short
circuits to wires and connector components.
Butt splices and wire ties are not an ideal solution for any transmission repair. If butt splices will be used,
then always use heat-shrinkable butt splices. Never use wire ties inside the transmission, to hold connector
components together in the place of a connector lock, or in the place of the correct strain relief components
and clips used to fasten harnesses to the vehicle or to retain vehicle connectors unless OEM approved for
the location and vehicle component being repaired.
The following procedures are not documented in any Allison service procedures or in any Allison
Troubleshooting Manual or Service Manual and therefore should not be used as a method to diagnose any
transmission DTC(s), function, or shift quality concern:
Copyright 2008 Allison Transmission, Inc.
6459
3000 AND 4000 PRODUCT FAMILIES TROUBLESHOOTING MANUALALLISON 4th GENERATION CONTROLS
terminals from the back-probed connector creating permanent or intermittent shorts and/or open circuits. If
possible, use the Breakout Box J 39700, appropriate harness adapters, and appropriate magnetic overlays
to troubleshoot the vehicle.
Load-testing any transmission-related circuits with any other electrical devices such as vehicle lamps or
relays, especially with the TCM connected to the harness. Use Breakout Box J 39700 and appropriate
harnesses with Allison DOC For PCService Tool to monitor the circuit performance in question unless
otherwise specified in the various Troubleshooting Manuals to use a digital volt-Ohm meter (DVOM) with
the Breakout.
Piercing a wire to check for voltages, shorts-to-grounds or other wires anywhere in the circuit but
especially at the TCM. This creates a leak path for moisture and damages the wire and insulation.
If needed, call for local distributor and/or factory support before downtime and expense of repair effect the
Allison Customer Experience. The phone number for the Technical Assistance Center in the United States is 1800-252-5283
Always use tools that are in good condition. Refer to the Allison Essential Tools list on the Allison Extranet to
complete any service procedure listed in an Allison publication. Also see appropriate Service Manuals and
Troubleshooting Manuals for service tools information.
Test Description
1. Review general troubleshooting procedures and DTC service tips.
2. Confirm DTC active.
3. Confirm the status of the clutch life using Allison DOC for PCService Tool.
4. Check for visual signs of clutch wear.
5. Confirm clutch system was repaired.
6. Perform resets.
7. Check for inactive DTC.
8. Check for selector issue.
9. Check for inactive DTC.
10. Check Diagnostic Aids section of this DTC.
11. Check for inactive DTC
Step
Action
Yes
No
Go to Step 2
2
6460
Go to Step 3
Copyright 2008 Allison Transmission, Inc.
Go to Step 7
3000 AND 4000 PRODUCT FAMILIES TROUBLESHOOTING MANUALALLISON 4th GENERATION CONTROLS
Action
Possible
Value(s)
Yes
No
OK / Not OK
Go to Step 4
Go to Step 7
Go to Step 5
Go to Step 10
Go to Step 6
Go to Step 5
Go to Step 7
Go to Step 6
Go to Step 11
Go to Step 1
Replace the
Allison selector
Go to Step 11
5
6
Go to Step 9
Go to Step 11
Go to Step 8
6461
3000 AND 4000 PRODUCT FAMILIES TROUBLESHOOTING MANUALALLISON 4th GENERATION CONTROLS
Step
Action
10
Yes
No
Go to Step 11
Go to Diagnostic Aids
Go to Step 1
System OK
Repair complete
6462
3000 AND 4000 PRODUCT FAMILIES TROUBLESHOOTING MANUALALLISON 4th GENERATION CONTROLS
80
41
60
21
40
20
CLOSED THROTTLE
THROTTLE
PEDAL
OPTIONAL
CUSTOMER
FURNISHED
VEHICLE
INTERFACE
WIRING
CONNECTOR
TCM
22
3
FULL THROTTLE
ECONOMY
SHIFT POINTS
ENGINE
OPERATING
RANGE
FULL THROTTLE
KICKDOWN
SHIFT POINTS PEDAL MOVEMENT BEYOND
THIS POINT MUST NOT
CHANGE ENGINE FUEL
MOMENTARY
SETTING OR TRANSMISSION
SWITCH
THROTTLE POSITION
V09142.00.00
Circuit Description
The Transmission Control Module (TCM) can be calibrated to receive an acceleration pedal kickdown input from
either an analog input wire or the digital data link. When the operator activates the kickdown feature in the
Economy Mode, the TCM uses Performance shift points. A momentary, normally open switch attached to the
throttle pedal typically generates the kickdown input signal. The switch provides a detente feel when full-throttle is
achieved. When the operator steps through the detente, the kickdown function is activated.
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 750 rpm for 5 seconds.
Conditions for Setting the DTC
DTC P278A sets if the TCM is calibrated to receive the kickdown input signal and both of the following conditions
are met:
6463
3000 AND 4000 PRODUCT FAMILIES TROUBLESHOOTING MANUALALLISON 4th GENERATION CONTROLS
DTC P278A indicates the TCM has detected a kickdown input signal for more than 5 seconds with less than
full throttle conditions. The code can be caused by:
Faulty wiring
Faulty connections to the accelerator pedal kickdown switch
A faulty accelerator pedal kickdown switch
Another controller improperly broadcasting kickdown signal on the data link when throttle conditions are
not met
A faulty TCM.
Inspect the wiring for poor electrical connections at the TCM and kickdown input switch. 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
J1939 Kickdown status can be read on Allison DOC For PCService Tool. Monitor data link
communications using Data Bus Viewer.
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.
4. Tests for status of analog input wire 122.
5. This step determines if kickdown function activated by a data link message.
6. Tests for shorts-to-ground in wire 122.
7. Tests for proper kickdown switch function.
9. Monitors received messages on the digital data link.
6464
3000 AND 4000 PRODUCT FAMILIES TROUBLESHOOTING MANUALALLISON 4th GENERATION CONTROLS
Action
Value(s)
Yes
No
Go to Step 2
Go to Section 35,
Beginning the
Troubleshooting
Process
1.
2.
3.
4.
Go to Step 3
Go to
Diagnostic Aids
Go to Step 4
Go to Step 9
Go to Step 5
Go to Step 6
Go to Step 9
Go to
Diagnostic Aids
Go to Step 8
Go to Step 7
Go to Step 9
Go to Step 8
6465
3000 AND 4000 PRODUCT FAMILIES TROUBLESHOOTING MANUALALLISON 4th GENERATION CONTROLS
Action
Value(s)
Yes
No
Go to Step 11
Go to Step 8
Go to
Diagnostic Aids
Go to Step 10
10
Go to Step 11
Go to Step 10
Begin the
diagnosis again.
System OK
6466
Go to Step 1
3000 AND 4000 PRODUCT FAMILIES TROUBLESHOOTING MANUALALLISON 4th GENERATION CONTROLS
80
41
60
21
40
20
3
13
12
8
ALLISON
4th GENERATION
CONTROLS
J1939 BASED
SHIFT SELECTOR
15
14
DIMMER INPUT
BATTERY VOLTAGE
IGNITION SENSE
J1939 HIGH
J1939 LOW
J1939 SHIELD
JUMPER INSTALLED IF
INTERNAL TERMINATION
RESISTOR IS USED
16
7
11
5
6
WIRE 134
TCM
34
BATTERY GROUND
Circuit Description
Allison 4th Generation Controls shift selectors communicate with the transmission control module (TCM) by
exchanging standardized digital messages over the SAE J1939 controller area network (CAN). The shift selectors
are also equipped with a single wire backup to the J1939 CAN data link. Allison 4th Generation shift selectors
transmit directional information (Forward, Neutral, and Reverse) in the form of an analog pulse-width modulated
(PWM) signal via wire 134 to the TCM. The shift selector switches an internal driver ON and OFF to vary the duty
cycle of the voltage on wire 134. When the driver in the shift selector is ON, the voltage on wire 134 is pulled to
ground. When the driver is OFF, the drivers output is open and the voltage on wire 134 is high. Since duty cycle is
measured when voltage is high, the drivers OFF-time determines the duty cycle. For example, if wire 134 duty
cycle is 15 percent, the shift selector driver is ON (pulled low) 85 percent of the time and OFF (open) 15 percent of
the time.
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).
Copyright 2008 Allison Transmission, Inc.
6467
3000 AND 4000 PRODUCT FAMILIES TROUBLESHOOTING MANUALALLISON 4th GENERATION CONTROLS
If CAN is also lost, the TCM will lock in last valid direction.
DTC P2793 is usually caused by an intermittent electrical defect in wire 134. Common causes include:
An intermittent open in wire 134 between the shift selector and the TCM.
An intermittent short-to-battery or short-to-ground in wire 134.
A poor connection at the shift selector or the TCM.
A defective shift selector.
Inspect PWM signal wire 134 for poor electrical connections at the shift selector(s). 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
The PWM signal characteristics are shown in Table 618. When the vehicle is equipped with a primary and
secondary shift selector, the TCM receives a PWM signal from the active shift selector only.
Table 618. PWM Signal Characteristics
Description
Unknown
Park
Reverse
Neutral
Forward
Error
6468
3000 AND 4000 PRODUCT FAMILIES TROUBLESHOOTING MANUALALLISON 4th GENERATION CONTROLS
Action
Value(s)
Yes
No
Go to Step 2
Go to Section 35,
Beginning the
Troubleshooting
Process
Go to Step 4
Go to Step 3
Go to Step 5
Go to Step 4
Go to Step 8
Go to Step 4
Go to Step 7
Go to Step 6
4.55.0V
6469
3000 AND 4000 PRODUCT FAMILIES TROUBLESHOOTING MANUALALLISON 4th GENERATION CONTROLS
Action
Value(s)
Yes
No
Go to Step 8
Go to Step 8
6470
Begin the
diagnosis again.
Go to Step 1
System OK
3000 AND 4000 PRODUCT FAMILIES TROUBLESHOOTING MANUALALLISON 4th GENERATION CONTROLS
While Diagnostic Response is active, the TCM ignores shift selector input.
This DTC indicates that the oncoming clutch controlled by PCS6 is not applied or applied too slowly. Common
causes include:
Erratic turbine or output speed signals.
A leak or obstruction in the C6 clutch apply circuit.
A defective solenoid.
A stuck PCS6 regulator valve.
PCS6 supplies hydraulic pressure to C6 clutch in low range for 7-speed models. To determine which clutch
circuit is suspect, check the Allison DOC For PCService Tool failure record data for previous or current
range information when the DTC was set.
Copyright 2008 Allison Transmission, Inc.
6471
3000 AND 4000 PRODUCT FAMILIES TROUBLESHOOTING MANUALALLISON 4th GENERATION CONTROLS
If the condition is intermittent, connect Allison DOC For PCService Tool and observe the speed sensor
indicated by the code. If the signal is erratic, investigate and eliminate the following:
Intermittent wiring connection
Excessive vibration (driveline or engine torsionals)
Irregular sensor gap (loose sensor, loose tone wheel, or damaged tone wheel)
Test Description
The numbers below refer to step numbers on the diagnostic table.
2. Tests for proper transmission fluid level.
3. Tests for active DTCs.
4. Tests ignition voltage.
5. Tests speed sensor readings.
6. Tests for C6 clutch pressure from PCS6.
7. Tests for evidence of clutch failure.
8. Tests for stuck or sticking valves and damaged valve body gaskets.
Action
Value(s)
Yes
No
Go to Step 2
Go to Section 35,
Beginning the
Troubleshooting
Process
Go to Step 3
1.
2.
3.
4.
5.
Go to Step 4
Go to
Diagnostic Aids
Go to Step 5
Go to General
Troubleshooting,
Section 8
6472
1.
2.
3.
4.
Install the Allison DOC For PCService Tool. 918V (12V TCM)
1832V (24V TCM)
Start the engine.
Record the DTC failure record data.
Using the Allison DOC For PCService Tool,
measure ignition voltage.
Is the voltage within the specified value?
Copyright 2008 Allison Transmission, Inc.
3000 AND 4000 PRODUCT FAMILIES TROUBLESHOOTING MANUALALLISON 4th GENERATION CONTROLS
Action
Value(s)
Yes
No
Go to the
appropriate speed
sensor DTC
Go to Step 6
Go to Step 7
Go to Step 8
Go to Step 10
Go to
Diagnostic Aids
Go to Step 11
Go to Step 9
Replace PCS6.
Go to Step 11
Go to Step 9
Go to Step 11
Go to Step 10
6473
3000 AND 4000 PRODUCT FAMILIES TROUBLESHOOTING MANUALALLISON 4th GENERATION CONTROLS
Action
Value(s)
6474
Yes
No
Begin the
diagnosis again.
System OK
Go to Step 1
3000 AND 4000 PRODUCT FAMILIES TROUBLESHOOTING MANUALALLISON 4th GENERATION CONTROLS
When DTC P2809 occurs, the TCM will command previous range.
While Diagnostic Response is active, the TCM ignores shift selector inputs.
This DTC indicates that the off-coming clutch controlled by PCS6 is not released or released too slowly.
Common causes include:
Erratic turbine and output speed sensor readings.
An obstruction in the C6 clutch exhaust circuit.
A defective PCS6 solenoid.
A stuck PCS6 regulator valve.
PCS6 supplies hydraulic pressure to C6 clutch in Low range for 7-speed models. To determine which clutch
circuit is suspect, check the Allison DOC For PCService Tool failure record data for previous or current
range information when the DTC was set.
Copyright 2008 Allison Transmission, Inc.
6475
3000 AND 4000 PRODUCT FAMILIES TROUBLESHOOTING MANUALALLISON 4th GENERATION CONTROLS
If the condition is intermittent, connect Allison DOC For PCService Tool and observe the speed sensor
indicated by the code. If the signal is erratic, investigate and eliminate the following:
Intermittent wiring connection
Excessive vibration (driveline or engine torsionals)
Irregular sensor gap (loose sensor, loose tone wheel, or damaged tone wheel)
Test Description
The numbers below refer to step numbers on the diagnostic table.
2. Tests for proper transmission fluid level.
3. Tests for active DTCs.
4. Tests ignition voltage.
5. Tests speed sensor readings.
6. Tests for C6 clutch pressure from PCS6.
7. Tests for evidence of clutch failure.
8. Tests for stuck or sticking valves and damaged valve body gaskets.
Yes
No
Action
Value(s)
Go to Step 2
Go to Section 35,
Beginning the
Troubleshooting
Process
Go to Step 3
1.
2.
3.
4.
5.
Go to Step 4
Go to
Diagnostic Aids
Go to Step 5
Go to General
Troubleshooting,
Section 8
6476
1.
2.
3.
4.
Install the Allison DOC For PCService Tool. 918V (12V TCM)
1832V (24V TCM)
Start the engine.
Record the DTC failure record data.
Using the Allison DOC For PCService Tool,
measure ignition voltage.
Is the voltage within the specified value?
Copyright 2008 Allison Transmission, Inc.
3000 AND 4000 PRODUCT FAMILIES TROUBLESHOOTING MANUALALLISON 4th GENERATION CONTROLS
Action
Value(s)
Yes
No
Go to the
appropriate speed
sensor DTC
Go to Step 6
Go to Step 7
Go to Step 8
Go to Step 10
Go to
Diagnostic Aids
Go to Step 11
Go to Step 9
Replace PCS6.
Go to Step 11
Go to Step 9
Go to Step 11
Go to Step 10
Begin the
diagnosis again.
System OK
11
Go to Step 1
6477
3000 AND 4000 PRODUCT FAMILIES TROUBLESHOOTING MANUALALLISON 4th GENERATION CONTROLS
END VIEW OF
20-WAY CONNECTOR
1
10
11
14
15
20
61
80
41
60
21
40
20
TRANSMISSION
TRANSID
HSD1
PCS4
PCS6
MAIN MOD
TCM
20
1
2
7
8
WIRE 176
WIRE 111
WIRE 155
WIRE 178
WIRE 174
76
11
TRANSID
HSD1
ANALOG
INTERFACE
55
78
V BATTERY
74
V09066.00.00
Circuit Description
Pressure Control Solenoid 6 (PCS6) is a normally closed solenoid used to apply the C6 clutch in low range (7speed models only). The TCM commands the solenoid ON to produce hydraulic pressure in the clutch apply
circuit. When PCS6 is commanded OFF, the clutch pressure is released.
The TCM sends control current to PCS6 from High Side Driver 1 (HSD1) via wire 111. HSD1 is continuously ON
unless the TCM detects a fault condition. The Transmission Control Module (TCM) regulates the amount of
current to PCS6 by switching PCS6 Low Side Driver (LSD) ON and OFF. Wire 178 completes the circuit between
PCS6 and its LSD. DTC P2812 indicates that the TCM has detected an open condition in PCS6 electrical circuit.
The open condition may exist in the high side (wire 111) or low side (wire 178).
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).
TCM initialization is in process or engine speed is greater than 200 rpm and less than 7500 rpm for 5 seconds.
3000 AND 4000 PRODUCT FAMILIES TROUBLESHOOTING MANUALALLISON 4th GENERATION CONTROLS
Hydraulic default (SOL OFF) is commanded. The shift selector position and hydraulic state of latch valves
determines the range attained.
You may have to drive the vehicle in order to experience a fault. Use the data obtained from failure records to
determine transmission range and/or certain vehicle operating variables such as temperature, run time etc. This
data can be useful in reproducing the failure mode when DTC was set.
Inspect the wiring for poor electrical connections at the TCM and transmission connector. Look for the
following conditions:
A bent terminal
A backed-out terminal
A damaged terminal
Poor terminal tension
A chafed wire
A broken wire inside the insulation
Inspect OEM wiring harness routing, look for possible contact points where chafing could occur leading to an
open or short circuit condition. Moving parts on the vehicle could be contacting the harness; this includes
parking brake drum, suspension components, etc.
When diagnosing for an intermittent short or open, massage the wiring harness while watching the test
equipment for a change.
Test Description
This DTC requires the use of the J 47275 TCM Breakout and J 47279 Transmission Breakout. The numbers below
refer to step numbers on the diagnostic table.
1. Tests for the proper ignition voltage.
2. Tests for an active DTC.
3. Tests the OEM harness for an excessive voltage drop caused by an open condition in either wire 111 or
wire 178 of the OEM chassis harness.
6. Tests for an open condition in the transmission internal harness.
7. Tests for the proper PCS6 resistance.
Copyright 2008 Allison Transmission, Inc.
6479
3000 AND 4000 PRODUCT FAMILIES TROUBLESHOOTING MANUALALLISON 4th GENERATION CONTROLS
Action
Value(s)
Yes
No
Go to Step 2
Go to Section 35,
Beginning the
Troubleshooting
Process
1. Install the Allison DOC For PCService Tool. 918V (12V TCM)
1832V (24V TCM)
2. Start the engine.
3. Record the failure records.
4. Monitor ignition voltage.
Is the voltage within the specified values?
Go to Step 3
Resolve voltage
problem
Go to Step 4
Go to
Diagnostic Aids
Go to Step 5
Go to Step 6
6480
3000 AND 4000 PRODUCT FAMILIES TROUBLESHOOTING MANUALALLISON 4th GENERATION CONTROLS
Action
Value(s)
Yes
No
Go to Step 11
Go to Step 5
Refer to Solenoid
Resistance Chart
(Appendix K)
Go to Step 10
Go to Step 7
Refer to Solenoid
Resistance Chart
(Appendix K)
Go to Step 8
Go to Step 9
Go to Step 11
Go to Step 8
Go to Step 11
Go to Step 9
Go to Step 11
Go to Step 10
Begin the
diagnosis again.
System OK
Replace PCS6.
Is the replacement complete?
10
11
Go to Step 1
6481
3000 AND 4000 PRODUCT FAMILIES TROUBLESHOOTING MANUALALLISON 4th GENERATION CONTROLS
END VIEW OF
20-WAY CONNECTOR
1
10
11
14
15
20
61
80
41
60
21
40
20
TRANSMISSION
TRANSID
HSD1
PCS4
PCS6
MAIN MOD
TCM
20
1
2
7
8
WIRE 176
WIRE 111
WIRE 155
WIRE 178
WIRE 174
76
11
TRANSID
HSD1
ANALOG
INTERFACE
55
78
V BATTERY
74
V09066.00.00
Circuit Description
Pressure Control Solenoid 6 (PCS6) is a normally closed solenoid used to apply the C6 clutch in low range (7speed models only). The TCM commands the solenoid ON to produce hydraulic pressure in the clutch apply
circuit. When PCS6 is commanded OFF, the clutch pressure is released.
The TCM sends control current to PCS6 from High Side Driver 1 (HSD1) via wire 111. HSD1 is continuously ON
unless the TCM detects a fault condition. The Transmission Control Module (TCM) regulates the amount of
current to PCS6 by switching PCS6 Low Side Driver (LSD) ON and OFF. Wire 178 completes the circuit between
PCS6 and its LSD. DTC P2814 indicates that the TCM has detected a short-to-ground condition in the low side of
PCS6 electrical circuit.
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).
TCM initialization is in process or engine speed is greater than 200 rpm and less than 7500 rpm for 5 seconds.
3000 AND 4000 PRODUCT FAMILIES TROUBLESHOOTING MANUALALLISON 4th GENERATION CONTROLS
Hydraulic default (SOL OFF) is commanded. The shift selector position and hydraulic state of latch valves
determines the range attained.
DTC P2814 indicates a short-to-ground in the electrical circuit for the PCS6 solenoid.
You may have to drive the vehicle in order to experience a fault. Use the data obtained from failure records to
determine transmission range and/or certain vehicle operating variables such as temperature, run time etc. This
data can be useful in reproducing the failure mode when DTC was set.
Inspect the wiring for poor electrical connections at the TCM and transmission connector. Look for the
following conditions:
A bent terminal
A backed-out terminal
A damaged terminal
Poor terminal tension
A chafed wire
A broken wire inside the insulation
Inspect OEM wiring harness routing, look for possible contact points where chafing could occur leading to an
open or short circuit condition. Moving parts on the vehicle could be contacting the harness; this includes
parking brake drum, suspension components, etc.
When diagnosing for an intermittent short or open, massage the wiring harness while watching the test
equipment for a change.
6483
3000 AND 4000 PRODUCT FAMILIES TROUBLESHOOTING MANUALALLISON 4th GENERATION CONTROLS
Action
Value(s)
Yes
No
Go to Step 2
Go to Section 35,
Beginning the
Troubleshooting
Process
1. Install the Allison DOC For PCService Tool. 918V (12V TCM)
1832V (24V TCM)
2. Start the engine.
3. Record the failure records.
4. Monitor ignition voltage.
Is the voltage within the specified values?
Go to Step 3
Resolve voltage
problem
Go to Step 4
Go to
Diagnostic Aids
Go to Step 5
Go to Step 6
6484
3000 AND 4000 PRODUCT FAMILIES TROUBLESHOOTING MANUALALLISON 4th GENERATION CONTROLS
Action
Value(s)
Yes
No
Go to Step 11
Go to Step 7
Go to Step 10
Go to Step 8
Go to Step 9
Go to Step 11
Go to Step 8
Go to Step 11
Go to Step 9
Go to Step 11
Go to Step 10
Begin the
diagnosis again.
System OK
Replace PCS6.
Is the replacement complete?
10
11
Go to Step 1
6485
3000 AND 4000 PRODUCT FAMILIES TROUBLESHOOTING MANUALALLISON 4th GENERATION CONTROLS
END VIEW OF
20-WAY CONNECTOR
1
10
11
14
15
20
61
80
41
60
21
40
20
TRANSMISSION
TRANSID
HSD1
PCS4
PCS6
MAIN MOD
TCM
20
1
2
7
8
WIRE 176
WIRE 111
WIRE 155
WIRE 178
WIRE 174
76
11
TRANSID
HSD1
ANALOG
INTERFACE
55
78
V BATTERY
74
V09066.00.00
Circuit Description
Pressure Control Solenoid 6 (PCS6) is a normally closed solenoid used to apply the C6 clutch in low range (7speed models only). The TCM commands the solenoid ON to produce hydraulic pressure in the clutch apply
circuit. When PCS6 is commanded OFF, the clutch pressure is released.
The TCM sends control current to PCS6 from High Side Driver 1 (HSD1) via wire 111. HSD1 is continuously ON
unless the TCM detects a fault condition. The Transmission Control Module (TCM) regulates the amount of
current to PCS6 by switching PCS6 Low Side Driver (LSD) ON and OFF. Wire 178 completes the circuit between
PCS6 and its LSD. DTC P2815 indicates that the TCM has detected a short-to-battery condition in the low side of
PCS6 electrical circuit.
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).
TCM initialization is in process or engine speed is greater than 200 rpm and less than 7500 rpm for 5 seconds.
3000 AND 4000 PRODUCT FAMILIES TROUBLESHOOTING MANUALALLISON 4th GENERATION CONTROLS
Hydraulic default (SOL OFF) is commanded. The shift selector position and hydraulic state of latch valves
determines the range attained.
DTC P2815 indicates a short-to-battery in the electrical circuit for the PCS6 solenoid.
You may have to drive the vehicle in order to experience a fault. Use the data obtained from failure records to
determine transmission range and/or certain vehicle operating variables such as temperature, run time etc. This
data can be useful in reproducing the failure mode when DTC was set.
Inspect the wiring for poor electrical connections at the TCM and transmission connector. Look for the
following conditions:
A bent terminal
A backed-out terminal
A damaged terminal
Poor terminal tension
A chafed wire
A broken wire inside the insulation
Inspect OEM wiring harness routing, look for possible contact points where chafing could occur leading to an
open or short circuit condition. Moving parts on the vehicle could be contacting the harness; this includes
parking brake drum, suspension components, etc.
When diagnosing for an intermittent short or open, massage the wiring harness while watching the test
equipment for a change.
6487
3000 AND 4000 PRODUCT FAMILIES TROUBLESHOOTING MANUALALLISON 4th GENERATION CONTROLS
Action
Value(s)
Yes
No
Go to Step 2
Go to Section 35,
Beginning the
Troubleshooting
Process
1. Install the Allison DOC For PCService Tool. 918V (12V TCM)
1832V (24V TCM)
2. Start the engine.
3. Record the failure records.
4. Monitor ignition voltage.
Is the voltage within the specified values?
Go to Step 3
Resolve voltage
problem
Go to Step 4
Go to
Diagnostic Aids
Go to Step 5
Go to Step 6
6488
3000 AND 4000 PRODUCT FAMILIES TROUBLESHOOTING MANUALALLISON 4th GENERATION CONTROLS
Action
Value(s)
Yes
No
Go to Step 11
Go to Step 5
Go to Step 7
Go to Step 10
Go to Step 8
Go to Step 9
Go to Step 11
Go to Step 8
Go to Step 11
Go to Step 9
Go to Step 11
Go to Step 10
Begin the
diagnosis again.
System OK
Refer to Solenoid
Resistance Chart
(Appendix K)
Replace PCS6.
Is the replacement complete?
10
11
Go to Step 1
6489
3000 AND 4000 PRODUCT FAMILIES TROUBLESHOOTING MANUALALLISON 4th GENERATION CONTROLS
GROUND
TERMINATION
RESISTOR
CAN 2
IESCAN
26
6
27
126
106
127
14
16
POWER
SHIELD
67
66
47
167
SHIELD WIRE
166
OPTION 1
TERMINATION RESISTOR
TCM
OPTION 2
(TCM PASS-THRU)
TCM
106
127
MODULE
OR DDL
S
S
167
SHIELD
MODULE
OR DDL
(CAN 2)
J1962
CONNECTOR
147
OPTION 3
INTERNAL TCM RESISTOR
TCM
106
127
MODULE
OR DDL
126
106
127
MODULE
OR DDL
167
166
147
MODULE
OR DDL
(CAN 2)
167
MODULE
OR DDL
(CAN 2)
V08981.02.00
Circuit Description
Beginnings in MY07, the Allison 4th Generation Controls transmission control module (TCM) is capable of
communicating with some Mercedes engines via the IESCAN. The TCM uses the high-speed Controller Area
Network 2 (CAN2) chip to exchange standardized messages with the engine controller and other vehicle systems.
The IESCAN physical network consists of a two-wire twisted pair, two 120 Ohm resistors and, in most cases, a
third shield wire. A 120 Ohm termination resistor is located at each end of the network. Vehicle OEMs may choose
to install external termination resistors or use internal termination resistors built into many IESCAN electronic
modules.
Conditions for Running the DTC
Ignition voltage is greater than 9V and less than 18V (12V TCM) or greater than 9V and less than 32V
(24V TCM).
Engine speed is greater than 200 rpm and less than 7500 rpm for 5 seconds.
3000 AND 4000 PRODUCT FAMILIES TROUBLESHOOTING MANUALALLISON 4th GENERATION CONTROLS
The TCM defaults to the most recent adaptive shift values and uses default throttle percentage.
Vehicle manufactures may use the following pin pairs for the J2284 CAN2 high and low wires:
Pins 6 and 7
Pins 66 and 47
Both pins 6 and 27, and pins 66 and 47 in a pass-through setup.
As a result, vehicle manufactures can wire the TCM into the CAN2 backbone in three different ways:
The TCM may be on its own stub as in traditional CAN backbones.
The TCM may be wired in a pass-through configuration such that the CAN high and low wires are
connected to two separate pin pairs in the TCM 80-way connector. Data link messages pass-through but
can still be viewed by the TCM.
The TCM may represent one end of the backbone. Typically, the internal resistor in the TCM will be used
in this setup.
An active U0001 prevents the Allison DOC For PCService Tool from communicating with the TCM. The
J 47276 T Breakout and TCM Reflashing Harness may be used to confirm the TCM is operational. Connect the
T-harness to the TCM and leave the OEM harness disconnected. Provide input power from the PCCS load box.
Inspect the J2284 CAN wires 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.
For proper J2284 data link communications, it is necessary to have two 120 Ohm resistors installed in parallel
at the J2284 CAN backbone.
Copyright 2008 Allison Transmission, Inc.
6491
3000 AND 4000 PRODUCT FAMILIES TROUBLESHOOTING MANUALALLISON 4th GENERATION CONTROLS
Value(s)
Yes
No
Go to Step 2
Go to Section 35,
Beginning the
Troubleshooting
Process
Go to
Diagnostic Aids
Go to Step 3
Go to Step 4
Go to Step 6
Go to Step 5
Go to
Diagnostic Aids
6492
3000 AND 4000 PRODUCT FAMILIES TROUBLESHOOTING MANUALALLISON 4th GENERATION CONTROLS
Value(s)
Yes
No
Go to Step 7
Go to Step 5
Go to Step 7
Go to Step 6
Begin the
diagnosis again.
System OK
Go to Step 1
6493
3000 AND 4000 PRODUCT FAMILIES TROUBLESHOOTING MANUALALLISON 4th GENERATION CONTROLS
9-PIN DIAGNOSTIC
TOOL CONNECTOR
J1939
Data
Link
J1939
Data
Link
120
Resistor
E
F
C
A
G
H
7
NOTE 1
NOTE 2
SHIELD
SHIELD
Should not
exceed 1 meter
PIN E
PIN C (+)
SHIELD PIN D ()
48 68 49 28 8
Pin ID
determined
by Engine
OEM
B
J
TERMINATION
RESISTOR
GREEN
120
RESISTOR
SHIELD
SHIELD
SHIELD
SHIELD
120
RESISTOR
V09132.00.00.A
Circuit Description
In Allison 4th Generation Controls, the preferred digital data link is the SAE J1939 Controller Area Network
(CAN). The TCM communicates with the engine control module and other controllers by exchanging standardized
digital messages over the SAE J1939 CAN. The physical network consists of a two-wire twisted pair, two 120
Ohm termination resistors and, in most cases, a third shield wire. A 120 Ohm termination resistor is located at each
end of the network. Vehicle OEMs may chose to install external termination resistors or use internal termination
resistors built into many J1939 electronic modules.
Conditions for Running the DTC
Ignition voltage is greater than 9V and less than 18V (12V TCM) or greater than 9V and less than 32V
(24V TCM).
Engine speed is greater than 200 rpm and less than 7500 rpm for 5 seconds.
6494
3000 AND 4000 PRODUCT FAMILIES TROUBLESHOOTING MANUALALLISON 4th GENERATION CONTROLS
The TCM defaults to the most recent adaptive shifts values and uses default throttle percentage.
Vehicle manufacturers may use the following pin pairs for the J1939 CAN high and CAN low wires:
Pins 8 and 28
Pins 48 and 68
Both Pins 8 and 28, and Pins 48 and 68 in a pass-through setup
As a result, vehicle manufacturers can wire the TCM into the CAN backbone in three different ways.
The TCM may be on its own stub as in traditional CAN backbones.
The TCM may be wired in a pass-through configuration such that the CAN high and low wires are
connected to two separate pin pairs in the TCM 80-way connector. Data link messages pass-through but
can still be viewed by the TCM.
The TCM may represent one end of the backbone. Typically, the internal resistor in the TCM will be used
in this setup.
An active U0010 prevents the Allison DOC For PCService Tool from communicating with the TCM. The
J 47276 T Breakout and TCM Reflashing Harness may be used to confirm that the TCM is operational.
Connect the T-harness to the TCM and leave the OEM harness disconnected. Provide input power from the
PCCS load box.
Inspect the J1939 CAN wires 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.
For proper J1939 data link communications, it is necessary to have two 120 Ohm resistors installed in parallel
at the J1939 CAN backbone.
Copyright 2008 Allison Transmission, Inc.
6495
3000 AND 4000 PRODUCT FAMILIES TROUBLESHOOTING MANUALALLISON 4th GENERATION CONTROLS
Action
Value(s)
Yes
No
Go to Step 2
Go to Section 35,
Beginning the
Troubleshooting
Process
Go to
Diagnostic Aids
Go to Step 3
Go to Step 4
Go to Step 6
Go to Step 5
Go to
Diagnostic Aids
Go to Step 7
Go to Step 5
6496
3000 AND 4000 PRODUCT FAMILIES TROUBLESHOOTING MANUALALLISON 4th GENERATION CONTROLS
Action
Value(s)
Yes
No
Go to Step 7
Go to Step 6
Begin the
diagnosis again.
System OK
Go to Step 1
6497
3000 AND 4000 PRODUCT FAMILIES TROUBLESHOOTING MANUALALLISON 4th GENERATION CONTROLS
TRANS (TCM)
120
Resistor
9-PIN DIAGNOSTIC
TOOL CONNECTOR
J1939
Data
Link
120
Resistor
E
F
C
A
Should not
exceed 1 meter
SHIELD
NOTE 4
NOTE 3
7
NOTE 2
NOTE 2
SHIELD
BATERY VOLTAGE
IGNITION SENSE
5 13 12 14 8 15 16 7 11 34 48 68 49 28 8
PIN E
PIN C (+)
SHIELD PIN D ()
SECONDARY
SELECTOR 2 ID
BATTERY
GROUND NOTE 1
6
B
J
TERMINATION
RESISTOR
GREEN
120
RESISTOR
SHIELD
SHIELD
SHIELD
SHIELD
120
RESISTOR
V09131.00.00.A
Circuit Description
In Allison 4th Generation Controls, the TCM is capable of communicating with the engine control module and
other controllers by exchanging standardized digital messages over the following data links:
The TCM sets a DTC U0100 when it stops receiving certain information (throttle position, coolant temperature, or
torque) from the engine controller via the J1587 serial communications interface.
Conditions for Running the DTC
Ignition voltage is greater than 9V and less than 18V (12V TCM) or greater than 9V and less than 32V (24V
TCM).
3000 AND 4000 PRODUCT FAMILIES TROUBLESHOOTING MANUALALLISON 4th GENERATION CONTROLS
Inspect the J1939 CAN wires for poor electrical connections at the TCM. Look for the following conditions:
A bent terminal
A backed-out terminal
A damaged terminal
Poor terminal tension
A chafed wire
A broken wire inside the insulation
When diagnosing for an intermittent short or open, massage the wiring harness while watching the test
equipment for a change.
Test Description
2. Tests for communications between the TCM and engine controller on the J1708/J1587 data link.
3. Tests for communications between the TCM and engine controller using the J 47276 T-harness.
4. Tests the J1708/J1587 serial communication interface wiring for open conditions or terminal damage.
Action
Value(s)
Yes
No
Go to Step 2
Go to Section 35,
Beginning the
Troubleshooting
Process
Go to Step 4
Go to Step 3
6499
3000 AND 4000 PRODUCT FAMILIES TROUBLESHOOTING MANUALALLISON 4th GENERATION CONTROLS
Action
Value(s)
Yes
No
Go to Step 4
Go to Step 7
Go to Step 5
Go to Step 6
Go to Step 8
Go to Step 5
Go to Step 8
Go to Step 6
Go to Step 8
Go to Step 7
6500
3000 AND 4000 PRODUCT FAMILIES TROUBLESHOOTING MANUALALLISON 4th GENERATION CONTROLS
Action
Value(s)
Yes
No
Begin the
diagnosis again.
System OK
Go to Step 1
6501
3000 AND 4000 PRODUCT FAMILIES TROUBLESHOOTING MANUALALLISON 4th GENERATION CONTROLS
TRANS (TCM)
120
Resistor
9-PIN DIAGNOSTIC
TOOL CONNECTOR
J1939
Data
Link
120
Resistor
E
F
C
A
B
J
5 13 12 14 8 15 16 7 11 34 48 68 49 28 8
Should not
exceed 1 meter
SHIELD
NOTE 4
NOTE 3
7
NOTE 2
NOTE 2
SHIELD
BATERY VOLTAGE
IGNITION SENSE
PIN E
PIN C (+)
SHIELD PIN D ()
SECONDARY
SELECTOR 2 ID
BATTERY
GROUND NOTE 1
TERMINATION
RESISTOR
GREEN
120
RESISTOR
SHIELD
SHIELD
SHIELD
120
RESISTOR
SHIELD
V09131.00.00.A
Circuit Description
Allison 4th Generation Controls shift selectors communicate with the transmission control module (TCM) by
exchanging standardized digital messages over the SAE J1939 Controller Area Network (CAN). The physical
network consists of a two-wire twisted pair, two 120 Ohm termination resistors and, in most cases, a third shield
wire. A 120 Ohm termination resistor is located at each end of the network to maintain good J1939 signal quality.
Vehicle OEMs may chose to configure the network to take advantage of 120 Ohm resistors built in to Allison
4th Generation Controls TCMs and shift selectors.
Conditions for Running the DTC
Ignition voltage is greater than 9V and less than 18V (12V TCM) or greater than 9V and less than 32V
(24V TCM).
Conditions for Setting the DTC
DTC U0103 sets when the TCM has not received a state of health (SOH) message from the primary shift selector
for 2 or more seconds.
6502
3000 AND 4000 PRODUCT FAMILIES TROUBLESHOOTING MANUALALLISON 4th GENERATION CONTROLS
The active shift selector will freeze the displays for 1.5 seconds, go blank for 10.5 seconds, then display cateyes, i.e. -\-, -\-.
Direction change shifts, i.e., forward to Reverse, etc., are allowed based on PWM signal from Allison shift
selectors.
Vehicle manufacturers can configure the controller area network to use a built-in termination resistor in Allison
shift selectors by installing a jumper between pins 7 and 18 at the primary shift selector connector. OEMs are
required to clearly indicate where internal termination resistors have been used.
Inspect the J1939 CAN wires for poor electrical connections at the primary shift selector. 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 proper power inputs to the primary shift selector.
3. Tests for wiring defects between the primary shift selector and the connection to the J1939 backbone.
Copyright 2008 Allison Transmission, Inc.
6503
3000 AND 4000 PRODUCT FAMILIES TROUBLESHOOTING MANUALALLISON 4th GENERATION CONTROLS
Action
Value(s)
Yes
No
Go to Step 2
Go to Section 35,
Beginning the
Troubleshooting
Process
Go to Step 6
Go to Step 3
Go to Step 4
Go to Step 5
Go to Step 6
Go to Step 4
Go to Step 6
Go to Step 5
6504
3000 AND 4000 PRODUCT FAMILIES TROUBLESHOOTING MANUALALLISON 4th GENERATION CONTROLS
Action
Value(s)
Yes
No
Re-install original
shift selector and
begin the
diagnosis again.
System OK
Go to Step 1
6505
3000 AND 4000 PRODUCT FAMILIES TROUBLESHOOTING MANUALALLISON 4th GENERATION CONTROLS
TRANS (TCM)
ENGINE (ECM)
9-PIN DIAGNOSTIC
TOOL CONNECTOR
J1939
Data
Link
J1939
Data
Link
120
Resistor
E
F
C
A
H
7
NOTE 1
NOTE 2
SHIELD
SHIELD
Should not
exceed 1 meter
PIN E
PIN C (+)
SHIELD PIN D ()
48 68 49 28 8
Pin ID
determined
by Engine
OEM
B
J
TERMINATION
RESISTOR
GREEN
120
RESISTOR
SHIELD
SHIELD
SHIELD
120
RESISTOR
SHIELD
V09132.00.00.A
Circuit Description
In Allison 4th Generation Controls, the TCM is capable of communicating with the engine control module and
other controllers by exchanging standardized digital messages over the following data links:
SAE J1939 Controller Area Network (CAN)
SAE J1708/J1587 Serial Communication Interface
SAE J2284 High Speed CAN for use in IESCAN applications.
The TCM sets a DTC U0115 when it stops receiving certain information (throttle position, coolant
temperature, or torque) from the engine controller via the J1939 CAN.
Ignition voltage is greater than 9V and less than 18V (12V TCM) or greater than 9V and less than 32V
(24V TCM).
3000 AND 4000 PRODUCT FAMILIES TROUBLESHOOTING MANUALALLISON 4th GENERATION CONTROLS
The TCM defaults to the most recent adaptive shifts values and uses default throttle percentage.
An active U0115 prevents the Allison DOC For PCService Tool from communicating with the TCM. The
J 47276 T Breakout and TCM Reflashing Harness may be used to confirm that the TCM is operational. The
T-harness is only useful to confirm that the TCM is able to communicate with Allison DOC diagnostic tool.
Vehicles that use SEM/LRTP may set a DTC U0115 when engine performance complaints are present. This
may include injector concerns that could cause an engine to default to a fail safe mode. Some engine
manufacturers may interrupt engine torque messaging, which will result in a DTC U0115. Inspect the engine
side for possible engine DTCs that may indicate that this condition is present and correct before performing
further troubleshooting on DTC U0115.
The following condition points to an open in one of the CAN wires at the Engine Control Module:
U0115 is active, and
Allison DOC For PCService Tool communicates with the TCM when plugged into the 9-pin connector.
This DTC can be caused if engine ECM parameters are improperly set.
Inspect the J1939 CAN wires 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.
For proper J1939 data link communications, it is necessary to have two 120 Ohm resistors installed in parallel
at the J1939 CAN backbone.
Copyright 2008 Allison Transmission, Inc.
6507
3000 AND 4000 PRODUCT FAMILIES TROUBLESHOOTING MANUALALLISON 4th GENERATION CONTROLS
Yes
No
Action
Value(s)
Go to Step 2
Go to Section 35,
Beginning the
Troubleshooting
Process
Go to Step 4
Go to Step 3
Go to Step 4
Go to Step 9
Go to Step 7
Go to Step 5
Go to Step 8
Go to Step 6
60 Ohms
6508
3000 AND 4000 PRODUCT FAMILIES TROUBLESHOOTING MANUALALLISON 4th GENERATION CONTROLS
Action
Value(s)
Yes
No
Go to Step 10
Go to Step 6
Go to Step 10
Go to Step 7
Go to Step 10
Go to Step 8
Go to Step 10
Go to Step 9
Begin the
diagnosis again.
System OK
10
Go to Step 1
6509
3000 AND 4000 PRODUCT FAMILIES TROUBLESHOOTING MANUALALLISON 4th GENERATION CONTROLS
TRANS (TCM)
120
Resistor
9-PIN DIAGNOSTIC
TOOL CONNECTOR
J1939
Data
Link
120
Resistor
E
F
C
A
B
J
5 13 12 14 8 15 16 7 11 34 48 68 49 28 8
Should not
exceed 1 meter
SHIELD
NOTE 4
NOTE 3
7
NOTE 2
NOTE 2
SHIELD
BATERY VOLTAGE
IGNITION SENSE
PIN E
PIN C (+)
SHIELD PIN D ()
SECONDARY
SELECTOR 2 ID
BATTERY
GROUND NOTE 1
TERMINATION
RESISTOR
GREEN
120
RESISTOR
SHIELD
SHIELD
SHIELD
120
RESISTOR
SHIELD
V09131.00.00.A
Circuit Description
Allison 4th Generation Controls shift selectors communicate with the transmission control module (TCM) by
exchanging standardized digital messages over the SAE J1939 Controller Area Network (CAN). The physical
network consists of a two-wire twisted pair, two 120 Ohm termination resistors and, in most cases, a third shield
wire. A 120 Ohm termination resistor is located at each end of the network to maintain good J1939 signal quality.
Vehicle OEMs may chose to configure the network to take advantage of 120 Ohm resistors built in to Allison
4th Generation Controls TCMs and shift selectors.
Conditions for Running the DTC
Ignition voltage is greater than 9V and less than 18V (12V TCM) or greater than 9V and less than 32V
(24V TCM).
Conditions for Setting the DTC
DTC U0291 sets when the TCM has not received a state of health (SOH) message from the secondary shift selector
for 2 or more seconds.
6510
3000 AND 4000 PRODUCT FAMILIES TROUBLESHOOTING MANUALALLISON 4th GENERATION CONTROLS
The active shift selector will freeze the displays for 1.5 seconds, go blank for 10.5 seconds, then display cateyes, i.e. -\-, -\-.
Direction change shifts i.e. forward to Reverse, etc are allowed based on PWM signal from Allison shift
selectors.
Vehicle manufacturers can configure the controller area network to use a built-in termination resistor in the
Allison shift selectors by installing a jumper between pins 7 and 18 at the secondary shift selector connector.
OEMs are required to clearly indicate where internal termination resistors have been used.
Inspect the J1939 CAN wires for poor electrical connections at the secondary shift selector. 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 proper power inputs to the secondary shift selector.
3. Tests for wiring defects between the secondary shift selector and the connection to the J1939 backbone.
Copyright 2008 Allison Transmission, Inc.
6511
3000 AND 4000 PRODUCT FAMILIES TROUBLESHOOTING MANUALALLISON 4th GENERATION CONTROLS
Action
Value(s)
Yes
No
Go to Step 2
Go to Section 35,
Beginning the
Troubleshooting
Process
Go to Step 6
Go to Step 3
Go to Step 4
Go to Step 5
Go to Step 6
Go to Step 4
Go to Step 6
Go to Step 5
6512
3000 AND 4000 PRODUCT FAMILIES TROUBLESHOOTING MANUALALLISON 4th GENERATION CONTROLS
Action
Value(s)
Yes
No
Re-install original
shift selector and
begin the
diagnosis again.
System OK
Go to Step 1
6513
3000 AND 4000 PRODUCT FAMILIES TROUBLESHOOTING MANUALALLISON 4th GENERATION CONTROLS
TRANS (TCM)
120
Resistor
9-PIN DIAGNOSTIC
TOOL CONNECTOR
J1939
Data
Link
120
Resistor
E
F
C
A
Should not
exceed 1 meter
SHIELD
NOTE 4
NOTE 3
7
NOTE 2
NOTE 2
SHIELD
BATERY VOLTAGE
IGNITION SENSE
5 13 12 14 8 15 16 7 11 34 48 68 49 28 8
PIN E
PIN C (+)
SHIELD PIN D ()
SECONDARY
SELECTOR 2 ID
BATTERY
GROUND NOTE 1
B
J
TERMINATION
RESISTOR
GREEN
120
RESISTOR
SHIELD
SHIELD
SHIELD
SHIELD
120
RESISTOR
V09131.00.00.A
Circuit Description
In Allison 4th Generation Controls, the Transmission Control Module (TCM) communicates with the shift selector
over the J1939 Controller Area Network (CAN). Allison J1939 shift selectors broadcast proprietary messages to
the TCM related to range selection and other operating modes.
Conditions for Running the DTC
Battery voltage is greater than 9 volts
6514
3000 AND 4000 PRODUCT FAMILIES TROUBLESHOOTING MANUALALLISON 4th GENERATION CONTROLS
Use the Allison DOC For PCService Tool to clear the code from the TCM history.
The TCM automatically clears the DTC from the TCM history if the vehicle completes 40 engine starts
without a reoccurrence of the code.
Diagnostic Aids
NOTE: OEM repairs necessary for transmission DTCs to go inactive are not covered under Allison
Transmission warranty.
If there are other vehicle DTCs present, the cause for transmission-related DTCs might be external to the
transmission and those vehicle systems must be corrected in order for the transmission DTCs to be resolved.
A transmission DTC must be active during the troubleshooting process to determine what caused the DTC. Use
the Snapshot feature and/or Databus Viewer of Allison DOC For PCService Tool while operating the
vehicle in the same conditions listed in the Failure Record (available in the Allison DOC For PCService
Tool Reports menu).
Using the Snapshot feature and/or Databus Viewer of Allison DOC For PCService Tool and/or a DVOM
and the Breakout Box J 39700 while manipulating the chassis harness and/or data link wiring may reveal
intermittent shorts to ground, shorts to another circuit, and open circuits that are causing an intermittent DTC.
NOTE: OEM vehicle harness repairs are not covered under Allison Transmission warranty.
OEM chassis wiring issues should be considered as possible causes for every DTC. Possible wiring and
connector issues include:
J1939 termination resistors may be disconnected or defective
Expanded female terminals in a connector. Use a mating pin or terminal to check for a light drag feel when
the mating terminal or pin is inserted and slowly removed. There should be some slight friction between
the matching terminal and pin combination. Expanded terminals have no feel of drag when the matching
pin or terminal is inserted and removed.
Broken terminal locks allow the pins or terminals to push back into the connector resulting in poor
connection or pin to pin shorts in the connector. Inspect for broken locks and displaced terminals in
connections. Never use paper clips or other devices to back-probe a connector while doing Allison service
work.
Poor pin crimps. Pin crimps should be pull-tested by the technician to verify the crimp is secure to the wire.
If the pin crimp is loose, the pin easily moves or even comes off the wire with a slight tug on the terminal
by the technician. This situation may not reveal itself as an active DTC but instead may exhibit other
symptoms like shift quality issues.
Connector and pin corrosion caused by moisture in connectors. Empty wire locations in connectors must
always have a plug to keep moisture from finding a path into the connector.
Poor harness routing and improper strain relief may cause damage resulting in electrical open and/or short
circuits to wires and connector components.
Copyright 2008 Allison Transmission, Inc.
6515
3000 AND 4000 PRODUCT FAMILIES TROUBLESHOOTING MANUALALLISON 4th GENERATION CONTROLS
then always use heat-shrinkable butt splices. Never use wire ties inside the transmission, to hold connector
components together in the place of a connector lock, or in the place of the correct strain relief components
and clips used to fasten harnesses to the vehicle or to retain vehicle connectors unless OEM approved for
the location and vehicle component being repaired.
The following procedures are not documented in any Allison service procedures or in any Allison
Troubleshooting Manual or Service Manual and therefore should not be used as a method to diagnose any
transmission DTC(s), function, or shift quality concern:
Back probing any connectors used for transmission features or functions may damage and/or unlock the
terminals from the back-probed connector creating permanent or intermittent shorts and/or open circuits. If
possible, use the J 39700 Breakout Box, appropriate harness adapters, and appropriate magnetic overlays
to troubleshoot the vehicle.
Load-testing any transmission-related circuits with any other electrical devices such as vehicle lamps or
relays, especially with the TCM connected to the harness. Use Breakout Box J 39700 and appropriate
harnesses with Allison DOC For PCService Tool to monitor the circuit performance in question unless
otherwise specified in the various Troubleshooting Manuals to use a digital volt-ohm meter (DVOM) with
the Breakout.
Piercing a wire to check for voltages, shorts-to-grounds or other wires anywhere in the circuit but
especially at the TCM. This creates a leak path for moisture and damages the wire and insulation.
If needed, call for local distributor and/or factory support before downtime and expense of repair effect the
Allison Customer Experience. The phone number for the Technical Assistance Center in the United States is 1800-252-5283
Always use tools that are in good condition. Refer to the Allison Essential Tools list on the Allison Extranet to
complete any service procedure listed in an Allison publication. Also see appropriate Service Manuals and
Troubleshooting Manuals for service tools information.
Action
Value(s)
Yes
No
Go to Step 2
Review the
information in
Section 3-5,
Section 6-6, and
Diagnostic Aids
listed for this DTC
Go to Step 1
6516
3000 AND 4000 PRODUCT FAMILIES TROUBLESHOOTING MANUALALLISON 4th GENERATION CONTROLS
Go to Step 3
Go to Step 5
Go to Step 4
Get Allison
approval prior to
using this selector.
Correct vehicle
power and ground
issues in order to
comply with
Allison
specification while
TCM and selector
are attempting
communication of
handshake data.
Correct pin-to-pin
vehicle wiring
between TCM and
selector for power
and grounds or
J1939 data link
wiring issue exists
Go to Step 5
Go to Step 5
5
Go to Step 1
System OK
Clear inactive
codes from history
Repair complete
6517
3000 AND 4000 PRODUCT FAMILIES TROUBLESHOOTING MANUALALLISON 4th GENERATION CONTROLS
TRANS (TCM)
120
Resistor
9-PIN DIAGNOSTIC
TOOL CONNECTOR
J1939
Data
Link
120
Resistor
E
F
C
A
Should not
exceed 1 meter
SHIELD
NOTE 4
NOTE 3
7
NOTE 2
NOTE 2
SHIELD
BATERY VOLTAGE
IGNITION SENSE
5 13 12 14 8 15 16 7 11 34 48 68 49 28 8
PIN E
PIN C (+)
SHIELD PIN D ()
SECONDARY
SELECTOR 2 ID
BATTERY
GROUND NOTE 1
B
J
TERMINATION
RESISTOR
GREEN
120
RESISTOR
SHIELD
SHIELD
SHIELD
SHIELD
120
RESISTOR
V09131.00.00.A
Circuit Description
In Allison 4th Generation Controls, the Transmission Control Module (TCM) communicates with the shift selector
over the J1939 Controller Area Network (CAN). Allison J1939 shift selectors broadcast proprietary messages to
the TCM related to range selection and other operating modes.
Conditions for Running the DTC
Battery voltage is greater than 9 volts
6518
3000 AND 4000 PRODUCT FAMILIES TROUBLESHOOTING MANUALALLISON 4th GENERATION CONTROLS
Use the Allison DOC For PCService Tool to clear the code from the TCM history.
The TCM automatically clears the DTC from the TCM history if the vehicle completes 40 engine starts
without a reoccurrence of the code.
Diagnostic Aids
NOTE: OEM repairs necessary for transmission DTCs to go inactive are not covered under Allison
Transmission warranty.
If there are other vehicle DTCs present, the cause for transmission-related DTCs might be external to the
transmission and those vehicle systems must be corrected in order for the transmission DTCs to be resolved.
A transmission DTC must be active during the troubleshooting process to determine what caused the DTC. Use
the Snapshot feature and/or Databus Viewer of Allison DOC For PCService Tool while operating the
vehicle in the same conditions listed in the Failure Record (available in the Allison DOC For PCService
Tool Reports menu).
Using the Snapshot feature and/or Databus Viewer of Allison DOC For PCService Tool and/or a DVOM
and the Breakout Box J 39700 while manipulating the chassis harness and/or data link wiring may reveal
intermittent shorts to ground, shorts to another circuit, and open circuits that are causing an intermittent DTC.
NOTE: OEM vehicle harness repairs are not covered under Allison Transmission warranty.
OEM chassis wiring issues should be considered as possible causes for every DTC. Possible wiring and
connector issues include:
J1939 termination resistors may be disconnected or defective
Expanded female terminals in a connector. Use a mating pin or terminal to check for a light drag feel when
the mating terminal or pin is inserted and slowly removed. There should be some slight friction between
the matching terminal and pin combination. Expanded terminals have no feel of drag when the matching
pin or terminal is inserted and removed.
Broken terminal locks allow the pins or terminals to push back into the connector resulting in poor
connection or pin to pin shorts in the connector. Inspect for broken locks and displaced terminals in
connections. Never use paper clips or other devices to back-probe a connector while doing Allison service
work.
Poor pin crimps. Pin crimps should be pull-tested by the technician to verify the crimp is secure to the wire.
If the pin crimp is loose, the pin easily moves or even comes off the wire with a slight tug on the terminal
by the technician. This situation may not reveal itself as an active DTC but instead may exhibit other
symptoms like shift quality issues.
Connector and pin corrosion caused by moisture in connectors. Empty wire locations in connectors must
always have a plug to keep moisture from finding a path into the connector.
Poor harness routing and improper strain relief may cause damage resulting in electrical open and/or short
circuits to wires and connector components.
Copyright 2008 Allison Transmission, Inc.
6519
3000 AND 4000 PRODUCT FAMILIES TROUBLESHOOTING MANUALALLISON 4th GENERATION CONTROLS
then always use heat-shrinkable butt splices. Never use wire ties inside the transmission, to hold connector
components together in the place of a connector lock, or in the place of the correct strain relief components
and clips used to fasten harnesses to the vehicle or to retain vehicle connectors unless OEM approved for
the location and vehicle component being repaired.
The following procedures are not documented in any Allison service procedures or in any Allison
Troubleshooting Manual or Service Manual and therefore should not be used as a method to diagnose any
transmission DTC(s), function, or shift quality concern:
Back probing any connectors used for transmission features or functions may damage and/or unlock the
terminals from the back-probed connector creating permanent or intermittent shorts and/or open circuits. If
possible, use the J 39700 Breakout Box, appropriate harness adapters, and appropriate magnetic overlays
to troubleshoot the vehicle.
Load-testing any transmission-related circuits with any other electrical devices such as vehicle lamps or
relays, especially with the TCM connected to the harness. Use Breakout Box J 39700 and appropriate
harnesses with Allison DOC For PCService Tool to monitor the circuit performance in question unless
otherwise specified in the various Troubleshooting Manuals to use a digital volt-ohm meter (DVOM) with
the Breakout.
Piercing a wire to check for voltages, shorts-to-grounds or other wires anywhere in the circuit but
especially at the TCM. This creates a leak path for moisture and damages the wire and insulation.
If needed, call for local distributor and/or factory support before downtime and expense of repair effect the
Allison Customer Experience. The phone number for the Technical Assistance Center in the United States is 1800-252-5283
Always use tools that are in good condition. Refer to the Allison Essential Tools list on the Allison Extranet to
complete any service procedure listed in an Allison publication. Also see appropriate Service Manuals and
Troubleshooting Manuals for service tools information.
Action
Value(s)
Yes
No
Go to Step 2
Review the
information in
Section 3-5,
Section 6-6, and
Diagnostic Aids
listed for this DTC
Go to Step 1
6520
3000 AND 4000 PRODUCT FAMILIES TROUBLESHOOTING MANUALALLISON 4th GENERATION CONTROLS
Go to Step 3
Go to Step 5
Go to Step 4
Get Allison
approval prior to
using this selector.
Correct vehicle
power and ground
issues in order to
comply with
Allison
specification while
TCM and selector
are attempting
communication of
handshake data.
Correct pin-to-pin
vehicle wiring
between TCM and
selector for power
and grounds or
J1939 data link
wiring issue exists
Go to Step 5
Go to Step 5
5
Replace shift
selector
Go to Step 2
System OK
Clear inactive
codes from history
Repair complete
6521
3000 AND 4000 PRODUCT FAMILIES TROUBLESHOOTING MANUALALLISON 4th GENERATION CONTROLS
TRANS (TCM)
120
Resistor
9-PIN DIAGNOSTIC
TOOL CONNECTOR
J1939
Data
Link
120
Resistor
E
F
C
A
Should not
exceed 1 meter
SHIELD
NOTE 4
NOTE 3
7
NOTE 2
NOTE 2
SHIELD
BATERY VOLTAGE
IGNITION SENSE
5 13 12 14 8 15 16 7 11 34 48 68 49 28 8
PIN E
PIN C (+)
SHIELD PIN D ()
SECONDARY
SELECTOR 2 ID
BATTERY
GROUND NOTE 1
B
J
TERMINATION
RESISTOR
GREEN
120
RESISTOR
SHIELD
SHIELD
SHIELD
SHIELD
120
RESISTOR
V09131.00.00.A
Circuit Description
The Controller Area Network (CAN) defined by SAE J1939 allows the integration of various vehicle components
into an overall vehicle system by providing a standard way of exchanging information between the various
modules used in a vehicle. Use of a J1939 network, or data link, for on-vehicle communication reduces the amount
of wiring in a vehicle, and allows the many different components and subsystems access to a wider range of
information. Allison uses the J1939 communication link for vehicle operation controls, powertrain interaction, and
conveying vehicle management information.
Conditions for Running the DTC
Transmission Control Module (TCM) initialization is complete
6522
3000 AND 4000 PRODUCT FAMILIES TROUBLESHOOTING MANUALALLISON 4th GENERATION CONTROLS
If there are other vehicle DTCs present, the cause for transmission-related DTCs might be external to the
transmission and those vehicle systems must be corrected in order for the transmission DTCs to be resolved.
A transmission DTC must be active during the troubleshooting process to determine what caused the DTC. Use
the Snapshot feature and/or Databus Viewer of Allison DOC For PCService Tool while operating the
vehicle in the same conditions listed in the Failure Record (available in the Allison DOC For PCService
Tool Reports menu).
Using the Snapshot feature and/or Databus Viewer of Allison DOC For PCService Tool and/or a DVOM
and the Breakout Box J 39700 while manipulating the chassis harness and/or data link wiring may reveal
intermittent shorts to ground, shorts to another circuit, and open circuits that ar causing an intermittent DTC.
NOTE: OEM vehicle harness repairs are not covered under Allison Transmission warranty.
OEM chassis wiring issues should be considered as possible causes for every DTC. The following possible
wiring and connector issues include:
J1939 termination resistors may be disconnected or defective
Expanded female terminals in a connector. Use a mating pin or terminal to check for a light drag feel when
the mating terminal or pin is inserted and slowly removed. There should be some slight friction between
the matching terminal and pin combination. Expanded terminals have no feel of drag when the matching
pin or terminal is inserted and removed.
Broken terminal locks allow the pins or terminals to push back into the connector resulting in poor
connection or pin to pin shorts in the connector. Inspect for broken locks and displaced terminals in
connections. Never use paper clips or other devices to back probe a connector while doing Allison service
work.
Poor pin crimps. Pin crimps should be pull-tested by the technician to verify the crimp is secure to the wire.
If the pin crimp is loose, the pin easily moves or even comes off the wire with a slight tug on the terminal
by the technician. This situation may not reveal itself as an active DTC but instead may exhibit other
symptoms like shift quality issues.
Connector and pin corrosion caused by moisture in connectors. Empty wire locations in connectors must
always have a plug to keep moisture from finding a path into the connector.
Poor harness routing and improper strain relief may cause damage resulting in electrical open and/or short
circuits to wires and connector components.
Butt splices and wire ties are not an ideal solution for any transmission repair. If butt splices will be used,
then always use heat-shrinkable butt splices. Never use wire ties inside the transmission, to hold connector
Copyright 2008 Allison Transmission, Inc.
6523
3000 AND 4000 PRODUCT FAMILIES TROUBLESHOOTING MANUALALLISON 4th GENERATION CONTROLS
The following procedures are not documented in any Allison service procedures or in any Allison
Troubleshooting Manual or Service Manual and therefore should not be used as a method to diagnose any
transmission DTC(s), function, or shift quality concern:
Back probing any connectors used for transmission features or functions may damage and/or unlock the
terminals from the back-probed connector creating permanent or intermittent shorts and/or open circuits. If
possible, use the Breakout Box J 39700, appropriate harness adapters, and appropriate magnetic overlays
to troubleshoot the vehicle.
Load-testing any transmission-related circuits with any other electrical devices such as vehicle lamps or
relays, especially with the TCM connected to the harness. Use Breakout Box J 39700 and appropriate
harnesses with Allison DOC For PCService Tool to monitor the circuit performance in question unless
otherwise specified in the various Troubleshooting Manuals to use a digital volt-ohm meter (DVOM) with
the Breakout.
Piercing a wire to check for voltages, shorts-to-grounds or other wires anywhere in the circuit but
especially at the TCM. This creates a leak path for moisture and damages the wire and insulation.
If needed, call for local distributor and/or factory support before downtime and expense of repair effect the
Allison Customer Experience. The phone number for the Technical Assistance Center in the United States is 1800-252-5283
Always use tools that are in good condition. Reference the Allison Essential Tools list on the Allison Extranet
to complete any service procedure listed in an Allison publication. Also see appropriate Service Manuals and
Troubleshooting Manuals for service tools information.
Action
Value(s)
Yes
No
Go to Step 2
Review the
information in
Section 3-5,
Section 6-6, and
Diagnostic Aids
listed for this DTC
Go to Step 1
6524
3000 AND 4000 PRODUCT FAMILIES TROUBLESHOOTING MANUALALLISON 4th GENERATION CONTROLS
Action
Value(s)
Yes
No
Go to Step 3
Go to Step 5
Go to Step 4
Go to Step 5
Contact Allison
Refer customer to
OEM service outlet Transmission to get
the information
to correct data link
message issue with necessary to load
the correct CIN at
SBS message.
1-800-252-5283
Go to Step 5
Go to Step 5
Go to Step 1
System OK
Clear inactive
codes from history
Repair complete
6525
3000 AND 4000 PRODUCT FAMILIES TROUBLESHOOTING MANUALALLISON 4th GENERATION CONTROLS
TRANS (TCM)
120
Resistor
9-PIN DIAGNOSTIC
TOOL CONNECTOR
J1939
Data
Link
120
Resistor
E
F
C
A
Should not
exceed 1 meter
SHIELD
NOTE 4
NOTE 3
7
NOTE 2
NOTE 2
SHIELD
BATERY VOLTAGE
IGNITION SENSE
5 13 12 14 8 15 16 7 11 34 48 68 49 28 8
PIN E
PIN C (+)
SHIELD PIN D ()
SECONDARY
SELECTOR 2 ID
BATTERY
GROUND NOTE 1
B
J
TERMINATION
RESISTOR
GREEN
120
RESISTOR
SHIELD
SHIELD
SHIELD
SHIELD
120
RESISTOR
V09131.00.00.A
Circuit Description
In Allison 4th Generation Controls, the Transmission Control Module (TCM) communicates with the shift selector
over the J1939 Controller Area Network (CAN). Allison J1939 shift selectors broadcast proprietary messages to
the TCM related to range selection and other operating modes.
Conditions for Running the DTC
Battery voltage is greater than 9 volts
3000 AND 4000 PRODUCT FAMILIES TROUBLESHOOTING MANUALALLISON 4th GENERATION CONTROLS
Use the Allison DOC For PCService Tool to clear the code from the TCM history.
The TCM automatically clears the DTC from the TCM history if the vehicle completes 40 engine starts
without a reoccurrence of the code.
Diagnostic Aids
NOTE: OEM repairs necessary for transmission DTCs to go inactive are not covered under Allison
Transmission warranty.
If there are other vehicle DTCs present, the cause for transmission-related DTCs might be external to the
transmission and those vehicle systems must be corrected in order for the transmission DTCs to be resolved.
A transmission DTC must be active during the troubleshooting process to determine what caused the DTC. Use
the Snapshot feature and/or Databus Viewer of Allison DOC For PCService Tool while operating the
vehicle in the same conditions listed in the Failure Record (available in the Allison DOC For PCService
Tool Reports menu).
Using the Snapshot feature and/or Databus Viewer of Allison DOC For PCService Tool and/or a DVOM
and the Breakout Box J 39700 while manipulating the chassis harness and/or data link wiring may reveal
intermittent shorts to ground, shorts to another circuit, and open circuits that are causing an intermittent DTC.
NOTE: OEM vehicle harness repairs are not covered under Allison Transmission warranty.
OEM chassis wiring issues should be considered as possible causes for every DTC. Possible wiring and
connector issues include:
J1939 termination resistors may be disconnected or defective
Expanded female terminals in a connector. Use a mating pin or terminal to check for a light drag feel when
the mating terminal or pin is inserted and slowly removed. There should be some slight friction between
the matching terminal and pin combination. Expanded terminals have no feel of drag when the matching
pin or terminal is inserted and removed.
Broken terminal locks allow the pins or terminals to push back into the connector resulting in poor
connection or pin to pin shorts in the connector. Inspect for broken locks and displaced terminals in
connections. Never use paper clips or other devices to back-probe a connector while doing Allison service
work.
Poor pin crimps. Pin crimps should be pull-tested by the technician to verify the crimp is secure to the wire.
If the pin crimp is loose, the pin easily moves or even comes off the wire with a slight tug on the terminal
by the technician. This situation may not reveal itself as an active DTC but instead may exhibit other
symptoms like shift quality issues.
Connector and pin corrosion caused by moisture in connectors. Empty wire locations in connectors must
always have a plug to keep moisture from finding a path into the connector.
Poor harness routing and improper strain relief may cause damage resulting in electrical open and/or short
circuits to wires and connector components.
Butt splices and wire ties are not an ideal solution for any transmission repair. If butt splices will be used,
then always use heat-shrinkable butt splices. Never use wire ties inside the transmission, to hold connector
Copyright 2008 Allison Transmission, Inc.
6527
3000 AND 4000 PRODUCT FAMILIES TROUBLESHOOTING MANUALALLISON 4th GENERATION CONTROLS
The following procedures are not documented in any Allison service procedures or in any Allison
Troubleshooting Manual or Service Manual and therefore should not be used as a method to diagnose any
transmission DTC(s), function, or shift quality concern:
Back probing any connectors used for transmission features or functions may damage and/or unlock the
terminals from the back-probed connector creating permanent or intermittent shorts and/or open circuits. If
possible, use the J 39700 Breakout Box, appropriate harness adapters, and appropriate magnetic overlays
to troubleshoot the vehicle.
Load-testing any transmission-related circuits with any other electrical devices such as vehicle lamps or
relays, especially with the TCM connected to the harness. Use Breakout Box J 39700 and appropriate
harnesses with Allison DOC For PCService Tool to monitor the circuit performance in question unless
otherwise specified in the various Troubleshooting Manuals to use a digital volt-ohm meter (DVOM) with
the Breakout.
Piercing a wire to check for voltages, shorts-to-grounds or other wires anywhere in the circuit but
especially at the TCM. This creates a leak path for moisture and damages the wire and insulation.
If needed, call for local distributor and/or factory support before downtime and expense of repair effect the
Allison Customer Experience. The phone number for the Technical Assistance Center in the United States is 1800-252-5283
Always use tools that are in good condition. Refer to the Allison Essential Tools list on the Allison Extranet to
complete any service procedure listed in an Allison publication. Also see appropriate Service Manuals and
Troubleshooting Manuals for service tools information.
Action
Value(s)
Yes
No
Go to Step 2
Review the
information in
Section 3-5,
Section 6-6, and
Diagnostic Aids
listed for this DTC
Go to Step 1
6528
3000 AND 4000 PRODUCT FAMILIES TROUBLESHOOTING MANUALALLISON 4th GENERATION CONTROLS
Go to Step 3
Go to Step 5
Go to Step 4
Get Allison
approval prior to
using this selector.
Correct vehicle
power and ground
issues in order to
comply with
Allison
specification while
TCM and selector
are attempting
communication of
handshake data.
Correct pin-to-pin
vehicle wiring
between TCM and
selector for power
and grounds or
J1939 data link
wiring issue exists
Go to Step 5
Go to Step 5
5
Replace shift
selector
Go to Step 2
System OK
Clear inactive
codes from history
Repair complete
6529
3000 AND 4000 PRODUCT FAMILIES TROUBLESHOOTING MANUALALLISON 4th GENERATION CONTROLS
J1939 BASED
SHIFT SELECTOR
J1939
Data
Link
TRANS (TCM)
120
Resistor
9-PIN DIAGNOSTIC
TOOL CONNECTOR
J1939
Data
Link
120
Resistor
E
F
C
A
Should not
exceed 1 meter
SHIELD
NOTE 4
NOTE 3
7
NOTE 2
NOTE 2
SHIELD
BATERY VOLTAGE
IGNITION SENSE
5 13 12 14 8 15 16 7 11 34 48 68 49 28 8
PIN E
PIN C (+)
SHIELD PIN D ()
SECONDARY
SELECTOR 2 ID
BATTERY
GROUND NOTE 1
6
B
J
TERMINATION
RESISTOR
GREEN
120
RESISTOR
SHIELD
SHIELD
SHIELD
SHIELD
120
RESISTOR
V09131.00.00.A
Circuit Description
The Controller Area Network (CAN) defined by SAE J1939 allows the integration of various vehicle components
into an overall vehicle system by providing a standard way of exchanging information between the various
modules used in a vehicle. Use of a J1939 network, or data link, for on-vehicle communication reduces the amount
of wiring in a vehicle, and allows the many different components and subsystems access to a wider range of
information. Allison uses the J1939 communication link for vehicle operation controls, powertrain interaction, and
conveying vehicle management information.
Conditions for Running the DTC
3000 AND 4000 PRODUCT FAMILIES TROUBLESHOOTING MANUALALLISON 4th GENERATION CONTROLS
Use the Allison DOC For PCService Tool to clear the inactive code from the TCM history. The TCM
automatically clears the DTC from the TCM history if the vehicle completes 40 engine starts without a
reoccurrence of the code.
Diagnostic Aids
NOTE: OEM repairs necessary for transmission DTCs to go inactive are not covered under Allison
Transmission warranty.
Typical cause for this DTC is engine/OEM issue and/or engine/OEM DTC
If there are other vehicle DTCs present, the cause for transmission-related DTCs might be external to the
transmission and those vehicle systems must be corrected in order for the transmission DTCs to be resolved.
A transmission DTC must be active during the troubleshooting process to determine what caused the DTC. Use
the Snapshot feature and/or Databus Viewer of Allison DOC For PCService Tool while operating the
vehicle in the same conditions listed in the Failure Record (available in the Allison DOC For PCService
Tool Reports menu).
Using the Snapshot feature and/or Databus Viewer of Allison DOC For PCService Tool and/or a DVOM
and the Breakout Box J 39700 while manipulating the chassis harness and/or data link wiring may reveal
intermittent shorts to ground, shorts to another circuit, and open circuits that ar causing an intermittent DTC.
NOTE: OEM vehicle harness repairs are not covered under Allison Transmission warranty.
OEM chassis wiring issues should be considered as possible causes for every DTC. Possible wiring and
connector issues include:
J1939 termination resistors may be disconnected or defective
Expanded female terminals in a connector. Use a mating pin or terminal to check for a light drag feel when
the mating terminal or pin is inserted and slowly removed. There should be some slight friction between
the matching terminal and pin combination. Expanded terminals have no feel of drag when the matching
pin or terminal is inserted and removed.
Broken terminal locks allow the pins or terminals to push back into the connector resulting in poor
connection or pin to pin shorts in the connector. Inspect for broken locks and displaced terminals in
connections. Never use paper clips or other devices to back-probe a connector while doing Allison service
work.
Poor pin crimps. Pin crimps should be pull-tested by the technician to verify the crimp is secure to the wire.
If the pin crimp is loose, the pin easily moves or even comes off the wire with a slight tug on the terminal
by the technician. This situation may not reveal itself as an active DTC but instead may exhibit other
symptoms like shift quality issues.
Connector and pin corrosion caused by moisture in connectors. Empty wire locations in connectors must
always have a plug to keep moisture from finding a path into the connector.
Poor harness routing and improper strain relief may cause damage resulting in electrical open and/or short
circuits to wires and connector components.
Butt splices and wire ties are not an ideal solution for any transmission repair. If butt splices will be used,
then always use heat-shrinkable butt splices. Never use wire ties inside the transmission, to hold connector
components together in the place of a connector lock., or in the place of the correct strain relief
Copyright 2008 Allison Transmission, Inc.
6531
3000 AND 4000 PRODUCT FAMILIES TROUBLESHOOTING MANUALALLISON 4th GENERATION CONTROLS
The following procedures are not documented in any Allison service procedures or in any Allison
Troubleshooting Manual or Service Manual, and therefore should not be used as a method to diagnose any
transmission DTC(s) or Service Manual and therefore should not be used as a method to diagnose any
transmission DTC(s), function, or shift quality concern:
Back-probing any connectors used for transmission features or functions may damage and/or unlock the
terminals from the back-probed connector creating permanent or intermittent shorts and/or open circuits. If
possible, use the Breakout Box J 39700, appropriate harness adapters, and appropriate magnetic overlays
to troubleshoot the vehicle.
Load-testing any transmission-related circuits with any other electrical devices such as vehicle lamps,
relays, etc. especially with the TCM connected to the harness. Use the approved SPX Break-out service
tool, J-39700 and appropriate harnesses with Allison DOC For PCService Tool to monitor the circuit
performance in question unless otherwise directed within a step in the various Troubleshooting Manuals to
use a digital volt-Ohm meter (DVOM) with the Breakout.
Piercing a wire to check for voltages, shorts-to-grounds or other wires anywhere in the circuit but
especially at the TCM. This creates a leak path for moisture and damages the wire and insulation.
If needed, call for local distributor and/or factory support before downtime and expense of repair effect the
Allison Customer Experience. The phone number for the Technical Assistance Center in the United States is 1800-252-5283
Always use tools that are in good condition. Refer to the Allison Essential Tools list on the Allison Extranet to
complete any service procedure listed in an Allison publication. Also see appropriate Service Manuals and
Troubleshooting Manuals for service tools information.
Action
Value(s)
Yes
No
Go to Step 2
Review the
information in
Section 3-5,
Section 6-6, and
Diagnostic Aids
listed for this DTC
Go to Step 1
6532
3000 AND 4000 PRODUCT FAMILIES TROUBLESHOOTING MANUALALLISON 4th GENERATION CONTROLS
Action
Value(s)
Yes
No
Go to Step 3
Go to Step 4
Advise customer
that engine/OEM
service outlet must
resolve the engine
derate to resolve
the transmission
DTC U0442
Go to Step 4
Go to Step 5
4
Go to Step 1
System OK
Clear inactive
codes from history
Repair complete
6533
3000 AND 4000 PRODUCT FAMILIES TROUBLESHOOTING MANUALALLISON 4th GENERATION CONTROLS
TRANS (TCM)
120
Resistor
9-PIN DIAGNOSTIC
TOOL CONNECTOR
J1939
Data
Link
120
Resistor
E
F
C
A
Should not
exceed 1 meter
SHIELD
NOTE 4
NOTE 3
7
NOTE 2
NOTE 2
SHIELD
BATERY VOLTAGE
IGNITION SENSE
5 13 12 14 8 15 16 7 11 34 48 68 49 28 8
PIN E
PIN C (+)
SHIELD PIN D ()
SECONDARY
SELECTOR 2 ID
BATTERY
GROUND NOTE 1
B
J
TERMINATION
RESISTOR
GREEN
120
RESISTOR
SHIELD
SHIELD
SHIELD
SHIELD
120
RESISTOR
V09131.00.00.A
Circuit Description
In Allison 4th Generation Controls, the Transmission Control Module (TCM) communicates with the shift selector
over the J1939 Controller Area Network (CAN). Allison J1939 shift selectors broadcast proprietary messages to
the TCM related to range selection and other operating modes.
Conditions for Running the DTC
6534
3000 AND 4000 PRODUCT FAMILIES TROUBLESHOOTING MANUALALLISON 4th GENERATION CONTROLS
Use the Allison DOC For PCService Tool to clear the code from the TCM history.
The TCM automatically clears the DTC from the TCM history if the vehicle completes 40 engine starts
without a reoccurrence of the code.
Diagnostic Aids
NOTE: OEM repairs necessary for transmission DTCs to go inactive are not covered under Allison
Transmission warranty.
If there are other vehicle DTCs present, the cause for transmission-related DTCs might be external to the
transmission and those vehicle systems must be corrected in order for the transmission DTCs to be resolved.
A transmission DTC must be active during the troubleshooting process to determine what caused the DTC. Use
the Snapshot feature and/or Databus Viewer of Allison DOC For PCService Tool while operating the
vehicle in the same conditions listed in the Failure Record (available in the Allison DOC For PCService
Tool Reports menu).
Using the Snapshot feature and/or Databus Viewer of Allison DOC For PCService Tool and/or a DVOM
and the Breakout Box J 39700 while manipulating the chassis harness and/or data link wiring may reveal
intermittent shorts to ground, shorts to another circuit, and open circuits that are causing an intermittent DTC.
NOTE: OEM vehicle harness repairs are not covered under Allison Transmission warranty.
OEM chassis wiring issues should be considered as possible causes for every DTC. Possible wiring and
connector issues include:
J1939 termination resistors may be disconnected or defective
Expanded female terminals in a connector. Use a mating pin or terminal to check for a light drag feel when
the mating terminal or pin is inserted and slowly removed. There should be some slight friction between
the matching terminal and pin combination. Expanded terminals have no feel of drag when the matching
pin or terminal is inserted and removed.
Broken terminal locks allow the pins or terminals to push back into the connector resulting in poor
connection or pin to pin shorts in the connector. Inspect for broken locks and displaced terminals in
connections. Never use paper clips or other devices to back-probe a connector while doing Allison service
work.
Poor pin crimps. Pin crimps should be pull-tested by the technician to verify the crimp is secure to the wire.
If the pin crimp is loose, the pin easily moves or even comes off the wire with a slight tug on the terminal
by the technician. This situation may not reveal itself as an active DTC but instead may exhibit other
symptoms like shift quality issues.
Connector and pin corrosion caused by moisture in connectors. Empty wire locations in connectors must
always have a plug to keep moisture from finding a path into the connector.
Copyright 2008 Allison Transmission, Inc.
6535
3000 AND 4000 PRODUCT FAMILIES TROUBLESHOOTING MANUALALLISON 4th GENERATION CONTROLS
then always use heat-shrinkable butt splices. Never use wire ties inside the transmission, to hold connector
components together in the place of a connector lock, or in the place of the correct strain relief components
and clips used to fasten harnesses to the vehicle or to retain vehicle connectors unless OEM approved for
the location and vehicle component being repaired.
The following procedures are not documented in any Allison service procedures or in any Allison
Troubleshooting Manual or Service Manual and therefore should not be used as a method to diagnose any
transmission DTC(s), function, or shift quality concern:
Back probing any connectors used for transmission features or functions may damage and/or unlock the
terminals from the back-probed connector creating permanent or intermittent shorts and/or open circuits. If
possible, use the J 39700 Breakout Box, appropriate harness adapters, and appropriate magnetic overlays
to troubleshoot the vehicle.
Load-testing any transmission-related circuits with any other electrical devices such as vehicle lamps or
relays, especially with the TCM connected to the harness. Use Breakout Box J 39700 and appropriate
harnesses with Allison DOC For PCService Tool to monitor the circuit performance in question unless
otherwise specified in the various Troubleshooting Manuals to use a digital volt-ohm meter (DVOM) with
the Breakout.
Piercing a wire to check for voltages, shorts-to-grounds or other wires anywhere in the circuit but
especially at the TCM. This creates a leak path for moisture and damages the wire and insulation.
If needed, call for local distributor and/or factory support before downtime and expense of repair effect the
Allison Customer Experience. The phone number for the Technical Assistance Center in the United States is 1800-252-5283
Always use tools that are in good condition. Refer to the Allison Essential Tools list on the Allison Extranet to
complete any service procedure listed in an Allison publication. Also see appropriate Service Manuals and
Troubleshooting Manuals for service tools information.
Action
Value(s)
Yes
No
Go to Step 2
Review the
information in
Section 3-5,
Section 6-6, and
Diagnostic Aids
listed for this DTC
Go to Step 1
6536
3000 AND 4000 PRODUCT FAMILIES TROUBLESHOOTING MANUALALLISON 4th GENERATION CONTROLS
Go to Step 3
Go to Step 5
Go to Step 4
Get Allison
approval prior to
using this selector.
Correct vehicle
power and ground
issues in order to
comply with
Allison
specification while
TCM and selector
are attempting
communication of
handshake data.
Correct pin-to-pin
vehicle wiring
between TCM and
selector for power
and grounds or
J1939 data link
wiring issue exists
Go to Step 5
Go to Step 5
5
Replace shift
selector
Go to Step 2
System OK
Clear inactive
codes from history
Repair complete
6537
3000 AND 4000 PRODUCT FAMILIES TROUBLESHOOTING MANUALALLISON 4th GENERATION CONTROLS
6538
3000 AND 4000 PRODUCT FAMILIES TROUBLESHOOTING MANUALALLISON 4th GENERATION CONTROLS
INPUT FUNCTIONS
Input functions are signals sent into the TCM that prompt the TCM to take action. Input functions are activated and
deactivated by switched ignition power or ground (wire 103) to the TCM (wired through the VIW), or through the
MODE button on the shift selector. The following input functions can be activated using the MODE button:
Secondary Shift Schedule
D1 Selection (available with pushbutton selector only)
PTO Enable
Auto 21 Preselect for 7-Speeds
The wiring schematic in Appendix J illustrates installation requirements for input functions and designates specific
wire numbers in the transmission control system to be used for the activation of these input functions. Appendix J
should be used for reference only. The vehicle manufacturer determines which input functions are programmed,
which wires are used, and whether voltage input was positive or ground. Wiring schematics for input and output
functions are shown in Appendix P. Use Allison DOC For PCService Tool to determine which wire was
programmed for a particular input function and the wiring schematic can be consulted to find out if input to the
TCM is + or voltage. Refer to Allison publication GN3433EN, User Guide for Allison DOC For PCService
Tool, for further information regarding special input functions and other inhibits.
NOTE:
The wiring schematic in Appendix J shows the intended use of the control features specified. These
features have only been validated in the configuration shown. ANY USE OF THESE FEATURES
WHICH DIFFERS FROM WHAT IS SHOWN IS NOT THE RESPONSIBILITY OF ALLISON
TRANSMISSION.
CAUTION:
NEVER use chassis ground as an INPUT FUNCTION ground. Chassis ground can
carry voltage potential of 1 or 2 volts above battery ground. This non-approved input
will confuse the TCM and cause erroneous input results. Be sure to use wire 103
which is signal ground.
Activating an input function can inhibit transmission operation in the same manner as a DTC. Use the Allison
DOC For PCService Tool to verify an active input function or a DTC inhibit. Refer to Allison publication
GN3433EN, User Guide for Allison DOC For PCService Tool, for further information regarding special input
functions and other inhibits. For more detailed information on input functions, refer to the Allison Tech Data Book
4th Generation Controls and General Information.
The maximum number of input and output functions which may be used in any installation depends upon the
transmission model and its features. Refer to Table 71.
Table 71. Input/Output Function Availability
Transmission Model
6-Speed and
4000 7-Speed Transmissions
3000 7-Speed Transmissions
Auxiliary Transmission
Controls Functions
Number Of Input
Functions
Number Of Output
Functions
Retarder
12 + Mode Button
Transfer Case
12 + Mode Button
71
3000 AND 4000 PRODUCT FAMILIES TROUBLESHOOTING MANUALALLISON 4th GENERATION CONTROLS
The following input function inhibits range and lockup shifts at high horsepower:
Shift Enable/Shift in Process (Oil Field Application)
transmission remains in N.
Wheel Lock disengages the lockup clutch and inhibits forward range downshifts and shifts to reverse
Anti-lock Brake Response deactivates the retarder and disengages the lockup clutch
High Throttle during N (Neutral) to any range shift causes a revised clutch pressure apply rate and turns
off shift adaptive
Power loss to the TCM restricts operation to certain ranges. Hydraulic default (SOL OFF) is commanded.
The shift selector position and hydraulic state of logic values determine the range attained.
72
3000 AND 4000 PRODUCT FAMILIES TROUBLESHOOTING MANUALALLISON 4th GENERATION CONTROLS
OUTPUT FUNCTIONS
Output functions are signals sent out by the TCM that activate or control devices or mechanisms. These control
devices or mechanisms are controlled by relays or direct connection signals from the TCM.
Many input and output functions are closely related. For example, the PTO Enable option (input function) also
includes PTO Output wiring information. When searching for output function information, be sure to review any
related input function information references.
The wiring schematics in Appendix J and Appendix P illustrate installation requirements for output functions as
well as input functions and designate specific wire numbers in the transmission control system to be used for the
activation of these output functions. The wiring schematics in Appendix J should be used for reference only. Ask
the vehicle manufacturer which specific output functions are programmed and which wires are used. Output
function polarity is not significant when an Allison-supplied VIM is used. The Allison DOC For PCService
Tool can also be utilized to determine which wire was programmed for a particular output function. For more
detailed information on output functions, refer to Allison Tech Data, Allison 4th Generation Controls 3000 and
4000 Product Families on the Allison Transmission Extranet. The schematics in Appendix P are from Allison Tech
Data.
73
3000 AND 4000 PRODUCT FAMILIES TROUBLESHOOTING MANUALALLISON 4th GENERATION CONTROLS
74
3000 AND 4000 PRODUCT FAMILIES TROUBLESHOOTING MANUALALLISON 4th GENERATION CONTROLS
Use the various sections of this manual to isolate the listed problems. The following charts address specific vehicle
complaints. Some complaints involve DTCs, so all troubleshooting should involve determining if the system has
set any DTCs.
81
3000 AND 4000 PRODUCT FAMILIES TROUBLESHOOTING MANUALALLISON 4th GENERATION CONTROLS
Probable Cause
Suggested Remedy
Dead battery
Recharge battery
Disconnected battery
Reconnect battery
Repair wiring
None, normal
Faulty TCM
82
3000 AND 4000 PRODUCT FAMILIES TROUBLESHOOTING MANUALALLISON 4th GENERATION CONTROLS
Probable Cause
Suggested Remedy
Faulty harness
Faulty TCM
Repair wiring
Faulty TCM
Replace TCM
83
3000 AND 4000 PRODUCT FAMILIES TROUBLESHOOTING MANUALALLISON 4th GENERATION CONTROLS
Probable Cause
Faulty TCM
Suggested Remedy
3000 AND 4000 PRODUCT FAMILIES TROUBLESHOOTING MANUALALLISON 4th GENERATION CONTROLS
TRANSMISSION LOCKUP
CLUTCH WILL NOT ENGAGE
Probable Cause
Suggested Remedy
Auto-neutral or quick-to-neutral
circuit (input function) faulty
Faulty solenoidleaking
Incorrect calibration
Hydraulic problem
Faulty TCM
Replace TCM
85
3000 AND 4000 PRODUCT FAMILIES TROUBLESHOOTING MANUALALLISON 4th GENERATION CONTROLS
TRANSMISSION DOES
NOT SHIFT PROPERLY
(ROUGH SHIFTS, SHIFTS
OCCURRING AT TOO LOW
OR TOO HIGH SPEED)
86
Probable Cause
Suggested Remedy
Intermittent problems
Incorrect calibration
3000 AND 4000 PRODUCT FAMILIES TROUBLESHOOTING MANUALALLISON 4th GENERATION CONTROLS
Probable Cause
Suggested Remedy
87
3000 AND 4000 PRODUCT FAMILIES TROUBLESHOOTING MANUALALLISON 4th GENERATION CONTROLS
Probable Cause
Suggested Remedy
3000 AND 4000 PRODUCT FAMILIES TROUBLESHOOTING MANUALALLISON 4th GENERATION CONTROLS
Probable Cause
EXCESSIVE FLARE
ENGINE OVERSPEED ON
FULL-THROTTLE UPSHIFTS
TPS Adjustment:
Suggested Remedy
Overstroke
Loose
Incorrect calibration
Correct calibration
Incorrect calibration
Verify calibration
* Refer to Appendix BMeasure main pressure, clutch pressure, and pressure specifications.
Copyright 2008 Allison Transmission, Inc.
89
3000 AND 4000 PRODUCT FAMILIES TROUBLESHOOTING MANUALALLISON 4th GENERATION CONTROLS
Probable Cause
Suggested Remedy
A. Ranges 1, 2, 3, 4 Only
(6-speed and 3000 7-speed)
Ranges Lo, 1, 2, 3, 4 only
(4000 7-Speed)
B. Ranges 4, 5, 6 Only
(6-speed, 7-speed)
C. Ranges 3, 5, R Only
(6-speed and 4000 7-speed)
Ranges Lo, 3, 5, R only
(3000 7-speed)
D. Ranges 2, 6 Only
(6-speed and 7-speed)
E. Ranges 1, R Only
(6-speed and 7-speed)
F. Range Lo Only
(7-Speed)
* Refer to Appendix BMeasure main pressure, clutch pressure, and pressure specifications.
810
3000 AND 4000 PRODUCT FAMILIES TROUBLESHOOTING MANUALALLISON 4th GENERATION CONTROLS
Probable Cause
Suggested Remedy
811
3000 AND 4000 PRODUCT FAMILIES TROUBLESHOOTING MANUALALLISON 4th GENERATION CONTROLS
Probable Cause
Suggested Remedy
Cooler plugged
Faulty gauge
Not in gear
Select D (Drive)
C1 or C5 clutch slipping.
NOTE: Use the Allison DOC
For PCService Tool to check
turbine speed.
812
3000 AND 4000 PRODUCT FAMILIES TROUBLESHOOTING MANUALALLISON 4th GENERATION CONTROLS
Probable Cause
Suggested Remedy
OVERHEATING IN ALL
RANGES
Engine overheat
813
3000 AND 4000 PRODUCT FAMILIES TROUBLESHOOTING MANUALALLISON 4th GENERATION CONTROLS
NOISE OCCURRING
INTERMITTENTLY (BUZZING)
814
Probable Cause
Suggested Remedy
Dipstick loose
Clogged filters
3000 AND 4000 PRODUCT FAMILIES TROUBLESHOOTING MANUALALLISON 4th GENERATION CONTROLS
LEAKING FLUID
(OUTPUT SHAFT)\
TRANSMISSION INPUT
DIRTY FLUID
Probable Cause
Suggested Remedy
Replace flange
Replace flange
Replace O-rings
Converter leaks
Excessive heat
Substandard fluid
Clutch/transmission failure
* Contact your nearest Allison dealer/distributor with specific questions relating to PTO repair.
Copyright 2008 Allison Transmission, Inc.
815
3000 AND 4000 PRODUCT FAMILIES TROUBLESHOOTING MANUALALLISON 4th GENERATION CONTROLS
Probable Cause
Suggested Remedy
B. Noisy PTO
C. No or Intermittent Operation
(Clutched Drive)
Replace seal
Loose flange
816
TPS adjustment
Wrong calibration
Calibrate properly
3000 AND 4000 PRODUCT FAMILIES TROUBLESHOOTING MANUALALLISON 4th GENERATION CONTROLS
Probable Cause
Suggested Remedy
Faulty C6 seals
817
3000 AND 4000 PRODUCT FAMILIES TROUBLESHOOTING MANUALALLISON 4th GENERATION CONTROLS
Voltage Signal**
Wiring to
Control Device
Terminals
Resistance
K 5%
% Retarder
Application
Voltage
0.2V
Device Terminal
Auto Full On
A to C
12
100
3.6
No connections
Pressure Switch
Full On
High
A to C
32
0
100
1.1
3.6
A
B
A to C
32
0
32
58
100
1.1
1.9
2.8
3.6
A
B
C
D
A to C
32
0
16
28
48
65
84
100
1.1
1.5
1.9
2.3
2.8
3.2
3.6
+
1
2
3
4
5
6
Auto 1/2 On
A to C
12
50
2.4
No connections
3 Pressure Switches
Low
A to C
32
0
32
1.1
1.9
Medium
68
2.3
High
100
3.6
32
1.9
Medium
68
2.8
High
100
3.6
0
100
0.71.2
3.43.5
Description
Auto 1/3 On
2 Pressure Switches
Auto
Dedicated Pedal
A to C
No Tests
21.4
Interface not a
resistance module
* Resistance module must be disconnected from the wiring harness and retarder control devices.
** These voltages must be measured between terminals A and B.
818
A
B
A
B
A
B
A
B
A
B
A
B
C
3000 AND 4000 PRODUCT FAMILIES TROUBLESHOOTING MANUALALLISON 4th GENERATION CONTROLS
APPENDICES
Appendix A
Appendix B
Appendix C
Appendix D
Wire/Connector Chart
Appendix E
Appendix F
Appendix G
Appendix H
Hydraulic Schematics
Appendix J
Appendix K
Appendix L
Appendix M
Appendix N
Appendix P
Input/Output Functions
Appendix Q
Appendix R
3000 AND 4000 PRODUCT FAMILIES TROUBLESHOOTING MANUALALLISON 4th GENERATION CONTROLS
APPENDICES
NOTES
A0
3000 AND 4000 PRODUCT FAMILIES TROUBLESHOOTING MANUALALLISON 4th GENERATION CONTROLS
Circuit Inspection
Intermittent power/ground problemscan cause voltage problems during TCM diagnostic checks
which can set various codes depending upon where the TCM was in the diagnostic process.
Damaged terminals.
Dirty or corroded terminals.
Terminals not fully seated in the connector. Inspect indicated wires by uncoupling connector and
gently pulling on the wire at the rear of the connector and testing for excessive terminal
movement.
B.
A1
3000 AND 4000 PRODUCT FAMILIES TROUBLESHOOTING MANUALALLISON 4th GENERATION CONTROLS
A2
3000 AND 4000 PRODUCT FAMILIES TROUBLESHOOTING MANUALALLISON 4th GENERATION CONTROLS
Determine if there are diagnostic or prognostic codes set which are related to the transmission
difficulty you are evaluating. Proceed to make mechanical preparations for measuring clutch
pressures after codes have first been evaluated.
A.
C6 (3000 PRODUCT
FAMILY ONLY)
C5
C3
C5
MAIN
C7
MAIN
LU
C2
LU
C4
T-CASE
CONNECTOR
C1
FRONT VIEW
C6 PRESSURE TAP
(On left side of
adapter housing,
near the bottom)
MAIN
C2
C4
C1
4000
PRODUCT
FAMILY
7-SPEED
V05929.01.02
CAUTION:
Be sure that the hydraulic fittings have the same thread as the plugs
removed (7/16-20 UNF-2A). Also please note that these fittings must be straight
thread, O-ring style. Failure to do this will result in damage to the control
module.
B1
3000 AND 4000 PRODUCT FAMILIES TROUBLESHOOTING MANUALALLISON 4th GENERATION CONTROLS
Recording Data
1. Use the Allison DOC For PCService Tool, which allows checking of individual range clutch
pressures, with the vehicle stationary. Consult Appendix N or Allison publication GN3433EN,
User Guide for Allison DOC PCService Tool, for Action Request and select Clutch Test Mode.
Follow instructions to test clutch pressures in individual ranges.
NOTE:
Determine lockup clutch pressure by driving the vehicle in a range where lockup can be obtained.
Record the pressure values at the engine speed and sump fluid temperature values shown in Table B
1. The lockup clutch is functioning correctly when engine speed and turbine speed values are equal as
recorded from Allison DOC For PCService Tool.
2. Consult Table B1 and locate the transmission model that you are testing.
3. Operate the transmission at the conditions shown in Table B1 and record engine speed,
transmission sump fluid temperature, main hydraulic pressure, and clutch pressures in the ranges
where a problem is suspected.
Table B1. Clutch Pressure Test Conditions
Engine rpm
Sump Fluid
Temperature
580620
7193C
(160200F)
580620
7193C
(160200F)
20802120
7193C
(160200F)
B2
Range
Neutral
Reverse
1C
2C (2nd range start)
Neutral
Reverse
LowC
1C
Reverse
Neutral
1C
2C
2L
3L
4L
5L
6L
Clutches
Pressurized
C5
C3 C5
C1 C5
C1 C4
C5
C3 C5
C3 C6
C1 C5
C3 C5
C5
C1 C5
C1 C4
C1 C4 LU
C1 C3 LU
C1 C2 LU
C2 C3 LU
C2 C4 LU
3000 AND 4000 PRODUCT FAMILIES TROUBLESHOOTING MANUALALLISON 4th GENERATION CONTROLS
Engine rpm
20802120
17801820
Sump Fluid
Temperature
7193C
(160200F)
7193C
(160200F)
Range
Reverse
Neutral
LowC
1C
2C
2L
3L
4L
5L
6L
Reverse
Neutral
LowC**
1C
2C
2L
3L
4L
5L
6L
Clutches
Pressurized
C3 C5
C5
C3 C6
C1 C5
C1 C4
C1 C4 LU
C1 C3 LU
C1 C2 LU
C2 C3 LU
C2 C4 LU
C3 C5
C5
C1 C6
C1 C5
C1 C4
C1 C4 LU
C1 C3 LU
C1 C2 LU
C2 C3 LU
C2 C4 LU
B3
3000 Product
FamilyIdle
Engine
rpm
580620
Range
Main Press.
Spec kPa
[psi]
Clutches
Applied
Range Clutch
Press. Spec*
kPa [psi]
Lube Pressure
Spec*
kPa [psi]
Dropbox Main
Press. Spec*
kPa [psi]
Neutral
Main Mod OFF
15152035
(220295)
C5
14402035
(210295)
1035
(15)
14402035
(210295)
Neutral
Main Mod ON
13101725
(190250)
C5
12351725
(180250
1035
(15)
12351725
(180250)
Reverse
Main Mod OFF
14502035
(210295)
C3, C5
13752035
(200295)
1035
(15)
13752035
(200295)
Reverse
Main Mod ON
11701585
(170230)
C3, C5
10951585
(160230)
1035
(15)
10951585
(160230)
12401725
(180250)
C3, C6
11651725
(170250)
1035
(15)
11651725
(170250)
8701340
(125195)
C3, C6
7951340
(115195)
1035
(15)
7951340
(115195)
1C
Main Mod OFF
12401725
(180250)
C1, C5
11651725
(170250)
1035
(15)
11651725
(170250)
1C
Main Mod ON
8701340
(125195)
C1, C5
7951340
(115195)
1035
(15)
7951340
(115195)
2C
Main Mod OFF
12401725
(180250)
C1, C4
11651725
(170250)
1035
(15)
11651725
(170250)
2C
Main Mod ON
8701340
(125195)
C1, C4
7951340
(115195)
1035
(15)
7951340
(115195)
Transmission
Model/Test
Type
B4
3000 Product
FamilyHigh Speed
Engine
rpm
Range
20802120 Neutral
Main Mod OFF
Main Press.
Spec kPa
[psi]
Clutches
Applied
Range Clutch
Press. Spec*
kPa [psi]
Lube Pressure
Spec*
kPa [psi]
Dropbox Main
Press. Spec*
kPa [psi]
18052205
(260320)
C5
17302205
(250320)
160240
(2335)
17302205
(250320)
Neutral
Main Mod ON
14151725
(205250)
C5
13351725
(195250)
160240
(2335)
13351725
(195250)
Reverse
18052205
(260320)
C3, C5
17302205
(250320)
160240
(2335)
17302205
(250320)
15501965
(225285)
C3, C6
14751965
(215285)
160240
(2335)
14751965
(215285)
1C
15501965
(225285)
C1, C5
14751965
(215285)
160240
(2335)
14751965
(215285)
2C
15501965
(225285)
C1, C4
14751965
(215285)
160240
(2335)
14751965
(215285)
2L
10801365
(155200)
C1, C4, LU
10051365
(145200)
160240
(2335)
10051365
(145200)
3C
15501965
(225285)
C1, C3
14751965
(215285)
160240
(2335)
14751965
(215285)
3L
10801365
(155200)
C1, C3, LU
10051365
(145200)
160240
(2335)
10051365
(145200)
4C
15501965
(225285)
C1, C2
14751965
(215285)
125200
(1830)
14751965
(215285)
4L
10801365
(155200)
C1, C4, LU
10051365
(145200)
125200
(1830)
10051365
(145200)
5C
15501965
(225285)
C2, C3
14751965
(215285)
125200
(1830)
14751965
(215285)
5L
10801365
(155200)
C2, C3, LU
10051365
(145200)
125200
(1830)
10051365
(145200)
6C
1345-1590
(220290)
C2, C4
1270-1590
(185-230)
125200
(1830)
1270-1590
(185-230)
6L
10351415
(150205)
C2, C4, LU
9601415
(140205)
125200
(1830)
9601415
(140205)
Transmission
Model/Test
Type
B5
4000 Product
FamilyIdle
Engine
rpm
580620
Range
Main Press.
Spec kPa
[psi]
Clutches
Applied
Range Clutch
Press. Spec*
kPa [psi]
Lube Pressure
Spec*
kPa [psi]
Neutral
Main Mod OFF
15152055
(220300)
C5
14402055
(210300)
3.5 min
(0.5 min)
Neutral
Main Mod ON
13101725
(190250)
C5
12351725
(180250)
3.5 min
(0.5 min)
Reverse
Main Mod OFF
14502055
(210300)
C3, C5
13752055
(200300)
3.5 min
(0.5 min)
Reverse
Main Mod ON
11701585
(170230)
C3, C5
10951585
(160230)
3.5 min
(0.5 min)
12401725
(180250)
C1, C6
11651725
(170250)
3.5 min
(0.5 min)
8701340
(125195)
C1, C6
7951340
(115195)
3.5 min
(0.5 min)
1C
Main Mod OFF
12401725
(180250)
C1, C5
11651725
(170250)
3.5 min
(0.5 min)
1C
Main Mod ON
8701340
(125195)
C1, C5
7951340
(115195)
3.5 min
(0.5 min)
2C
Main Mod OFF
12401725
(180250)
C1, C4
11651725
(170250)
3.5 min
(0.5 min)
2C
Main Mod ON
8701340
(125195)
C1,C4
7951340
(115195)
3.5 min
(0.5 min)
Dropbox Main
Press. Spec*
kPa [psi]
Transmission
Model/Test
Type
B6
4000 Product
FamilyHigh Speed
Engine
rpm
Range
17801820 Neutral
Main Mod OFF
Main Press.
Spec kPa
[psi]
Clutches
Applied
Range Clutch
Press. Spec*
kPa [psi]
Lube Pressure
Spec*
kPa [psi]
18052055
(260300)
C5
17302055
(250300)
160240
(2335)
Neutral
Main Mod ON
14151725
(205240)
C5
13401725
(195240)
160240
(2335)
Reverse
18052055
(260300)
C3, C5
17302055
(250300)
160240
(2335)
15501795
(225260)
C1, C6
14751795
(215260)
160240
(2335)
1C
15501795
(225260)
C1, C5
14751795
(215260)
160240
(2335)
2C
15501795
(225260)
C1, C4
14751795
(215260)
160240
(2335)
2L
10801365
(155200)
C1, C4, LU
10051365
(145200)
160240
(2335)
3C
15501795
(225260)
C1, C3
14751795
(215260)
160240
(2335)
3L
10801365
(155200)
C1, C3, LU
10051365
(145200)
160240
(2335)
4C
15501795
(225260)
C1, C2
14751795
(215260)
125200
(1830)
4L
10801365
(155200)
C1, C4, LU
10051365
(145200)
125200
(1830)
5C
15501795
(225260)
C2, C3
14751795
(215260)
125200
(1830)
5L
10801365
(155200)
C2, C3, LU
10051365
(145200)
125200
(1830)
6C
13451590
(195230)
C2, C4
12701590
(185230)
125200
(1830)
6L
10351235
(150180)
C2, C4, LU
9601235
(140180)
125200
(1830)
Dropbox Main
Press. Spec*
kPa [psi]
B7
* To pass this specification, measured clutch pressures must be within 75kPa (10 psi) of actual measured main pressure and still be within the minimum and maximum value of this specification.
Transmission
Model/Test
Type
3000 AND 4000 PRODUCT FAMILIES TROUBLESHOOTING MANUALALLISON 4th GENERATION CONTROLS
High Capacity
Medium Capacity
Low Capacity
10801365
(155200)
215310
(3145)
150 (300) Max (Ref)
10801365
(155200)
215310
(3145)
150 (300) Max (Ref)
10801365
(155200)
215310
(3145)
150 (300) Max (Ref)
High Capacity
10801365
(155200)
539608
(7888)
150 [300] Max (Ref)
Medium Capacity
10801365
(155200)
446521
(6576)
150 [300] Max (Ref)
Low Capacity
10801365
(155200)
384444
(5664)
150 [300] Max (Ref)
B8
High Capacity
10801365
(155200)
148232
(2134)
150 [300] Max (Ref)
Medium Capacity
10801365
(155200)
148232
(2134)
150 [300] Max (Ref)
Low Capacity
10801365
(155200)
148232
(2134)
150 [300] Max (Ref)
3000 AND 4000 PRODUCT FAMILIES TROUBLESHOOTING MANUALALLISON 4th GENERATION CONTROLS
High Capacity
10801365
(155200)
373434
(5463)
150 [300] Max (Ref)
Medium Capacity
10801365
(155200)
320381
(4655)
150 [300] Max (Ref)
Low Capacity
10801365
(155200)
267330
(3948)
150 [300] Max (Ref)
B9
3000 AND 4000 PRODUCT FAMILIES TROUBLESHOOTING MANUALALLISON 4th GENERATION CONTROLS
B10
3000 AND 4000 PRODUCT FAMILIES TROUBLESHOOTING MANUALALLISON 4th GENERATION CONTROLS
PCS1
N/O
PCS2
N/O
PCS3
N/C
PCS4
N/C
TCC
N/C
4
3
X
X
NC5
NVL
NC4
NC3
NOTE:
Clutches
X
X
SS1
On/Off
C1
C2
C3
C4
LU
Y
Y
C5
O
Y
O
Y
Y
X
7-SPEED CONFIGURATION
(3000 and 4000 Product Families)
Clutches
X
X
4
3
LO-3700
X
X
Y
Y
LO-4700
X
X
NVL
NC4
NC3
X
X
Y
Y
Y
Y
Y
Y
X
NC5
NOTE:
X
X
Y
Y
O
Y
Y
X
O
Y
C1
3000 AND 4000 PRODUCT FAMILIES TROUBLESHOOTING MANUALALLISON 4th GENERATION CONTROLS
Blank
Optional ON or OFF.
NVL
As a diagnostic response:
If Turbine Speed is below 150 rpm when Output Speed is below 100 rpm and Engine Speed is
above 400 rpm, Neutral Very Low (NVL) is commanded when NC5 (Neutral) is the selected
range. NVL is achieved by turning PCS4 solenoid on in addition to PCS3 being on, which
locks the output. Otherwise, PCS4 solenoid is turned off N1 (Neutral).
As a commanded range when shifting to Fire Truck Pump Mode:
While wire 123 is energized before wire 122 is energized when going into Fire Truck Pump
Mode, Neutral Very Low (NVL) will be commanded to lock the output to assist the shifting of
the split-shaft PTO transfer case from road mode to pump mode. While wire 123 is de-energized
before wire 122 is de-energized when shifting out of Fire Truck Pump Mode, Neutral Very Low
(NVL) will be commanded to lock the output to assist the shifting of the split-shaft PTO transfer
case from pump mode to road mode.
C2
3000 AND 4000 PRODUCT FAMILIES TROUBLESHOOTING MANUALALLISON 4th GENERATION CONTROLS
The following abbreviation guide should be used to locate connector termination points for wires in
the Allison 4th Generation wiring harness(es).
Table D1. Appendix D Abbreviation Guide
Connector Name
ABS
ARTN
Analog Return
CAN
DDRD
Diagnostic ConnectorDeutsch
DDRP
Diagnostic ConnectorPackard
FM
GPI
GPO
J1939
NE
NO
NT
OBD-II
OLS
OM
PCS
PS
PWM
RMR
RNGTRM
RTEMP
SCI
SS
Shift Solenoid
TCASE
TM
TPS
TRANS
VIM
D1
3000 AND 4000 PRODUCT FAMILIES TROUBLESHOOTING MANUALALLISON 4th GENERATION CONTROLS
END VIEW OF
80-WAY CONNECTOR
END VIEW OF
80-WAY CONNECTOR
80
61
61
80
60
41
41
60
40
21
21
40
20
20
V09236.00.00
Color
Blue
Yellow
Yellow
Yellow
Orange
Yellow
Yellow
Green
Gray
Pink
Orange
Pink
Wire No.
101
102
103
104
105
106
107
108
109
110
111
112
13
14
15
White
Blue
White
113
114
115
GPO 8 ()
Strip Shift Selector Bit-4
Pressure Control Solenoid (PCS5)
16
17
18
19
Blue
Blue
Yellow
Blue
116
117
118
119
OLS
GPI 10 ()
PS2
Shift Solenoid (SS2)
20
Blue
120
21
22
23
24
25
Green
Yellow
Green
White
Tan
121
122
123
124
125
ABS/GPI 8 ()
GPI 4 ()
GPI 1 (+)
GPO 5
Vehicle Speed Signal
26
27
28
29
Yellow
Green
Yellow
Green
126
127
128
129
D2
Description
GPI 6 ()
GPI 2 (+)
TCM Digital Return
GPO 2 ()
GPO 4 ()
CAN 2 High (+)
Internal Terminating Resister CAN 1 (TCM)
CAN 1 Low ()
Battery ()
Battery (+)
High Side Driver Feed (HSD1)
Signal Reference 5V
Termination Point(s)
Vehicle System
Vehicle System
Vehicle System
Vehicle System or VIM-B1
Vehicle System or VIM-C2
IES CAN A or H
Vehicle System
J1939 B or L
Vehicle System or VIM-A2
Vehicle System or VIM-E2
Trans Connector (Pin 1)
Trans Connector (Pin 16) TPS (Pin C)
RMR (Pin C)
Vehicle System
Strip Shift Selector (Pin C)
Retarder Solenoid (Pin A) or T-Case
(Pin A)
Trans Connector (Pin 15)
Vehicle System
Trans Connector (Pin 17)
Trans Connector (Pin 17) or Retarder
Accumulator Solenoid (Pin A)
NT-B (4000) or Trans Connector
(Pin 14) (3000)
Vehicle System
Vehicle System
Vehicle System
Vehicle System
Input for Vehicle Speedometer or
VIM-B2
Vehicle System
IES CAN B or L
J1939 A or H
Vehicle System
3000 AND 4000 PRODUCT FAMILIES TROUBLESHOOTING MANUALALLISON 4th GENERATION CONTROLS
Wire No.
130
GPO 1 (+)
131
HSD3
Description
32
33
34
35
36
37
38
39
40
41
White
Yellow
No Color
Blue
Orange
White
Tan
Orange
Green
Tan
132
133
134
135
136
137
138
139
140
141
42
43
44
45
46
47
48
49
50
51
52
53
54
55
56
57
58
White
Blue
Blue
Orange
N/A
Green
Yellow
N/A
Pink
White
Green
Green
Tan
White
Yellow
White
Green
142
143
144
145
146
147
148
149
150
151
152
153
154
155
156
157
158
GPI 5 ()
GPI 3 (+)
PWM/TPS Input
GPO 3 ()
ISO 9141
CAN 2 Low
CAN 1 High
CAN 1 Shield
GPO 7 ()
SS1
PCS2
Strip Shift Selector Bit-2
Sump Temp Sensor
PCS4
Retarder Request Sensor
GPI 12 ()
TCM Analog Return
59
60
61
62
63
64
65
66
67
68
69
70
71
72
73
Tan
Yellow
Orange
Yellow
Yellow
Blue
Tan
Yellow
N/A
Green
Gray
Pink
Yellow
Blue
Orange
159
160
161
162
163
164
165
166
167
168
169
170
171
172
173
Termination Point(s)
Vehicle System or VIM-D2
Trans Connector (Pin 11), Retarder
Accumulator Solenoid (Pin B), and
Retarder Solenoid (Pin B) or T-Case
(Pin-B)
J1708 High
Trans Connector (Pin 9)
Allison J1939 Shift Selector (Pin 11)
Engine Water Temp (Pin A)
Trans Connector (Pin 4)
Trans Connector (Pin 12)
Strip Shift Selector (Pin E)
NE-B
NO-B or T-Case (Pin D)
To OEM supplied starter relay or
VIM-D1
Vehicle System
Vehicle System
Vehicle System or TPS (Pin B)
Vehicle System or VIM-F3
Vehicle System
IES CAN B or L
J1939 A ot H
J1939 C or S
Vehicle System
Trans Connector (Pin 10)
Trans Connector (Pin 5)
Strip Shift Selector (Pin B)
Trans Connector (Pin 18)
Trans Connector (Pin 2)
RMR (Pin B)
Vehicle System
Trans Connector (Pin 19), RMR
(Pin A), TPS (Pin A), Engine Water
Temp (Pin B), Retarder Temp (Pin B)
NE-A
NO-A or T-Case (Pin C)
Vehicle System
Vehicle System or VIM-F1
Vehicle System or VIM-F1
Vehicle System
Vehicle System or VIM-F2
IES CAN A or H
IES CAN C or S
J1939 B or L
Vehicle System or VIM-A1
Vehicle System or VIM-E1
Trans Connector (Pin 6)
J1708 Low
Strip Shift Selector (Pin A)
D3
3000 AND 4000 PRODUCT FAMILIES TROUBLESHOOTING MANUALALLISON 4th GENERATION CONTROLS
D4
Wire No.
174
175
176
177
178
179
181
Description
MAIN MOD Solenoid
Retarder Temperature
TransID
PS1
PCS6
GPI 11 ()
Turbine Speed SensorHigh
Termination Point(s)
Trans Connector (Pin 8)
Retarder Temp (Pin A)
Trans Connector (Pin 20)
Trans Connector (Pin 3)
Trans Connector (Pin 7)
Vehicle System
NT-A (4000) or Trans Connector
(Pin 13) (3000)
3000 AND 4000 PRODUCT FAMILIES TROUBLESHOOTING MANUALALLISON 4th GENERATION CONTROLS
10
10
14
11
11
14
20
15
15
20
V09239.00.00
Wire
No.
111 HSD1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
White
Green
Orange
Green
Yellow
White
Blue
Yellow
White
Yellow
White
Orange
Blue
Blue
Pink
Blue
Tan
Green
155
177
136
152
171
178
174
133
151
131
137
180
120
116
112
119
154
158
20
Yellow
176
Description
Termination Point(s)
TCM-11, TID Wire 176, MAIN MOD-A,
PCS4-A, PCS6-A
PCS4, Low
TCM-55, PCS4-B
Pressure Switch PS1 Input
TCM-77, PS1-A
PCS1, Low
TCM-36, PCS1-B
PCS2, Low
TCM-52, PCS2-B
HSD2
TCM-71, PCS1-A, PCS2-A, PCS3-A, SS1-A
PCS6, Low (7-speed only)
TCM-78, PCS6-B
MAIN MOD Solenoid, Low
TCM-74, MAIN MOD-B
PCS3, Low
TCM-33, PCS3-B
SS1, Low
TCM-51, SS1-B
HSD3
TCM-31, TCC-A, SS2-A (7-speed only)
TCC Solenoid, Low
TCM-37, TCC-B
Turbine Speed Sensor, High (3000 only) TCM-80, NT-A
Turbine Speed Sensor, Low (3000 only) TCM-20. NT-B
OLS Input
TCM-16, OLS-B
5V Reference Voltage
TCM-12, OLS-C, TPS-C, RMR-C
SS2, Low (7-speed only)
TCM-19, SS2-B
Sump Temperature Sensor Input
TCM-58, Sump Temp-B
Analog Return
TCM-58, OLS-A, Sump Temp-A, PS1-B,
RMR-A, TPS-A, RTR Temp-B,
Engine Water Temp-B
TransID
TCM-76, Wire 111
D5
3000 AND 4000 PRODUCT FAMILIES TROUBLESHOOTING MANUALALLISON 4th GENERATION CONTROLS
16
V09272.00.00
D6
Wire
No.
Description
Dimmer Input
Battery Ground
Shift Selector 2 ID
J1939 Internal Termination Resistor
Jumper, if used
CAN High J1939
Termination Point(s)
Vehicle System
Battery Ground
Shift Selector Pin 16
J1939 A or H
TCM-34
Vehicle System
Vehicle System
J1939 B or L
Shift Selector Pin 7
3000 AND 4000 PRODUCT FAMILIES TROUBLESHOOTING MANUALALLISON 4th GENERATION CONTROLS
D
COLOR CODE GREEN
HARNESS
DEVICE
T
A
L
V03369
Wire
No.
173
153
114
Description
Strip Selector, Data Bit 1
Strip Selector, Data Bit 2
Strip Selector, Data Bit 4
Termination Point(s)
TCM-73
TCM-53
TCM-14
138
TCM-38
150
Lamp Ground
TCM-50
103
Digital Ground
Switch Power
TCM-3
Vehicle System
D7
3000 AND 4000 PRODUCT FAMILIES TROUBLESHOOTING MANUALALLISON 4th GENERATION CONTROLS
MUSHROOM TYPE
SPEED SENSOR CONNECTOR
Color
Tan
Orange
Wire No.
159
139
Description
Engine Speed Sensor High
Engine Speed Sensor Low
Termination Point(s)
TCM-59
TCM-39
Color
Orange
Blue
Wire No.
180
120
Description
Turbine Speed Sensor High
Turbine Speed Sensor Low
Termination Point(s)
TCM-80
TCM-20
Color
Yellow
Green
Wire No.
160
140
Description
Output Speed Sensor High
Output Speed Sensor Low
Termination Point(s)
TCM-60
TCM-40
D8
Color
White
Yellow
Wire No.
115
131
Description
PCS5 Low
PCS5 High
Termination Point(s)
TCM-15
TCM-31, TRANS-11
3000 AND 4000 PRODUCT FAMILIES TROUBLESHOOTING MANUALALLISON 4th GENERATION CONTROLS
D
E
C
A
B
J
G
H
9-PIN
V04851.01.00
Wire No.
109 or 169
110 or 170
128 or 148
108 or 168
149
132
172
Description
Battery Return ()
Battery Power (+)
J1939 High
J1939 Low
J1939 Shield/Ground
Serial Communication (+)
Serial Communication ()
Termination Point(s)
TCM-9 or TCM-69
TCM-10 or TCM-70
TCM-28 or TCM-48, J1939-A/H
TCM-8 or TCM-68, J1939-B/L
TCM-49, J1939-C/S
TCM-23, SCI-A
TCM-72, SCI-B
D9
3000 AND 4000 PRODUCT FAMILIES TROUBLESHOOTING MANUALALLISON 4th GENERATION CONTROLS
1
V03370
Color
Wire No.
Description
Gray
109 or 169
White
106
132
CAN High
Serial Communication Interface, High
TCM-32, SCI-A
Blue
Yellow
107
172
163
CAN Low
Serial Communication Interface, Low
Ignition Sense (+)
TCM-72, SCI-B
TCM-63, VIWS-E
Battery Return ()
Termination Point(s)*
* Terminal number and termination points shown only apply when an Allison Transmission recommended harness configuration and
bulkhead connector are used.
D10
3000 AND 4000 PRODUCT FAMILIES TROUBLESHOOTING MANUALALLISON 4th GENERATION CONTROLS
V00645
Color
Green
Blue
Pink
Wire No.
158
144
112
Description
Analog Return
TPS Signal
TPS High
Termination Point(s)
TCM-58; TRANS-19, RMR-A
TCM-44
TCM-12, RMR-C, TRANS-16
D11
3000 AND 4000 PRODUCT FAMILIES TROUBLESHOOTING MANUALALLISON 4th GENERATION CONTROLS
A
B
E
D
V01675
D12
Color
White
Yellow
Yellow
Green
Wire No.
115
131
160
140
Description
PCS5 (Diff Lock) Low
PCS5 (Diff Lock) High
Output Speed Sensor High
Output Speed Sensor Low
Termination Point(s)
TCM-15
TCM-31, TRANS-11
TCM-60
TCM-40
3000 AND 4000 PRODUCT FAMILIES TROUBLESHOOTING MANUALALLISON 4th GENERATION CONTROLS
V00645
Color
Green
Wire No.
158
B
C
Yellow
Pink
156
112
Description
Analog Return
Retarder Mod.
Retarder Mod. High
Termination Point(s)
TCM-58, TRANS-19, TPS-A,
Engine Water Temp-B, RMR-A,
Retarder Temp-B
TCM-56
TCM-12, TRANS-16, TPS-C
D13
3000 AND 4000 PRODUCT FAMILIES TROUBLESHOOTING MANUALALLISON 4th GENERATION CONTROLS
V04843
Figure D11. Retarder Temperature Sensor Connector (3000 and 4000 Product Families)
D14
Color
Orange
Green
Wire No.
175
158
Description
Retarder Temperature Input
Analog Return
Termination Point(s)
TCM-75
TCM-58, TRANS-19, RMR-A,
TPS-A, Engine Water Temp-B
3000 AND 4000 PRODUCT FAMILIES TROUBLESHOOTING MANUALALLISON 4th GENERATION CONTROLS
A3
F1
F3
V01100
Color
Gray
Gray
Wire No.
169
109
Yellow
Tan
104
125
White
124
Tan
Orange
141
130
Pink
Pink
170
110
Yellow
Tan
White
163
165
145
Description
Battery Return ()
Battery Return ()
Reserved
GPO 2
Speedometer Signal
Reserved
Reserved
GPO 4
Reserved
Neutral Start
GPO 3
Reserved
Battery Power (+)
Battery Power (+)
Reserved
Ignition Sense (+)
Reverse Warning
GPO 1
Termination Point(s)
TCM-69
TCM-9
TCM-4
TCM-25
TCM-24
TCM-41
TCM-45
TCM-70
TCM-10
TCM-63
TCM-65
TCM-30
D15
3000 AND 4000 PRODUCT FAMILIES TROUBLESHOOTING MANUALALLISON 4th GENERATION CONTROLS
K3
V01240
Color*
Wire No.*
Description
Reverse Warning RelayNormally Open
Output Wire 145 RelayCommon
Output Wire 145 RelayNormally Open
Reverse Warning RelayCommon
Output Wire 145 RelayNormally Closed
Reserved
Ignition Power
Output Wire 130 RelayNormally Closed
Reserved
Output Wire 124 RelayNormally Closed
Output Wire 104 RelayNormally Closed
Reserved
Output Wire 124 RelayCommon
Output Wire 104 RelayCommon
Output Wire 104 RelayNormally Open
Neutral Start RelayNormally Open
Output Wire 130 RelayCommon
Output Wire 130 RelayNormally Open
Neutral Start RelayCommon
Reserved
Reserved
Reserved
SpeedometerUnfiltered
Reserved
Battery Power
Battery Power
Reserved
Battery Return
Battery Return
Reserved
* Colors, wire numbers, and termination points are determined by OEM electrical system design.
D16
Termination Point(s)*
3000 AND 4000 PRODUCT FAMILIES TROUBLESHOOTING MANUALALLISON 4th GENERATION CONTROLS
A
B
LO
V00570
Figure D14. Resistance Module Type 2Single Pressure Switch and SCI Interface
Color
White
Blue
Wire No.
Description
132
Serial Communication Interface, High
172
Termination Point(s)
TCM-32, 9-pin Diagnostic Tool
Connector-F
TCM-72, 9-pin Diagnostic Tool
Connector-G
* Terminal number and termination points shown only apply when an Allison Transmission recommended harness configuration and
bulkhead connector are used.
D17
3000 AND 4000 PRODUCT FAMILIES TROUBLESHOOTING MANUALALLISON 4th GENERATION CONTROLS
D
C
B
A
V
B
V00571
D18
Wire Color
Blue
Violet
Orange
White
3000 AND 4000 PRODUCT FAMILIES TROUBLESHOOTING MANUALALLISON 4th GENERATION CONTROLS
100%
NC
6 (R)
5 (Y)
4 (G)
3 (V)
2 (O)
1 (B)
+ (W)
0%
V03471.00.01
Wire Color
White
Blue
Orange
Violet
Green
Yellow
Red
D19
3000 AND 4000 PRODUCT FAMILIES TROUBLESHOOTING MANUALALLISON 4th GENERATION CONTROLS
SIGNAL (Y)
+5V (W)
C
B
GND (G)
A
V00573
D20
Wire Color
Green
Yellow
White
3000 AND 4000 PRODUCT FAMILIES TROUBLESHOOTING MANUALALLISON 4th GENERATION CONTROLS
A
B
HI
LABEL INDICATES
PRESSURE LEVEL
A
B
MED
LABEL INDICATES
PRESSURE LEVEL
A
B
LO
LABEL INDICATES
PRESSURE LEVEL
V00574.01
Wire Color
White
Blue
Medium Pressure
Terminal No.
A
B
Wire Color
White
Orange
High Pressure
Terminal No.
A
B
Wire Color
White
Violet
D21
3000 AND 4000 PRODUCT FAMILIES TROUBLESHOOTING MANUALALLISON 4th GENERATION CONTROLS
A
B
HI
LABEL INDICATES
PRESSURE LEVEL
A
B
MED
V00575
Wire Color
White
Orange
High Pressure
Terminal No.
A
B
D22
Wire Color
White
Violet
3000 AND 4000 PRODUCT FAMILIES TROUBLESHOOTING MANUALALLISON 4th GENERATION CONTROLS
3-WAY
V07109.01.00
Terminal No.
A
B
C
Color
Black
White
Red
Wire No.
158
116
112
Description
Analog Return
OLS Input
Sensor Power
Termination Point(s)
20-Way Feedthrough
Harness Connector
TRANS-19
TRANS-15
TRANS-16
D23
3000 AND 4000 PRODUCT FAMILIES TROUBLESHOOTING MANUALALLISON 4th GENERATION CONTROLS
A or H
C or S
B or L
V07110
Wire No.
Description
128
J1939 Controller #1, High
108
J1939 Controller #1, Low
149
J1939 Shield #1
Termination Point(s)
TCM-28 and/or TCM-48
TCM-8 and/or TCM-68
TCM-49
D24
Wire No.
Description
106
CAN Controller #2, High
127
CAN Controller #2, Low
167
CAN Shield #2
Termination Point(s)
TCM-6 and/or TCM-66
TCM-27 and/or TCM-47
TCM-67
3000 AND 4000 PRODUCT FAMILIES TROUBLESHOOTING MANUALALLISON 4th GENERATION CONTROLS
Wire No.
119
131
Description
SS2 Low
SS2 High
Termination Point(s)
TCM-19
TCM-31, TRANS-11
D25
3000 AND 4000 PRODUCT FAMILIES TROUBLESHOOTING MANUALALLISON 4th GENERATION CONTROLS
D26
3000 AND 4000 PRODUCT FAMILIES TROUBLESHOOTING MANUALALLISON 4th GENERATION CONTROLS
E1
E2
E3
E4
E5
E6
E7
E8
E9
E10
E11
E12
E13
E14
E15
E16
NOTE:
Contents
Page
List of Special Tools Required To Service Allison 4th Generation Controls Wiring Harnesses
AFL Automotive 80F Bolt Assist Connectors (TCM Connector)
AFL Automotive 80F CAM-Assist Connectors (TCM Connector)
AFL Automotive 20-Way Bolt-Assist Connectors (TCM Connector)
Delphi-Packard Micro-Pack 100W Connectors (CAN and Strip Shift Selectors)
Delphi-Packard GT150 Series ConnectorsPush-to-Seat (Speed Sensor; Retarder Solenoid)
Delphi-Packard Metri-Pack 150 Series ConnectorsPush-to-Seat (Turbine Speed Sensor;
30-Way and 18-Way VIM; Retarder Temperature Sensor; and Retarder Accumulator
Solenoid)
Delphi-Packard Metri-Pack 150 Series ConnectorsPush-to-Seat (Oil Level Sensor)
Delphi-Packard Metri-Pack 150 Series ConnectorsPush-to-Seat (All Models, Sump
Temperature Thermistor)
Delphi-Packard Metri-Pack 280 Series ConnectorsPull-to-Seat (Internal Harness Solenoid
and C3 Pressure Switch)
Delphi-Packard WeatherPack Connectors (TPS; 3-Way RMR Sensor; 3-Way RMR Device
(Dedicated Pedal))
Amp Products Connectors (8-Way RMR Device (Hand Lever))
Deutsch IPD/ECD Connectors (J1939 Diagnostic Data Link 9-Way Diagnostic Tool
Connector)
ITT Cannon ConnectorsCrimped (Bulkhead 6-Way Transfer Case)
Deutsch DT Series Connectors (3-Way J1939 Connector)
Repair of a Broken Wire with In-Line Butt Splice
AFL Automotive 2-Way, 90 Degree Solenoid Connector
E2
E7
E14
E18
E23
E28
E31
E35
E38
E40
E42
E46
E48
E51
E54
E56
E59
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 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 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
E1
3000 AND 4000 PRODUCT FAMILIES TROUBLESHOOTING MANUALALLISON 4th GENERATION CONTROLS
Tool Type
Paragraph Reference
23046604
E15
23046605
E15
J 25070
Heat Gun
E15
J 34182
Crimping Tool
J 34513
Remover Tool
E12
J 35123
E5, E6, E7
J 35606
E10
J 35615
Wire Stripper
J 35689-A
Remover Tool
J 38125-6
Crimping Tool
E10
J 38125-7
Crimping Tool
J 38125-8
Crimping Tool
E16
J 38125-10
Remover Tool
E10
J 38125-12A
Crimping Tool
J 38125-13
Remover Tool
E11, E16
J 38528-3
Remover Tool
E12
J 38852
E10
J 39227
Remover Tool
E4
J 39842
E13
J 41193
E13
J 41193-1
Guide Pin
E13
J 41193-2
Insertion Tool
E13
J 41194
Extractor/Inserter
E12
Crimping Tool
E8
E1, E2, E3
E1, E2, E3
E1, E2, E3
J 42215
J 47139
63811-6000
64016-0133 *
For more information regarding this change, refer to SIL 19-TR-08 Rev. A.
E2
3000 AND 4000 PRODUCT FAMILIES TROUBLESHOOTING MANUALALLISON 4th GENERATION CONTROLS
E3
3000 AND 4000 PRODUCT FAMILIES TROUBLESHOOTING MANUALALLISON 4th GENERATION CONTROLS
REMOVAL TOOL
J 38125-12A
SPACER
RETAINER, BOLT
or
SEAL, INTERFACIAL
J 39227
CONNECTOR BODY, F
SEAL, GROMMET
RETENTION TAB (4)
RETAINER, GROMMET
LOCKING
FINGER (4)
SEE VIEW A
SLOT (2)
TYPICAL WIRE
COVER,
WIRE DRESS
SEALS (2)
DIRECTION OF
WIRE REMOVAL
VIEW A
WIRE
STOP
BLADE
BOLT
push
VIEW B
33001-0004 (Former)
33001-2004 (Current)
Note: St. Clair P/N 300247
remains the same.
OUT
CORE
LOCK TERMINAL HERE
J47139 (Former)
63811-6000 (Current)
CRIMP
WINGS
WIRE
VIEW C
V09216.00.00.A
E4
3000 AND 4000 PRODUCT FAMILIES TROUBLESHOOTING MANUALALLISON 4th GENERATION CONTROLS
REMOVAL TOOL
J 38125-12A
SPACER
RETAINER, BOLT
or
SEAL, INTERFACIAL
J 39227
CONNECTOR, BODY
SEAL, GROMMET
RETENTION TABS (4)
RETAINER, GROMMET
LOCKING
FINGER (4)
COVER, BOTTOM
SEE VIEW
RETENTION FEATURE
SLOT (2)
TYPICAL WIRE
DIRECTION OF
WIRE REMOVAL
VIEW A
SEALS (2)
BOLT
WIRE
STOP
BLADE
push
VIEW B
33001-0004 (Former)
33001-2004 (Current)
Note: St. Clair P/N 300247
remains the same.
OUT
CORE
LOCK TERMINAL HERE
J47139 (Former)
63811-6000 (Current)
CRIMP
WINGS
WIRE
VIEW C
V09217.00.00.A
E5
3000 AND 4000 PRODUCT FAMILIES TROUBLESHOOTING MANUALALLISON 4th GENERATION CONTROLS
REMOVAL TOOL
J 38125-12A
SPACER
or
RETAINER, BOLT
SEAL, INTERFACIAL
J 39227
BODY, CONNECTOR
SEAL, GROMMET
RETENTION TAB (4)
RETAINER, GROMMET
LOCKING
FINGER (4)
RETENTION FEATURE (4)
SEE VIEW
SLOT (2)
DIRECTION OF
WIRE REMOVAL
COVER,
WIRE DRESS
TYPICAL WIRE
SEALS (2)
RETENTION FEATURE (2)
COVER,
BOTTOM
VIEW A
BOLT
WIRE
STOP
BLADE
push
VIEW B
33001-0004 (Former)
33001-2004 (Current)
Note: St. Clair P/N 300247
remains the same.
OUT
CORE
LOCK TERMINAL HERE
J47139 (Former)
63811-6000 (Current)
CRIMP
WINGS
WIRE
VIEW C
V09219.00.00.A
E6
3000 AND 4000 PRODUCT FAMILIES TROUBLESHOOTING MANUALALLISON 4th GENERATION CONTROLS
Use
Description
St. Clair
P/N
300276
300243
300244
300290
300291
300247
300008
300235
300245
300246
Bolt Kit
Bolt
Seal, Bolt
Retainer, Bolt
300234
Manufacturers
P/N
R-61991-001
E-4540
E-4539
E-4538
E-4543-001
E-4544
E-4545
E-4541
E-4542
E-4550
E-4551
33001-2004
12034413
E-4550
E-4551
E-4543-001
E-4544
E-4545
E7
3000 AND 4000 PRODUCT FAMILIES TROUBLESHOOTING MANUALALLISON 4th GENERATION CONTROLS
TCM Connector, Assembly 80F Bolt Assist, Direction A 90 Degree Wire Dress
(refer to Figure E1B)
Required Tools
Crimping Tool
Remover Tool
Use
Description
TCM Connector
St. Clair
P/N
300243
300244
300247
300008
R-61991-001
E-4540
E-4539
E-4538
E-4543-001
E-4544
E-4545
E-4541
E-4542
E-6206-002
E-4555
33001-2004
12034413
300236
E8
Manufacturers
P/N
E-6206-001
E-4555
3000 AND 4000 PRODUCT FAMILIES TROUBLESHOOTING MANUALALLISON 4th GENERATION CONTROLS
TCM Connector, Assembly 80F Bolt Assist, Direction B 90 Degree Wire Dress
(refer to Figure E1C)
Required Tools
Crimping Tool
Remover Tool
Use
Description
D.
St. Clair
P/N
Manufacturers
P/N
300278
300243
300244
300247
300008
R-61991-001
E-4540
E-4539
E-4538
E-4543-001
E-4544
E-4545
E-4541
E-4542
E-6206-001
E-4555
33001-2004
12034413
300237
E-6206-002
E-4555
Terminal Removal
1. Loosen the bolt (Figure E1A, B, or C, View B) that retains 80-way connector to the transmission
control module (TCM).
2. Separate the 80-way connector from the TCM.
3. Refer to the proper Figure for the connector being used:
a. Refer to Figure E1A, View B. Use a small-bladed screwdriver to gently unlatch the retention
features (4) of the wire dress cover and separate the two halves.
b. Refer to Figures E1B or E1C, View B. Use a small-bladed screwdriver to gently unlatch the
retention features (2) of the wire dress cover and remove it from the backshell wire dress. Gently release the retention features (4) of the backshell wire dress and remove it from the connector body.
4. Insert a small-bladed screwdriver in between the connector body and the grommet retainer (Figure
E1A, B, or C, View B) and carefully pry the grommet retainer away from the connector body.
Slide the grommet retainer along the wires away from the connector body. If the grommet seal
stayed with the connector body, also slide it away from the connector body and seat it into the
grommet retainer, allowing better access to the wires.
E9
3000 AND 4000 PRODUCT FAMILIES TROUBLESHOOTING MANUALALLISON 4th GENERATION CONTROLS
NOTE:
Care should be taken not to damage or break the terminal locking fingers during removal. If a locking
finger is damaged or broken, proper terminal retention will be lost after reassembly.
E.
Terminal Crimping
1. Carefully strip the insulation from the wire to leave 4.705.60 mm (0.1850.220 inch) of bare wire
(core) exposed.
2. Refer to Figures E1A, B, or C, View C. Pull out the wire stop blade of the crimping tool so it is
clear of the terminal crimp area. Place the terminal all the way into the appropriate wire size
opening of the J 47139 (former) or 63811-6000 (Molex P/N, current) crimping tool until it contacts
the stop and is properly oriented. Squeeze the handle enough to keep the terminal in place in the
tool but not enough to compress the crimp wings.
3. Push in the wire stop blade until it touches the terminal. Insert the wire core into the terminal, with
the core held against the wire stop blade.
4. Hold the wire and terminal against the stops until the terminal is fully crimped. Squeeze the
crimper handle until the ratchet releases.
5. Pull out the wire stop blade and remove the crimped terminal and wire.
NOTE:
If cavities do not have a terminal/wire lead or grommet cover pin (or if grommet cover pin is damaged)
install cavity plug #12034413 into corresponding cavity in grommet seal in connector body.
6. Repeat as necessary.
7. Slide the grommet retainer containing the grommet seal along the wires and snap it into place on
the connector body.
8. When all terminals have been inserted, be sure the green interfacial seal is properly located on the
connector body and not damaged. Install the red spacer into the connector body. Push it into the
connector body until it is fully seated against the connector body.
E10
3000 AND 4000 PRODUCT FAMILIES TROUBLESHOOTING MANUALALLISON 4th GENERATION CONTROLS
E11
3000 AND 4000 PRODUCT FAMILIES TROUBLESHOOTING MANUALALLISON 4th GENERATION CONTROLS
REMOVAL TOOL
J 38125-12A
SPACER
or
SEAL, INTERFACIAL
J 39227
BODY, CONNECTOR
TYPICAL WIRE
GROMMET
RETENTION TAB (4)
RETAINER, GROMMET
COVER, BOTTOM
LOCKING
FINGER (4)
SEE VIEW
SLOT (2)
RETENTION
FEATURE (4)
DIRECTION OF
WIRE REMOVAL
HANDLE,
CAM LOCK 80-WAY
VIEW A
CPA
COVER,
WIRE DRESS
WIRE
STOP
BLADE
SECONDARY
LEVER LOCK
push
VIEW B
33001-0004 (Former)
33001-2004 (Current)
Note: St. Clair P/N 300247
remains the same.
OUT
CORE
LOCK TERMINAL HERE
J47139 (Former)
63811-6000 (Current)
CRIMP
WINGS
WIRE
VIEW C
V09220.00.00.A
E12
3000 AND 4000 PRODUCT FAMILIES TROUBLESHOOTING MANUALALLISON 4th GENERATION CONTROLS
REMOVAL TOOL
J 38125-12A
SPACER
SEAL, INTERFACIAL
or
BODY, CONNECTOR
J 39227
RETAINER, GROMMET
SEE VIEW
SLOT (2)
DIRECTION OF
WIRE REMOVAL
COVER,
WIRE DRESS
TYPICAL WIRE
VIEW A
COVER,
BOTTOM
WIRE
STOP
BLADE
push
VIEW B
SECONDARY
LEVER LOCK
33001-0004 (Former)
33001-2004 (Current)
Note: St. Clair P/N 300247
remains the same.
CORE
OUT
CPA
J47139 (Former)
63811-6000 (Current)
CRIMP
WINGS
WIRE
VIEW C
V09218.00.00.A
E13
3000 AND 4000 PRODUCT FAMILIES TROUBLESHOOTING MANUALALLISON 4th GENERATION CONTROLS
Use
Description
TCM Connector
E14
Manufacturers
P/N
R-62004-001
300244
300247
300008
E-4540
E-4539
E-4547
E-4554
E-4553
E-4548
E-4545
E-4541
E-4542
E-4589
E-4555
33001-2004
12034413
300238
E-4555
E-4589
3000 AND 4000 PRODUCT FAMILIES TROUBLESHOOTING MANUALALLISON 4th GENERATION CONTROLS
Use
Description
TCM Connector
St. Clair
P/N
Manufacturers
P/N
R-62004-002
300244
300247
300008
E-4540
E-4539
E-4547
E-4554
E-4553
E-4548
E-4545
E-4541
E-4542
E-4588
E-4555
33001-2004
12034413
300239
E-4555
E-4588
NOTE:
Do not attempt to move CAM lever after it is disengaged from the TCM, doing so can break the internal
latching mechanism
3. Refer to Figures E2A or B, View B. Use a small-bladed screwdriver to gently unlatch the retention
features (2) of the wire dress cover and remove it from the backshell wire dress. Gently release the
retention features (4) of the backshell wire dress and remove it from the connector body.
4. Insert a small-bladed screwdriver in between the connector body and the grommet retainer
(Figure E2A or B, View B) and carefully pry the grommet retainer away from the connector
body. Slide the grommet retainer along the wires away from the connector body. If the grommet
seal stayed with the connector body, also slide it away from the connector body and seat it into the
grommet retainer, allowing better access to the wires.
Copyright 2008 Allison Transmission, Inc.
E15
3000 AND 4000 PRODUCT FAMILIES TROUBLESHOOTING MANUALALLISON 4th GENERATION CONTROLS
3000 AND 4000 PRODUCT FAMILIES TROUBLESHOOTING MANUALALLISON 4th GENERATION CONTROLS
or
SPACER
SEAL, INTERFACIAL
RETAINER, BOLT
CONNECTOR BODY
TYPICAL WIRE
SEAL, GROMMET
RETAINER, GROMMET
RETENTION
FEATURE (4)
SLOT (2)
DIRECTION OF
WIRE REMOVAL
RETENTION TAB (3)
SEAL, BOLT (2)
RETENTION FEATURE (3)
VIEW A
COVER WIRE DRESS
BOLT
WIRE
STOP
BLADE
push
VIEW B
33001-0004 (Former)
33001-2004 (Current)
Note: St. Clair P/N 300247
remains the same.
OUT
CORE
LOCK TERMINAL HERE
J47139 (Former)
63811-6000 (Current)
CRIMP
WINGS
WIRE
VIEW C
V09221.00.00.A
E17
3000 AND 4000 PRODUCT FAMILIES TROUBLESHOOTING MANUALALLISON 4th GENERATION CONTROLS
Connector/Terminal Tools
Required Tools
Crimping Tool
Remover Tool
Use
Description
TCM Connector
(20-way Bolt assist)
St. Clair
P/N
Manufacturers
P/N
300278
300252
300253
300254
300251
300247
300008
Bolt Kit
Bolt
Seal, Bolt
Retainer, Bolt
300241
300242
R-62183-001
E-4564
E-4542
E-4561
E-6187-001
E-4590
E-4545
E-4565
E-4566
E-4569
E-4570
33001-2004
12034413
E-6187-001
E-4590
E-4545
E-4569
E-4570
3000 AND 4000 PRODUCT FAMILIES TROUBLESHOOTING MANUALALLISON 4th GENERATION CONTROLS
NOTE:
Care should be taken not to damage or break a terminal locking finger during removal. If a locking
finger is damaged or broken, proper terminal retention will be lost after reassembly.
B.
Terminal Crimping
1. Carefully strip the insulation from the wire to leave 4.705.60 mm (0.1850.220 inch) of bare wire
(core) exposed.
2. Refer to Figures E3, View C. Pull out the wire stop blade of the crimping tool so it is clear of the
terminal crimp area. Place the terminal all the way into the appropriate wire size opening of the
J 47139 (former) or 63811-6000 (Molex P/N, current) crimping tool until it contacts the stop and is
properly oriented. Squeeze the handle enough to keep the terminal in place in the tool but not
enough to compress the crimp wings.
3. Push in the wire stop blade until it touches the terminal. Insert the wire core into the terminal, with
the core held against the wire stop blade.
4. Hold the wire and terminal against the stops until the terminal is fully crimped. Squeeze the
crimper handle until the ratchet releases.
5. Pull out the wire stop blade and remove the crimped terminal.
NOTE:
NOTE:
If cavities do not have a terminal/wire lead or grommet cover pin (or if grommet cover pin is damaged)
install cavity plug #12034413 into corresponding cavity in grommet seal in connector body.
6. Repeat as necessary.
7. Slide the grommet retainer containing the grommet seal along the wires and snap it into place on
the connector body (only if removed).
8. Be sure the interfacial seal is properly located on the connector body and not damaged. Install the
spacer into the connector body. Push it into the connector body until it is fully seated against the
connector body.
If the spacer will not seat properly on the connector body, be sure all terminals are fully seated.
9. Refer to Figures E3, View A. Align the three retention features of the backshell wire dress with
the three lock tabs on the grommet retainer and press the backshell wire dress onto the grommet
retainer until all three retention features lock. Align the wire dress cover with the backshell wire
dress and press into place until it locks on both sides.
10. Reconnect the 20-way connector to the transmission pass-through connector and tighten connector
bolt to specified torque value (Nm or lb ft) shown on the wire dress cover (DO NOT OVERTORQUE).
Copyright 2008 Allison Transmission, Inc.
E19
3000 AND 4000 PRODUCT FAMILIES TROUBLESHOOTING MANUALALLISON 4th GENERATION CONTROLS
CONNECTOR
TYPICAL WIRE
SEAL
LOCKTAB (SECURES
RETAINER)
TERMINAL LOCKING
FINGER
LOCKING POST
STRAIN RELIEF
LOCKTABS
Lock terminal
here
SOCKET TERMINAL
WIRE
E20
3000 AND 4000 PRODUCT FAMILIES TROUBLESHOOTING MANUALALLISON 4th GENERATION CONTROLS
CONNECTOR
TYPICAL WIRE
SEAL
LOCKTAB (SECURES
RETAINER)
TERMINAL LOCKING
FINGER
LOCKING POST
STRAIN RELIEF
LOCKTABS
Lock terminal
here
SOCKET TERMINAL
WIRE
E21
3000 AND 4000 PRODUCT FAMILIES TROUBLESHOOTING MANUALALLISON 4th GENERATION CONTROLS
SECONDARY LOCK
MATING CONNECTOR
WITH FEMALE (SOCKET)
TERMINALS
J 39227
REMOVAL
TOOL
LOCKTAB
(RETAINS LOCK ASSIST)
WIRE SEAL
LOCK ASSIST
VIEW A
LOCKING
FINGERS
WIRE
MATING CONNECTOR
WITH MALE (PIN)
TERMINALS
WIRE SEAL
VIEW A
CAVITY PLUG
CONDUIT CLIP
SOCKET
TERMINAL
WIRE
E22
V03421.01.00
3000 AND 4000 PRODUCT FAMILIES TROUBLESHOOTING MANUALALLISON 4th GENERATION CONTROLS
Connector/Terminal Repairs
Crimping Tool
Remover Tool
J 42215
J 39227
Use
Description
St. Clair
P/N
300279
300255
300256
300257
300258
300087
300105
300114
12191065
12191066
12191067
12191068
12084912
12129557
12177289
300280
300255
300256
300257
300259
300087
300105
300114
12191065
12191066
12191067
15460298
12084912
12129557
12177289
Manufacturers
P/N
Connector
Wire Seal
Secondary Lock
Terminal, Socket
Cavity Plug
Conduit Clip
12160280
15304882
12160494
12084912
12129557
12176394
Connector, Gray
Wire Seal
Lock Assist/Seal
Terminal, Pin
Cavity Plug
Conduit Clip, Black
12160542
12110693
12191176
12060551
12129557
12176394
E23
3000 AND 4000 PRODUCT FAMILIES TROUBLESHOOTING MANUALALLISON 4th GENERATION CONTROLS
Terminal Removal
1. CAN Shift Selector Harness Connectors (Figure E4A, 4B, and 4C)
CAUTION:
The color-code of the strain relief should match the color-code of the retainer. However,
cases have been reported where this has not occurred. The retainer color-code and key
configuration ensures that the proper wiring harness connector is in the right socket of
the ECU. The color-code of the strain relief is of secondary importance and may not
agree with the retainer. Change the strain relief to match the color-code of the retainer
(Figure E1A) when color-code mismatch is found.
a. Use a small-bladed screwdriver to gently release the locktabs at the splitline of the strain relief.
b. Spread the strain relief open.
c. Remove the retainer from the connector by using a small-bladed screwdriver to depress the
locktabs on the side of the connector.
d. Remove a selected terminal by pushing forward on the wire or by lifting the locking finger and
pulling the wire and terminal rearward out of the connector.
Terminal Crimping
1. Carefully strip insulation to leave 5.0 mm 0.5 mm (0.20 0.02 inch) of bare wire showing.
2. Insert the new terminal to be crimped in the J 42215 crimping tool. There is a spring-loaded
terminal positioner at the front of the tool to hold the terminal in place. Squeeze the crimper
handles for a few clicks to start the crimping process but leave room to insert the wire end.
3. Insert the bare wire end into the terminal. Squeeze the crimper handles to complete the crimping
process and until the crimper handles open when released to remove the terminal/wire from the
tool.
E24
3000 AND 4000 PRODUCT FAMILIES TROUBLESHOOTING MANUALALLISON 4th GENERATION CONTROLS
NOTE:
All terminals must be properly positioned to install the retainer in Step (5c).
c. Install the retainer on the connector body to lock the terminals in position. Pull rearward on the
wire to be sure that the terminal is fully seated. Install cavity plugs as needed.
d. Position the conduit inside the strain relief and snap the strain relief halves together.
E25
3000 AND 4000 PRODUCT FAMILIES TROUBLESHOOTING MANUALALLISON 4th GENERATION CONTROLS
CPA LOCK
CONNECTOR BODY
VIEW A
DELPHI 1535996
18-16
TERMINAL
HOLDER
-16
18
0.8-1.0
0.3
-20
2250.5
22-20
WIRE SIDE
CORE
TERMINAL
CORE CRIMP
INSULATION CRIMP
VIEW B
E26
V09249.00.00
3000 AND 4000 PRODUCT FAMILIES TROUBLESHOOTING MANUALALLISON 4th GENERATION CONTROLS
CONNECTOR BODY
SEAL, CONNECTOR
LIFT UP
LATCH
TO RELEASE
TERMINAL
BOWTIE
CONNECTOR CAP
VIEW
A
VIEW
LOCKTAB
PRY HERE
PRY HERE
REMOVE
REMOVE
INSTALL
LOCK STOP 1
LOCK STOP 2
LOCK STOPS 1 AND 2
VIEW
D
V09252.00.00
Figure E5B. Delphi-Packard GT150 Series ConnectorsPush-to-Seat (Speed Sensor; Accumulator Solenoid;
Retarder Solenoid)
E27
3000 AND 4000 PRODUCT FAMILIES TROUBLESHOOTING MANUALALLISON 4th GENERATION CONTROLS
Connector/Terminal Repairs
Tool Description
Wire Stripper
Crimp Tool
Alternate Crimp Tool
Part Number
J 35615
Delphi 15359996
Remover Tool
Alternate Removal Tool
J 38125-6 Anvil 1
J 38125-7 Anvil E
J 38125-12A
J 35689-A
Use
Description
13520101
15496486
15326267
15305351
15358890
13523048
15496486
15326267
15305351
15358890
13520104
15305351
15326267
15496486
15358890
15490464
13513314
Terminal Removal
Do not solder crimps.
1. The CPA lock has two positions. The fully locked position retains the connector to the mating
connector. The second position allows the connector to be released from the mating connector. To
facilitate terminal removal, completely remove the CPA lock by depressing the lock tang and
pulling the lock up and away from the connector (Figure E5A, View A).
2. Remove the convolute capture from the rear of the GT150 connector by raising the retainer clip
and pulling on the harness.
3. Remove the convolute capture from the convolute by applying pressure with a small-bladed
screwdriver inserted into the front locking tang. Repeat the process on the rear locking tang and
open the capture. The wires are now loose in the convolute and can be pulled out a short distance
to make terminal installation easier.
4. Two different connector caps, bowtie or mushroom, are used (Figure E5B, View A). Each
connector cap has two stops (Figure E5B, View C). The cap must be completely removed from
E28
3000 AND 4000 PRODUCT FAMILIES TROUBLESHOOTING MANUALALLISON 4th GENERATION CONTROLS
on the terminal so it does not drop out of the tool, but not enough to compress the crimp wings.
4. Push in the wire stop blade until it touches the terminal. Insert the wire core into the terminal, with the core
held against the wire stop blade. Position the seal on the wire so the small diameter is in the insulation
crimp wing (Figure E5B, View D).
5. Hold the wire and terminal against the stops and be sure the seal is in the insulation crimp wing.
Squeeze the crimping tool handle until it releases. Pull out the wire stop blade and remove the wire
and terminal from the tool.
6. Lightly pull on the wire while holding the terminal to be sure the crimp is tight.
7. Repeat as needed to crimp another wire.
8. Insert the terminal and sealed wire into the connector (Figure E5B, View D) until it stops. Lightly
pull on the wire to be sure it is held in the connector by the terminal lock finger.
9. Install connector cap (Figure E5B, View A) onto front of connector body.
10. Close the convolute capture over the convolute until both locks are engaged.
11. Push the convolute capture into the connector body until both locks are engaged. Install the CPA
lock onto the connector body.
D.
E29
3000 AND 4000 PRODUCT FAMILIES TROUBLESHOOTING MANUALALLISON 4th GENERATION CONTROLS
SEALING PLUG
RETAINER
Seal plug
butts up here
12 WAY
SEAL PLUG
Remove in
this direction
WIRE AND
TERMINAL
SPECIAL
BOLT
J 35689-A
HARNESS
CONNECTOR
Seat in
this direction
Insertion of removal tool (J 35689-A) forces
lock tang toward body of terminal
VIEW A
Butt wire against terminal holder
18-16
B
D
J 38125-7
22-20
A
C
E
WIRE SIDE
TERMINAL
VIEW B
Push lock to insert
terminal end
J 35123
WIRE SIDE
VIEW C
18-16
22-20
TERMINAL HOLDER
V01685.01.00
E30
3000 AND 4000 PRODUCT FAMILIES TROUBLESHOOTING MANUALALLISON 4th GENERATION CONTROLS
Connector/Terminal Repairs
Wire Stripper
Crimping Tool
Wire Crimp
Insulation Crimp
Alternate Crimping Tool
Remover Tool
J 35615
J 38125-7
Anvil E
Anvil C
J 35123
J 35689-A
Use
Turbine Speed (Nt) Sensor
(3000 Product Family)
Vehicle Interface Module (VIM)
Description
Connector
Terminal
Connector (VIM)
Connector Body
9-Way Seal (x2)
30-Way Strain Relief
Special Bolt
Bolt Retainer
Sealing Ring
Terminal
Vehicle Interface Module (Vehicle) Connector (VIM)
Connector Body
15-Way Seal (x2)
18-Way Strain Relief
Special Bolt
Bolt Retainer
Sealing Ring
Terminal
Vehicle Interface Module (Vehicle) Connector (OEM)
Connector Body
15-Way Seal (x2)
30-Way Strain Relief
Special Bolt
Bolt Retainer
Sealing Plug
Terminal
Retarder Temperature Sensor
Connector Assembly, 2F M/P 150
Connector Body, Black
Connector Seal
Cable Seal
Terminal
Retarder Accumulator Solenoid
Connector Assembly, 2F M/P 150
Connector Body, Black
Connector Seal
Cable Seal
Terminal
Copyright 2008 Allison Transmission, Inc.
Manufacturers P/N
15490953
12110236
12040920
12040936
12110545
12129426
12034236
12034413
12103881
12034397
12040879
12110546
12129426
12034236
12034413
12103881
12034397
12040879
12110546
12129426
12034236
12034413
12103881
12162852
12162734
12110513
12110514
12124075
15326143
15326141
12040751
12110514
12124075
E31
3000 AND 4000 PRODUCT FAMILIES TROUBLESHOOTING MANUALALLISON 4th GENERATION CONTROLS
Terminal Removal
Do not solder crimps.
1. Insert needle end of terminal remover J 35689-A into the small notch between the connector and
the terminal to be removed (Figure E6, View A). Push the lock tang toward the terminal.
2. Push the wire and terminal out of the connectorthis is a pull-to-seat terminal.
3. Pull terminal as far as necessary from the connector. This will be limited by the number of other
wires inserted into the connector and by the distance between the back side of the connector and
the beginning of the harness covering.
4. If terminal is to be replaced, cut the terminal between the core and insulation crimp to minimize
wire loss.
C.
D.
E32
3000 AND 4000 PRODUCT FAMILIES TROUBLESHOOTING MANUALALLISON 4th GENERATION CONTROLS
E33
3000 AND 4000 PRODUCT FAMILIES TROUBLESHOOTING MANUALALLISON 4th GENERATION CONTROLS
Install in
this direction
Remove in
this direction
SECONDARY LOCK
Insertion of removal
tool (J 35689) forces
lock tang toward body
of terminal
J 35689-A
VIEW
18-16
22-20
E
WIRE SID
TERMINAL
J 35123
A
C
E
Push lock
to insert
terminal end
J 38125-7
VIEW
18-16
22-20
WIRE SIDE
TERMINAL
HOLDER
VIEW
C
V09268.00.00
Figure E7. Delphi-Packard Metri-Pack 150 Series Connectors Push-To-Seat (Oil Level Sensor)
E34
3000 AND 4000 PRODUCT FAMILIES TROUBLESHOOTING MANUALALLISON 4th GENERATION CONTROLS
B.
NOTE:
Connector/Terminal Repairs
Wire Stripper
Crimping Tool
J 35615
J 381257
Wire Crimp
Anvil E
Insulation Crimp
Anvil C
J 35123
Remover Tool
J 35689A
Use
Description
3-Pin Plug
Terminal (Socket)
Secondary Lock, TPA
Manufacturers P/N
12064758
12047767
12047783
Terminal Removal
Do not solder crimps.
1. Remove the secondary lock.
2. Insert needle end of terminal remover J 35689-A into the small notch between the connector and
the terminal to be removed (Figure E7, View A). Push the lock tang toward the terminal.
3. Pull the wire and terminal out the rear of the connectorthis is a push-to-seat terminal.
4. Pull terminal as far as necessary from the connector. This will be limited by the number of other
wires inserted into the connector and by the distance between the back side of the connector and
the beginning of the harness covering.
5. If terminal is to be replaced, cut the terminal between the core and insulation crimp to minimize
wire loss.
C.
Terminal Crimping
1. Carefully strip insulation 4.5 mm 0.5 mm (0.18 0.02 inch). Unless insulation crimp is
overtight, Automatic Wire Stripper J 35615 will remove insulation and crimp from old terminal
without damaging wire.
2. Place core crimp portion of terminal on bed of anvil E and squeeze crimper enough to keep
terminal from dropping (Figure E7, View C).
3. Position wire core in terminal and squeeze crimper tool to complete the core crimp. Be sure to
orient the terminal so that it is properly aligned with the terminal cavity in the connector.
The terminal should be positioned so that the lock tang is on the side of the cavity which has the
notch in the middle (for the remover tool).
4. Position insulation crimp of terminal on anvil C so that the entire insulation crimp area and a
portion of the terminal between the core and insulation crimp areas are supported by the anvil.
Complete the insulation crimp.
5. Be sure lock tang is lifted to allow proper reseating of the terminal.
6. Push on the wire until the terminal is completely into the cavity. A click will be heard and the
terminal should stay in place when the wire is lightly pulled.
Copyright 2008 Allison Transmission, Inc.
E35
3000 AND 4000 PRODUCT FAMILIES TROUBLESHOOTING MANUALALLISON 4th GENERATION CONTROLS
E36
3000 AND 4000 PRODUCT FAMILIES TROUBLESHOOTING MANUALALLISON 4th GENERATION CONTROLS
SECONDARY LOCK
P/N 12047664
TERMINAL
P/N 12047767
CONNECTOR
P/N 12047662
LOCK TANG
REMOVER TOOL
J 35689-A
REMOVER
NOTCH
Lock terminal
here
SOCKET TERMINAL
WIRE
V04852.01.00
E37
3000 AND 4000 PRODUCT FAMILIES TROUBLESHOOTING MANUALALLISON 4th GENERATION CONTROLS
B.
Connector/Terminal Repairs
Crimping Tool
Remover Tool
J 35689-A
Use
Description
12129691
Connector, Black
12047662
Terminal
12047767
Secondary Lock
12047664
Manufacturers P/N
Terminal Removal
1. Remove the secondary lock from the connector.
2. Insert needle end of terminal remover J 35689-A into the small notch in the front of the connector
cavity of the terminal to be removed (Figure E8).
3. Push the lock tang toward the terminal.
4. Pull the wire and terminal out of the connector.
5. Cut the terminal between the core and insulation crimp to minimize wire loss.
C.
Terminal Crimping
1. Strip insulation approximately 4.5 mm (0.18 inch).
2. Remove the spring-loaded terminal positioner from the J 42215 crimping tool.
3. Insert the new terminal to be crimped in the J 42215 crimping tool. Squeeze the crimper handles a
couple clicks to start the crimping process but leave room to insert the wire end.
4. Insert the bare wire end into the terminal. Squeeze the crimper handles to complete the crimping
process and until the crimper handles open when released to remove the terminal/wire from the
tool.
5. Be sure the lock tang is positioned to allow proper retention of the terminal in the connector.
6. Push the terminal completely into the cavity. A click will be heard and the terminal should stay in
place if the wire is pulled.
7. Install the secondary lock in the connector.
E38
3000 AND 4000 PRODUCT FAMILIES TROUBLESHOOTING MANUALALLISON 4th GENERATION CONTROLS
J 38125-13
J 38125-13
Remove in
this direction
SOLENOID/C3 PRESSURE
SWITCH CONNECTOR
CONNECTOR TO C3
PRESSURE SWITCH (HARNESS)
Install in
this direction
A
C
E
VIEW A
J 38125-7
VIEW B
V03422
E39
3000 AND 4000 PRODUCT FAMILIES TROUBLESHOOTING MANUALALLISON 4th GENERATION CONTROLS
Connector/Terminal Repairs
Wire Stripper
Crimping Tool
J 35615
J 38125-7
NOTE:
Crimping anvils will be listed following the terminal part numbers for the various
connectors in this section. The anvil for the core crimp is always listed first.
Remover Tool
J 38125-13
B.
Use
Description
Manufacturers P/N
Connector
29541590
Connector
12110139
Terminal
(Use crimping anvils C and D)
12124639
Terminal
(Use crimping anvils C and D)
12066337
Terminal Removal
1. Depress locktab on terminal (accessible in slot of connector) and push terminal out front of
connector (Figure E9, View A).
2. If replacing terminal, cut terminal between core and insulation crimp (to minimize wire loss).
C.
Terminal Crimping
1. Carefully strip insulation 6.5 mm 0.5 (0.26 0.02 inch). Unless insulation crimp is overtight,
Automatic Wire Stripper J 35615 will remove insulation and crimp from old terminal without
damaging wire.
2. Place core crimp portion of terminal on bed of anvil indicated and squeeze crimper enough to hold
terminal from dropping (Figure E9, View B).
3. Position wire core in terminal and squeeze crimper tool to complete the core crimp. Be sure to
orient the terminal so that it is properly aligned with the terminal cavity in the connector.
4. Position insulation crimp of terminal on anvil indicated so that the entire insulation crimp area and
a portion of the terminal between the core and insulation crimp areas are supported by the anvil.
Complete the insulation crimp.
5. Slip the wire through the slot in the connector and pull to fully seat the terminal(s).
E40
3000 AND 4000 PRODUCT FAMILIES TROUBLESHOOTING MANUALALLISON 4th GENERATION CONTROLS
WIRE SEAL
TERMINAL
CONNECTOR
SECONDARY LOCK
THROTTLE SENSOR
CONNECTOR
J 38125-10
REMOVER TOOL
VIEW A
VIEW B
WIRE SEAL
CORE CRIMP
INSULATED WIRE
STRIPPED WIRE
VIEW C
WIRE SEAL
CORE CRIMP
TERMINAL
INSULATION AND SEAL CRIMP
J 38125-6
1
3
5
1
3
5
VIEW D
VIEW E
V01689.01.00
Figure E10. Delphi-Packard WeatherPack Connectors (TPS; 3-Way RMR Sensor; Type 3;
3-Way RMR Device (Dedicated Pedal))
E41
3000 AND 4000 PRODUCT FAMILIES TROUBLESHOOTING MANUALALLISON 4th GENERATION CONTROLS
Connector/Terminal Repairs
Crimping Tool
Wire Crimp
J 38125-6
Anvil 2
Insulation Crimp
E42
Anvil 5
J 35606 or J 38852
J 38125-10
Use
Description
Connector
Terminal
Wire Seal
12015793
12089040
12089444
RMR Device
Connector
Terminal
Wire Seal
12015795
12089040
12089444
Connector
Terminal (Socket)
Wire Seal
12010973
12089188
12089444
Manufacturers P/N
3000 AND 4000 PRODUCT FAMILIES TROUBLESHOOTING MANUALALLISON 4th GENERATION CONTROLS
Terminal Removal
1. Unlatch and open the secondary lock on the connector (Figure E10, View A).
2. On the front of the connector, insert remover tool J 38125-10 over the terminal. Push the tool over
the terminal and pull the terminal out of the back end of the connector (Figure E10, View B).
3. If terminal is to be replaced, cut terminal between core and insulation crimp (this minimizes
wire loss).
NOTE:
Two special tools are available for this operation: tool J 38125-6 (Paragraph C); tool J 35606
(Figure E11) or J 38852 (Paragraph D).
C.
D.
E43
3000 AND 4000 PRODUCT FAMILIES TROUBLESHOOTING MANUALALLISON 4th GENERATION CONTROLS
E44
3000 AND 4000 PRODUCT FAMILIES TROUBLESHOOTING MANUALALLISON 4th GENERATION CONTROLS
J 38125-13
VIEW A
INSULATION
STRIPPED WIRE
INSULATION CRIMP
A
C
E
CORE CRIMP
J 38125-7
TERMINAL LOCKTAB
SIDE VIEW
VIEW B
VIEW C
V03423.00.02
Figure E12. Amp Products Connectors (8-Way RMR Device (Hand Lever))
E45
3000 AND 4000 PRODUCT FAMILIES TROUBLESHOOTING MANUALALLISON 4th GENERATION CONTROLS
Connector/Terminal Repairs
Crimping Tool
B.
J 38125-7
Wire Crimp
Anvil E
Insulation Crimp
Anvil A
Remover Tool
J 38125-13
Use
Description
8-Way Receptacle
Terminal (Socket)
Manufacturers P/N
163007-0
42100-2
Terminal Removal
1. Insert removal tool J 38125-13 into the small notch at the front of the connector to release the
terminal locktab (Figure E12, View A).
2. Pull the terminal and wire out the back of the connector.
3. If replacing terminal, cut terminal between core and insulation crimp (this minimizes wire loss).
C.
Terminal Crimping
1. Strip wire to approximately 4.0 0.25 mm (0.16 0.01 inch) (Figure E12, View B).
2. Place new terminal onto crimping tool J 38125-7, anvil E (Figure E12, View C).
3. Slightly close the crimping tool to hold the terminal steady.
4. Insert the wire so that the stripped portion of the wire is in the core crimp area and the insulated
portion of the wire is in the insulation crimping area.
5. Crimp the stripped section of the wire (Figure E12, View B).
6. Remove the terminal from the crimping tool.
7. Use a pair of needle nose pliers, if necessary, to start the bend on the insulation crimp wings.
8. Crimp the insulated section of the wire using anvil A of the crimpers (Figure E9, View C).
9. Remove the terminal from the crimping tool.
10.Tug on the terminal to make sure the crimp is tight.
11.Insert the terminal into the connector. The terminal will click into place and should not pull out.
E46
3000 AND 4000 PRODUCT FAMILIES TROUBLESHOOTING MANUALALLISON 4th GENERATION CONTROLS
WIRES
VIEW C
CONNECTOR
RECEPTACLE
REMOVER
J 34513
REMOVER
J 38582-3
VIEW A
J 34182 CRIMPER
TERMINAL EXTRACTOR / INSERTER
J 41194
RA
I
INSPECTION HOLE
PIN TERMINAL
TE
TO ROTA
SE
SEL
NO.
TERMINAL
INSPECTION HOLE
WIRE SIZE
INDICATOR
SOCKET TERMINAL
LOCKING RING
CAVITY PLUG
VIEW B
V05748
Figure E13. Deutsch IPD/ECD Connectors (9-Way Optional Diagnostic Tool Connector)
E47
3000 AND 4000 PRODUCT FAMILIES TROUBLESHOOTING MANUALALLISON 4th GENERATION CONTROLS
Connector/Terminal Repairs
Required Tools
NOTE:
Crimper Tool
Extractor/Inserter Tool
Remover Tool Set
Remover Tool (Diagnostic
Tool Connector)
J 34182
J 41194 (18 GA ECD Bulkhead)
J 34513
J 38528-3 (1214 GA)
Use
Description
St. Clair
P/N
Manufacturers
P/N
300217
300267
300007
300273
300000
300269
300268
HD10-9-1939P
0460-202-1631
0460-247-1631
114017
HD18
HDC16-6
If difficulty is encountered in removing or installing the plug backshell, insert the plug into the
receptacle, but do not lock it into place, and loosen the backshell.
B.
NOTE:
C.
E48
3000 AND 4000 PRODUCT FAMILIES TROUBLESHOOTING MANUALALLISON 4th GENERATION CONTROLS
D.
E49
3000 AND 4000 PRODUCT FAMILIES TROUBLESHOOTING MANUALALLISON 4th GENERATION CONTROLS
J 39841 INSTALLER
(J 39842 IS SIMILAR FOR
3000 PRODUCT FAMILY 7-SPEED)
RETARDER CONNECTOR
3000 PRODUCT FAMILY
J 39841 REMOVER
(J 39842 IS SIMILAR FOR
3000 PRODUCT FAMILY 7-SPEED)
VIEW A
J 41193-2 INSTALLER
J 41193-1
GUIDE PIN FOR SOCKET TERMINALS
FMTV CONNECTOR
(CRIMP STYLE 37-WAY)
J 41193-3 REMOVER
VIEW B
J 34182 CRIMPER
RA
I
TE
TO ROTA
SE
SEL
NO.
TERMINAL
LOCKING RING
DEPTH ADJUSTMENT SCREW
VIEW C
E50
V01691.00.02
3000 AND 4000 PRODUCT FAMILIES TROUBLESHOOTING MANUALALLISON 4th GENERATION CONTROLS
B.
Connector/Terminal Repair
Crimping Tool
Connector Repair Kit (FMTV)
Guide Pin
Insertion Tool
Terminal Remover
Terminal Remover/Installer
(3000 7-Speed T-Case Connector)
J 34182
J 41193-1
J 41193-2
J 41193-3
J 39842
Use
Description
Manufacturers P/N
CA3106E28-21P-B
CA3100E28-21S-B
KPSE06E10-6S
031-9174-004
225-0070-000
KPSE07E10-6P
030-9173-006
225-0070-000
C.
E51
3000 AND 4000 PRODUCT FAMILIES TROUBLESHOOTING MANUALALLISON 4th GENERATION CONTROLS
D.
Terminal Insertion
1. Select the proper insertion tool for the connector or receptacle that is being reassembled.
2. Place the terminal and wire in the insertion tool (Figure E14, View A and B).
NOTE:
When installing a socket terminal for the FMTV plug, use the J 41193-1 guide pin.
3. Insert the terminal through the correct hole in the back of the connector and push until the terminal
is seated. Remove the insertion tool. Check to see that the terminal is at the same height as other
terminals. Tug on the wire at the rear of the connector to ensure that the terminal is locked in place.
4. Insert cavity plugs into all unused cavities.
E52
3000 AND 4000 PRODUCT FAMILIES TROUBLESHOOTING MANUALALLISON 4th GENERATION CONTROLS
CONNECTOR SEAL
CONNECTOR
STANDARD SOCKET
TERMINAL
TO ROT
A
ISE
TE
RA
J 34182 CRIMPER
SEL
NO.
TERMINAL
LOCKING RING
DEPTH ADJUSTMENT SCREW
V07138.01.00
E53
3000 AND 4000 PRODUCT FAMILIES TROUBLESHOOTING MANUALALLISON 4th GENERATION CONTROLS
Connector/Terminal Repairs
Crimping Tool
B.
J 34182
St. Clair
P/N
Use
Description
Manufacturers P/N
300283
300206
300275
300005
300035
300274
DT06-3S-EP11
W3S-P012
0462-201-1631
0462-221-1631
ATUM-34-0
300282
300270
300271
300007
300273
300274
300272
DT06-3P-EE01
W3P
0462-202-1631
0462-247-1631
ATUM-34-0
DT06-3S-P006
C.
E54
3000 AND 4000 PRODUCT FAMILIES TROUBLESHOOTING MANUALALLISON 4th GENERATION CONTROLS
D.
Terminal Insertion
1. Slide the wire with the crimped terminal attached into the rear of the connector.
2. Push the terminal and wire into the connector until it locks into position. (Figure E15). Check the
front of the connector to see that the terminal is at the same height as the other terminals. Tug on
the wire at the rear of the connector to be sure that the terminal is locked in place.
3. Insert the wedge lock to hold the terminal in place. Slide the sealing plug back into place at the rear
of the connector.
4. Slide the shrink tubing over the raised area at the rear of the connector. Use a heat gun to shrink the
tubing into position over the connector and cable.
E55
3000 AND 4000 PRODUCT FAMILIES TROUBLESHOOTING MANUALALLISON 4th GENERATION CONTROLS
Ensure that terminals are secure in the connector. Clean, straighten, or replace parts as required.
2. Reconnect all previous unmated connectors. Ensure connectors are fully inserted or twisted until
they lock in place. Connectors with locking tabs make an audible click when the lock is engaged.
3. If trouble recurs after starting the vehicle, follow proper repair procedures for trouble code or complaint.
4. If trouble does not recur, or if the correct repairs and/or replacements have been made, the problem
should be corrected.
B.
Special Tools
Heat Gun, J 25070 or equivalent
Crimping Tool for Pre-insulated Crimp J 38125-8 (Figure E16)
NOTE:
NOTE:
E56
Each splice must be properly crimped and then heated to shrink the covering to protect and insulate
the splice. Insulation piercing splice clips should not be used.
3000 AND 4000 PRODUCT FAMILIES TROUBLESHOOTING MANUALALLISON 4th GENERATION CONTROLS
J 38125-8
V01694.00.01
C.
E57
3000 AND 4000 PRODUCT FAMILIES TROUBLESHOOTING MANUALALLISON 4th GENERATION CONTROLS
CONNECTOR CAP
90 DEGREE TERMINAL
LOCK TANG
CONNECTOR BODY
J 38125-13
REMOVAL TOOL
V09228.00.00
E58
3000 AND 4000 PRODUCT FAMILIES TROUBLESHOOTING MANUALALLISON 4th GENERATION CONTROLS
Connector/Terminal Repairs
Crimping Tool
Remover Tool
Alternate Remover Tool
Use
PCS Solenoid Connector
J 38125-8
J 38125-13
J 38125-12A
Description
Connector, 2-Way
Cap, Connector
Terminal with 0.5 m (20 inches) wire
In-Line Splice Connector
Manufacturers P/N
R-61992-001
R-62189-001
R-61970-001
23046605
Terminal Removal
1. Separate the 2-way connector from the solenoid (Figure E17).
2. Remove the connector cap from the connector body.
3. Make a note for reassembly purposes of which wire (number) goes into which terminal cavity in
the connector body.
4. Insert the metal blade of J 38125-13 or J 38125-12A remover into the bottom of the connector
where terminal blade protrudes from the connector body.
5. Apply pressure to the terminal blade. Lift selected terminal from connector body when lock tang
releases.
6. Repeat Steps 4 and 5 for the remaining terminal leads.
C.
Terminal Crimping
Crimping of AFL 2-way, 90 degree terminals is not permitted. Perform repairs using a precrimped, 90 degree terminal and wire assembly. New terminal/wire leads are serviced as follows:
1. Locate damaged wire in terminal wiring harness.
2. Identify a location to cut the damaged wire where the butt splice connector(s) will not interfere
with re-assembly and re-installation of the hydraulic control module.
3. Cut wire and strip 8.0 mm (0.3 inch) of insulation from the end. Be careful not to nick or cut wire
strands.
4. Insert the stripped end of the wire into the crimp barrel and crimp.
5. Cut the 90 degree terminal and wire assembly to an appropriate length that will allow the crimped
wire to securely fit into the plastic channel of the internal wiring harness. Strip 8.0 mm (0.3 inch)
of installation from the end of wire, being careful no to nick or cut wire strands.
6. Insert the stripped end of the wire into the other end of the crimp barrel and crimp.
7. Pull on connector to be sure crimp is tight.
8. Heat splice with heat gun until covering shrinks and adhesive flows from under the covering.
Copyright 2008 Allison Transmission, Inc.
E59
3000 AND 4000 PRODUCT FAMILIES TROUBLESHOOTING MANUALALLISON 4th GENERATION CONTROLS
E60
PART NAME
SCT
Part #
SCT
Kit #
MANUFACTURER
CONFIG
MATING
P/N
MFG. P/N
Spacer, 80F
Seal, Industrial
Connector Body, 80F Bolt
R-61991-001
Bolt
300243
Seal, Bolt
Retainer, Bolt
TCM, 80-Way,
Bolt Assist
300276
Grommet, Retainer
300244
E-4550
300245
AFL Automotive
E-4551
300246
33001-2004
Terminal
300247
Molex
12034413
300008
Delphi
1-PC/TCM
TCM Header
1-PC/TCM
TCM Header
Spacer, 80F
Seal, Industrial
Connector Body, 80F Bolt
R-61991-001
TCM, 80-Way,
Bolt-Assist,
Dir A 90
Degree Wire
E-4542
Dress
E-6206-002
Bolt
300243
Seal, Bolt
AFL Automotive
Retainer, Bolt
300276
300244
E-4555
Cover, Bottom
33001-2004
Terminal
300247
Molex
12034413
300008
Delphi
Spacer, 80F
Seal, Industrial
Connector Body, 80F Bolt
R-61991-001
TCM, 80-Way,
Bolt-Assist,
Dir B 90
Degree Wire
E-4542
Dress
E-6206-001
Bolt
300243
Seal, Bolt
AFL Automotive
Retainer, Bolt
300276
300244
E-4555
Cover, Bottom
33001-2004
Terminal
300247
Molex
12034413
300008
Delphi
1-PC/TCM
TCM Header
E61
3000 AND 4000 PRODUCT FAMILIES TROUBLESHOOTING MANUALALLISON 4th GENERATION CONTROLS
MFG. P/N
CONNECTOR
PART NAME
Spacer, 80F
SCT
Part #
SCT
Kit #
MANUFACTURER
CONFIG
MATING
P/N
MFG. P/N
Seal, Industrial
Connector Body, 80F Bolt
R-62004-001
Cam-Left
Cam, Right
TCM, 80-Way,
Cam-Assist
A Dir
Handle, Cam
E-4542
Grommet, Retainer
E-4555
Cover, Bottom
E-4589
1-PC/TCM
TCM Header
1-PC/TCM
TCM Header
St. Clair
1-PC/TCM
TCM Header
AFL Automotive
Seal, Industrial
Connector Body, 80F Bolt
R-62004-002
Cam, Right
TCM, 80-Way,
Cam-Assist
B Dir
AFL Automotive
Handle, Cam
Grommet, Wire Seal
E-4542
Grommet, Retainer
E-4555
Cover, Bottom
E-4588
TCM, 80-Way, E-4540
80W, All
E-4539
Bolt Kit, TCM,
80W, All
Cam-Left
300244
300234
300234
St. Clair
1-PC/TCM
TCM Header
300235
300235
St. Clair
1-PC/TCM
TCM Header
300236
300236
St. Clair
1-PC/TCM
TCM Header
300237
300237
St. Clair
1-PC/TCM
TCM Header
300238
300238
St. Clair
1-PC/TCM
TCM Header
Retainer, Bolt
Wire Cover
Kit, 80W Bolt
Wire Cover
Kit, 80W Bolt,
Dir A 90
Degree
Wire Cover
Kit, 80W Bolt,
Dir A Dir
Wire Cover
Kit, 80W CAM
A Dir
Cover, Bottom
Cover, Bottom
3000 AND 4000 PRODUCT FAMILIES TROUBLESHOOTING MANUALALLISON 4th GENERATION CONTROLS
MFG. P/N
E62
CONNECTOR
Wire Cover
Kit, 80W Cam
B Dir
PART NAME
Cover, Bottom
Cover, Wire Dress
SCT
Part #
SCT
Kit #
300239
300239
MANUFACTURER
St. Clair
CONFIG
MATING
P/N
MFG. P/N
1-PC/TCM
CPA
Spacer, 20F
Seal, Industrial
Connector Body, 20F
R-62183-001
Bolt
Seal, Bolt
TRANS, 20F,
Bolt-Assist
R-62000001-D
300252
300278
Retainer, Bolt
R-62000-001-D
AFL Automotive
1-PC/TCM
St. Clair
1-PC/TCM
300241
St. Clair
1-PC/TCM
300242
St. Clair
1-PC/TCM
300227
Delphi
1-PC/COMP
Delphi
1-PC/COMP
TPS Header
Delphi
1-PC/COMP
TRANS, 20F,
Bolt-Assist
E-4566
Grommet, Retainer
300253
E-4569
300254
E-4570
Clip, Convolute
300251
E-4564
Spacer, 20F
E-4562
Seal, INterfacial
Bolt
Bolt Kit,
TRANS, 20W
Seal, Bolt
Retainer, Bolt
Cover, Wire Dress
Wire Cover
Kit, 20W
NE, NO, NT
TPS
Clip, Convolute
15490464
15496486
300261
15326267
Terminal, F GT150
300262
15305351
300263
15358890
Convolute Capture/TPA
Lock, Black
300264
12015793
Connector, 3-Way
12089040
Terminal, Pin
12089444
300260
12191065
Connector, 16F
300255
12191066
300256
300257
300258
12084912
300087
12129557
Cavity Plug
300105
12177289
300114
300278
E63
3000 AND 4000 PRODUCT FAMILIES TROUBLESHOOTING MANUALALLISON 4th GENERATION CONTROLS
MFG. P/N
CONNECTOR
12191066
300256
DTC, 9-Pin
J1939
RFT
RMR
SCT
Kit #
MANUFACTURER
CONFIG
MATING
P/N
MFG. P/N
300257
300259
12084912
300087
12129557
Cavity Plug
300105
12177289
300114
12160280
12160542
12160542
15304882
12110693
12110693
12160494
1-PC/COMP 12191176
12191176
12084912
12060551
12060551
12129557
12129557
12129557
12176394
12176394
12176394
HD10-9-1939P
0460-202-1631
Contact, Pin
300007
0460-247-1631
300273
114017
Sealing Plug
300000
Strain Relief
300269
Cap, Connector
300268
0462-201-1631
300005
0462-221-1631
300035
23-000-13
300206
W3S-P012
300275
13513314
15326267
Terminal, F GT150
15496486
300261
15305351
300263
15358890
Convolute Capture/TPA
Lock, Black
300264
Connector, 3-Way
12089444
300217
Delphi
1-PC/COMP
Diagnostic Tool
29511369
Deutsch IPD
300283
DT06-3S-EP11
Terminal, Pin
1-PC/COMP
300267
HDC16-6
12089040
Delphi
Delphi
HD18
12015795
300280
0460-202-1631
0460-247-1631
DT04-3P-EE01
W3P
Wedgelock, Receptacle
1-PC/COMP
Deutsch IPD
29542490
R-62184-001-A
Delphi
1-PC/COMP
Retarder Solenoid
12015092
12015092
Delphi
1-PC/COMP 12089188
12089188
Terminal, Socket
12089444
12089444
300262
3000 AND 4000 PRODUCT FAMILIES TROUBLESHOOTING MANUALALLISON 4th GENERATION CONTROLS
PART NAME
Connector, 16F
Strip SS
SCT
Part #
300255
MFG. P/N
12191065
E64
CONNECTOR
RMRX
12089188
Terminal, Socket
12089444
12162852
RTEMP
12124075
15326143
RTDR Air Sol
12124075
STANDOFF
PCS Sol
19134000
12092125
R-61992-001
R-62189-001
SS2 Sol,
7-Speed
PS1
OLS
NT1
OILT
TEMP
VIM, 18-Way
29541590
12124639
29541590
12124639
Seal, Interfacial
O-ring Seal
Connector, 2F
Cap, Connector
Connector, 2F
Cap, Connector
Terminal with 0.5 meter wire
In-line Splice connection
Connector, 2W Solenoid
Terminal, 280 Series Socket
Connector, 2W Solenoid
Terminal, 280 Series Socket
12110139
12066337
Connector
Assembly, 2M, 29544184
90 Sol Kit
SS1 Sol
PART NAME
Connector, Shroud 3-Way
12064758
3-Pin Plug
12047767
Terminal, Socket
12047783
15490953
Connector, 2-Way
12110236
Terminal, 150F
12129691
12047662
Connector, 2-Way
12047664
12047767
Terminal, Socket
12040920
12040936
Seal, 15-Way
12110545
Strain Relief,308-Way
12129426
12034236
12103881
Terminal, 150F
12034413
SCT
Part #
SCT
Kit #
MANUFACTURER
Delphi
CONFIG
Resist Mod
MATING
P/N
12015795
MFG. P/N
12015795
12089040
12089040
Terminal, Pin
12089444
12089444
12015792
12015792
Delphi
1-PC/COMP
Delphi
1-PC/COMP
AFL Automotive
Minnesota
Parker Seal
Internal
AFL Automotive
Internal
PCS Solenoid
Allison Transmission
PDC
Internal
PCS Solenoid
Delphi
Internal
Solenoid SS1
Delphi
Internal
Delphi
Internal
Delphi
Internal
Delphi
Internal
Phillips
Internal
Delphi
Internal
Delphi
1-PC/COMP
12084669
Accumulator Solenoid
Control Module
E65
3000 AND 4000 PRODUCT FAMILIES TROUBLESHOOTING MANUALALLISON 4th GENERATION CONTROLS
MFG. P/N
12015092
CONNECTOR
12034397
VIM, 30-Way
XFER
PART NAME
SCT
Part #
SCT
Kit #
MANUFACTURER
CONFIG
MATING
P/N
MFG. P/N
12040879
Seal, 9-Way
12110546
12129426
12034236
12103881
Terminal, 150F
12034413
Delphi
1-PC/COMP
ITT Cannon
1-PC/COMP
3000 AND 4000 PRODUCT FAMILIES TROUBLESHOOTING MANUALALLISON 4th GENERATION CONTROLS
MFG. P/N
E66
CONNECTOR
3000 AND 4000 PRODUCT FAMILIES TROUBLESHOOTING MANUALALLISON 4th GENERATION CONTROLS
Description of Operation
1. To properly communicate throttle position to the Transmission Control Module (TCM), the
throttle position sensor must convert its mechanical movement to an electrical form the TCM can
understand. To accomplish this, contacts move across a resistive strip inside the sensor which
translates position into voltage (refer to Figure F1).
V00656.01
2. Each position gives a different voltage. The TCM then converts this voltage into percent. Each
millimeter of travel converts to approximately 0.110 volts. Figure F2 diagrams the voltage and
throttle movement relationship.
0 Volt
4.444 Volts
0.278 Volts
ERROR
ZONE
5 Volts
0.972 Volts
ERROR
ZONE
3.889 Volts
APPROX.
19 mm (0.75 in.) STROKE
CLOSED
THROTTLE
FULLY
RETRACTED
(AT REST)
8.9 mm
(0.35 in.)
2.5 mm
(0.1 in.)
0 mm
WIDE OPEN
THROTTLE
Total Stroke
CTWOT
15.2 mm22.9 mm
(0.60 in.0.9 in.)
1.6672.500 Volts
FULLY
EXTENDED
35.7 mm
(1.4 in.)
40.6 mm
(1.6 in.)
45.7 mm
(1.8 in.)
V05746.00.02
3. Throttle percent is proportional to the amount of travel of the throttle position sensor (refer to
Table F1). Therefore a small amount of travel corresponds to a low throttle percentage and a large
amount of travel corresponds to a high throttle percentage.
4. The throttle position sensor (TPS) is self-calibrating within its normal range of operation. Each time
the vehicle is started and the TCM is initialized, the idle position that is stored for closed throttle is
increased from its previous lowest reading. Also, the wide open throttle position is reduced from its
previous highest reading. Once the new position is read from the TPS, the idle and wide open
Copyright 2008 Allison Transmission, Inc.
F1
3000 AND 4000 PRODUCT FAMILIES TROUBLESHOOTING MANUALALLISON 4th GENERATION CONTROLS
NOTE:
F2
Volts
0
0.110
0.220
0.329
0.439
0.549
0.659
0.768
0.878
0.988
1.098
1.207
1.317
1.427
1.537
1.646
1.756
1.866
1.976
2.085
2.195
2.305
2.415
2.524
mm
24
25
26
27
28
29
30
31
32
33
34
35
36
37
38
39
40
41
42
43
44
45
46
Volts
2.634
2.744
2.854
2.964
3.073
3.183
3.293
3.403
3.512
3.622
3.732
3.842
3.951
4.061
4.171
4.281
4.390
4.500
4.610
4.720
4.829
4.939
5.049
3000 AND 4000 PRODUCT FAMILIES TROUBLESHOOTING MANUALALLISON 4th GENERATION CONTROLS
BENDING LOAD
APPLIED
UNACCEPTABLE INSTALLATION
10.0 MAX INSTALLED
OPERATING ANGLE
IN ALL DIRECTIONS
LOADING IN
TENSION ONLY
ACCEPTABLE INSTALLATION
Attachment must provide freedom
of motion to allow cable loading in
tension only (no bending loads).
WIRING HARNESS
55.0 mm (2.17 in.)
MIN REQUIRED
FOR CONNECTION
REMOVAL
FULLY EXTENDED
FORCE REQUIRED
26.7 N (6.0 LB) MAX
FULLY
RETRACTED
FULL THROTTLE
118.1 mm (4.65 in.)
CLOSED THROTTLE
95.2 mm (3.75 in.)
CLOSED THROTTLE
FULL THROTTLE
160.2 mm (6.31 in.) MIN
SAME AS WITHOUT
SLIP-LINK
FULLY EXTENDED
V00430.07
F3
3000 AND 4000 PRODUCT FAMILIES TROUBLESHOOTING MANUALALLISON 4th GENERATION CONTROLS
Description
Throttle Position Sensor x length
Slip-Link
Throttle Position Sensor x length
Slip-Link
Engine Bracket
Engine-mounted
with Slip-Link
Grommet
Ferrule
0.250-20 x 2.250 long; bolt with nylon patch
Throttle Position Sensor x length
Slip-Link
TransmissionEngine Bracket
mounted (right or
Grommet
left) with Slip-Link
Ferrule
0.250-20 x 2.250 long; bolt with nylon patch
Part Number
Various
29503631
Various
29503631
29500824
29509441
29509442
25944294
Various
29503631
29508371
29509441
29509442
2954494
Quality
1
1
1
1
1
3
3
3
1
1
1
3
3
3
The bolt for attaching the throttle sensor to the ferrules in engine and transmission brackets is torqued to 811 Nm
(7298 inch lbs).
F4
3000 AND 4000 PRODUCT FAMILIES TROUBLESHOOTING MANUALALLISON 4th GENERATION CONTROLS
Do not jump start a vehicle with arc welding equipment. Arc welding
equipments dangerously high currents and voltages cannot be reduced to safe
levels.
WARNING!
G2.
The Allison Vehicle Interface Module (VIM) containing all Allison system relays and fuses must be used as the
interface to all vehicle wiring. Refer to Figure G2 for VIM component location and pin-out. To close an open
VIM, tighten the bolts in the numerical order shown in Figure G1 to provide a sealed, water-tight box. Torque the
bolts to 58 Nm (46 lb ft).
2
4
3
V00657
G1
3000 AND 4000 PRODUCT FAMILIES TROUBLESHOOTING MANUALALLISON 4th GENERATION CONTROLS
(K4)
WIRE 145/SFO 1
A3/30
S3/18
(K5)
WIRE 124/SFO 4
C1/30
N2/18
B2/30
1
IGNITION FUSE
K1 & 2/30
C2/30
S1/18
A2/30
E1/30
F2/30
(K2)
WIRE 104/SFO 2
E3/30
(K3)
WIRE 141/NEUTRAL START
F1/30
S1/18
(K1)
WIRE 165/REVERSE WARNING
A1/30
S2/18
P2/18
C1/30
D1/30
S1/18
C1/30
(K6)
WIRE 130/SFO 3
F3/30
M1/18
C1/30
C1/30
S1/18
L1 & 2/18
P1/18
D2/30
()
(+)
S1/18
K1 & 2/30
G1/30
E2/30
B1/30
J1 & 2/30
MAIN FUSE
R1 & R2/18
2
3
3
A
30-WAY CONNECTOR
(PIN ID/30)
See page D-16 for
wire/terminal usage.
L
A
M
B
N
C
P
D
R
E
S
F
18-WAY CONNECTOR
(PIN ID/18)
See page D-15 for
wire/terminal usage.
TERMINAL BOARD
IDENTIFICATION
HARNESS
CONNECTOR
IDENTIFICATION
87
86
87A
85
30
Pin numbering on
bottom of relay
1
V07114.01.00
G2
3000 AND 4000 PRODUCT FAMILIES TROUBLESHOOTING MANUALALLISON 4th GENERATION CONTROLS
Description
Page No.
H1
H3/H4
H2
H5/H6
H3
H7/H8
H4
H9/H10
H5
H11/H12
H6
H13/H14
H7
H15/H16
H8
H17/H18
H9
H19/H20
H10
H21/H22
H11
H23/H24
H12
H25/H26
H13
H27/H28
H14
H29/H30
H15
H31/H32
H16
H33/H34
H17
H35/H36
H18
H37/H38
H19
H39/H40
H20
H41/H42
H21
H43/H44
H22
H45/H46
H1
3000 AND 4000 PRODUCT FAMILIES TROUBLESHOOTING MANUALALLISON 4th GENERATION CONTROLS
H2
3000 AND 4000 PRODUCT FAMILIES TROUBLESHOOTING MANUALALLISON 4th GENERATION CONTROLS
LUBE
FILTER
COOLER
CONVERTER OUT
LUBE
LUBE
CONVERTER IN
TORQUE
CONVERTER
Orifice
EX
EX
CONVERTER
REGULATOR
CONVERTER
FLOW
EX
LUBE
REGULATOR
REAR
SPLITLINE
TCC *
EX
EX
PCS1
N/O
N/C
EX
PCS2
N/O
EX
PCS4
N/C
EX
PCS3
N/C
EX
EX
EX
EX
Accumulator
Accumulator
Accumulator
EX
EX
CONTROL
MAIN
Accumulator
EX
EX
MAIN
EX
EX
MAIN
FILTER
SS1
N/C
Pressure
Relief
EX
Orifice
***
PS1
DIAGNOSTIC
EX
PCS6
N/C
EX
EX
SS2
N/C
EX
MAIN
REGULATOR
PUMP
EX
6-Speed
Only
EX
EXHAUST
BACKFILL
Accumulator
MAIN
MOD **
N/C
EX
C2
LATCH
EX
EX
C1
LATCH
EX
SUCTION
FILTER
EX
C1
C2
C1
C3
C2
C4
C3
C5
C4
SUMP
C6
C5
C6
NOTES:
LEGEND:
* TCC Solenoid is generally ON from 2nd-range thru 6th-range
MAIN
** Main Mod Solenoid may be ON in Reverse, Neutral, Low (7-speed),
CONTROL MAIN
1st, or 2nd as determined by calibration.
EXHAUST
*** PS1 = Diagnostic Pressure Switch
SUCTION
MAIN MOD
= 7-Speed Transmissions only
COOLER/LUBE
EX. BACKFILL
CONVERTER
C5
V09253.00.00
H3/H4
3000 AND 4000 PRODUCT FAMILIES TROUBLESHOOTING MANUALALLISON 4th GENERATION CONTROLS
LOCKUP
LUBE
FILTER
COOLER
CONVERTER OUT
LUBE
LUBE
CONVERTER IN
TORQUE
CONVERTER
Orifice
EX
EX
CONVERTER
REGULATOR
CONVERTER
FLOW
EX
LUBE
REGULATOR
REAR
SPLITLINE
TCC *
EX
EX
PCS1
N/O
N/C
EX
PCS22
PCS
N/O
EX
EX
PCS3
N/C
EX
PCS4
N/C
EX
EX
EX
Accumulator
Accumulator
Accumulator
EX
EX
CONTROL
MAIN
Accumulator
EX
EX
MAIN
EX
EX
MAIN
FILTER
SS1
N/C
Pressure
Relief
EX
Orifice
DIAGNOSTIC
***
PS1
EX
PCS6
N/C
EX
EX
SS2
N/C
EX
MAIN
REGULATOR
PUMP
EX
6-Speed
Only
EX
EXHAUST
BACKFILL
Accumulator
MAIN
MOD **
N/C
EX
C2
LATCH
EX
EX
C1
LATCH
EX
SUCTION
FILTER
EX
C1
C2
C1
C3
C2
C4
C3
C5
C4
SUMP
C6
C5
C6
NOTES:
LEGEND:
* TCC Solenoid is generally ON from 2nd-range thru 6th-range
MAIN
** Main Mod Solenoid may be ON in Reverse, Neutral, Low (7-speed),
CONTROL MAIN
1st, or 2nd as determined by calibration.
EXHAUST
*** PS1 = Diagnostic Pressure Switch
SUCTION
MAIN MOD
= 7-Speed Transmissions only
COOLER/LUBE
EX. BACKFILL
CONVERTER
C3
C5
V09254.00.00
H5/H6
3000 AND 4000 PRODUCT FAMILIES TROUBLESHOOTING MANUALALLISON 4th GENERATION CONTROLS
LOCKUP
LUBE
FILTER
COOLER
CONVERTER OUT
LUBE
LUBE
CONVERTER IN
TORQUE
CONVERTER
Orifice
EX
EX
CONVERTER
REGULATOR
CONVERTER
FLOW
EX
LUBE
REGULATOR
REAR
SPLITLINE
TCC *
EX
EX
PCS1
N/O
N/C
EX
PCS2
N/O
EX
EX
PCS3
N/C
EX
PCS4
N/C
EX
EX
EX
Accumulator
Accumulator
Accumulator
EX
EX
CONTROL
MAIN
Accumulator
EX
MAIN
EX
EX
EX
MAIN
FILTER
SS1
N/C
Pressure
Relief
EX
Orifice
***
PS1
DIAGNOSTIC
EX
PCS6
N/C
EX
EX
SS2
N/C
EX
MAIN
REGULATOR
PUMP
EX
EX
EXHAUST
BACKFILL
Accumulator
C2
LATCH
EX
EX
C1
LATCH
SUCTION
FILTER
MAIN
MOD **
N/C
EX
EX
EX
C1
C2
C1
C3
C2
C4
C3
C5
C4
SUMP
C6
C5
C6
NOTES:
* TCC Solenoid is generally ON from 2nd-range thru 6th-range
** Main Mod Solenoid may be ON in Reverse, Neutral, Low (7-speed),
1st, or 2nd as determined by calibration.
*** PS1 = Diagnostic Pressure Switch
= 7-Speed Transmissions only
LEGEND:
MAIN
CONTROL MAIN
EXHAUST
SUCTION
FWD. KDN.
MAIN MOD
LOCKUP
COOLER/LUBE
EX. BACKFILL
CONVERTER
C3
C6
V09261.00.00
H7/H8
3000 AND 4000 PRODUCT FAMILIES TROUBLESHOOTING MANUALALLISON 4th GENERATION CONTROLS
LUBE
FILTER
COOLER
CONVERTER OUT
LUBE
LUBE
CONVERTER IN
TORQUE
CONVERTER
Orifice
EX
EX
CONVERTER
REGULATOR
CONVERTER
FLOW
EX
LUBE
REGULATOR
REAR
SPLITLINE
TCC *
EX
EX
PCS1
N/O
N/C
EX
PCS2
N/O
EX
PCS4
N/C
EX
PCS3
N/C
EX
EX
EX
EX
MAIN
Accumulator
Accumulator
Accumulator
EX
EX
CONTROL
MAIN
Accumulator
EX
EX
EX
EX
MAIN
FILTER
SS1
N/C
Pressure
Relief
EX
Orifice
***
PS1
EX
DIAGNOSTIC
PCS6
N/C
EX
EX
SS2
N/C
EX
MAIN
REGULATOR
PUMP
EX
EX
EXHAUST
BACKFILL
Accumulator
C2
LATCH
EX
EX
C1
LATCH
SUCTION
FILTER
MAIN
MOD **
N/C
EX
EX
EX
C1
C2
C1
C3
C2
C4
C3
C5
C4
SUMP
C6
C5
C6
NOTES:
* TCC Solenoid is generally ON from 2nd-range thru 6th-range
** Main Mod Solenoid may be ON in Reverse, Neutral, Low (7-speed),
1st, or 2nd as determined by calibration.
*** PS1 = Diagnostic Pressure Switch
= 7-Speed Transmissions only
LEGEND:
MAIN
CONTROL MAIN
EXHAUST
SUCTION
FWD. KDN.
MAIN MOD
LOCKUP
COOLER/LUBE
EX. BACKFILL
CONVERTER
C1
C6
V09262.01.00
H9/H10
3000 AND 4000 PRODUCT FAMILIES TROUBLESHOOTING MANUALALLISON 4th GENERATION CONTROLS
Lube
Filter
Cooler
CONVERTER OUT
Lube
Lube
CONVERTER IN
TORQUE
CONVERTER
Orifice
EX
EX
CONVERTER
REGULATOR
CONVERTER
FLOW
EX
LUBE
REGULATOR
REAR
SPLITLINE
TCC *
EX
EX
PCS1
N/O
N/C
EX
PCS2
N/O
EX
PCS4
N/C
EX
PCS3
N/C
EX
EX
EX
EX
Accumulator
Accumulator
Accumulator
EX
EX
EX
CONTROL
MAIN
Accumulator
EX
EX
EX
MAIN
FILTER
SS1
N/C
Pressure
Relief
EX
Orifice
EX
PCS6
N/C
DIAGNOSTIC
EX
EX
SS2
N/C
EX
MAIN
REGULATOR
PUMP
EX
6-Speed
Only
EX
EXHAUST
BACKFILL
Accumulator
MAIN
MOD **
N/C
EX
C2
LATCH
EX
EX
EX
SUCTION
FILTER
EX
C1
LATCH
SUMP
C1
C2
C3
C4
C5
C6
NOTES:
LEGEND:
* TCC Solenoid is generally ON from 2nd-range thru 6th-range
MAIN
CONTROL MAIN
** Main Mod Solenoid may be ON in Reverse, Neutral, Low (7-speed),
EXHAUST
1st, or 2nd as determined by calibration.
SUCTION
*** PS1 = Diagnostic Pressure Switch
FWD. KDN.
= 7-Speed Transmissions only
MAIN MOD
COOLER/LUBE
EX. BACKFILL
CONVERTER
C1
C5
V09255.01.00
Figure H5. 3000 and 4000 Product Families Hydraulic SchematicFirst Range
Copyright 2008 Allison Transmission, Inc.
H11/H12
3000 AND 4000 PRODUCT FAMILIES TROUBLESHOOTING MANUALALLISON 4th GENERATION CONTROLS
LUBE
FILTER
COOLER
CONVERTER OUT
LUBE
LUBE
CONVERTER IN
TORQUE
CONVERTER
Orifice
EX
EX
CONVERTER
REGULATOR
CONVERTER
FLOW
EX
LUBE
REGULATOR
REAR
SPLITLINE
TCC *
EX
EX
PCS1
N/O
N/C
EX
PCS2
N/O
EX
EX
PCS3
N/C
EX
PCS4
N/C
EX
EX
EX
Accumulator
Accumulator
Accumulator
EX
EX
CONTROL
MAIN
Accumulator
EX
EX
MAIN
EX
EX
MAIN
FILTER
SS1
N/C
Pressure
Relief
EX
Orifice
***
PS1
DIAGNOSTIC
EX
PCS6
N/C
EX
EX
SS2
N/C
EX
MAIN
REGULATOR
PUMP
EX
6-Speed
Only
EX
EXHAUST
BACKFILL
Accumulator
MAIN
MOD **
N/C
EX
C2
LATCH
EX
EX
C1
LATCH
EX
SUCTION
FILTER
EX
C1
C2
C1
C3
C2
C4
C3
C5
C4
SUMP
C6
C5
C6
NOTES:
LEGEND:
* TCC Solenoid is generally ON from 2nd-range thru 6th-range
MAIN
** Main Mod Solenoid may be ON in Reverse, Neutral, Low (7-speed),
CONTROL MAIN
EXHAUST
1st, or 2nd as determined by calibration.
SUCTION
*** PS1 = Diagnostic Pressure Switch
FWD. KDN.
= 7-Speed Transmissions only
MAIN MOD
LOCKUP
COOLER/LUBE
EX. BACKFILL
CONVERTER
C1
C4
V09256.00.00
Figure H6. 3000 and 4000 Product Families Hydraulic SchematicSecond Range
Copyright 2008 Allison Transmission, Inc.
H13/H14
3000 AND 4000 PRODUCT FAMILIES TROUBLESHOOTING MANUALALLISON 4th GENERATION CONTROLS
LUBE
FILTER
COOLER
CONVERTER OUT
LUBE
LUBE
CONVERTER IN
TORQUE
CONVERTER
Orifice
EX
EX
CONVERTER
REGULATOR
CONVERTER
FLOW
EX
LUBE
REGULATOR
REAR
SPLITLINE
TCC *
EX
EX
PCS1
N/O
N/C
EX
PCS2
N/O
EX
EX
PCS3
N/C
EX
PCS4
N/C
EX
EX
EX
MAIN
Accumulator
Accumulator
Accumulator
EX
EX
CONTROL
MAIN
Accumulator
EX
EX
EX
EX
MAIN
FILTER
SS1
N/C
Pressure
Relief
EX
Orifice
***
PS1
DIAGNOSTIC
EX
PCS6
N/C
EX
EX
SS2
N/C
EX
MAIN
REGULATOR
PUMP
EX
6-Speed
Only
EX
EXHAUST
BACKFILL
Accumulator
MAIN
MOD **
N/C
EX
C2
LATCH
EX
EX
C1
LATCH
EX
SUCTION
FILTER
EX
C1
C2
C1
C3
C2
C4
C3
C5
C4
SUMP
C6
C5
C6
NOTES:
* TCC Solenoid is generally ON from 2nd-range thru 6th-range
** Main Mod Solenoid may be ON in Reverse, Neutral, Low (7-speed),
1st, or 2nd as determined by calibration.
*** PS1 = Diagnostic Pressure Switch
= 7-Speed Transmissions only
LEGEND:
MAIN
CONTROL MAIN
EXHAUST
SUCTION
FWD. KDN.
LOCKUP
COOLER/LUBE
EX. BACKFILL
CONVERTER
C1
C3
V09257.00.00
Figure H7. 3000 and 4000 Product Families Hydraulic SchematicThird Range
Copyright 2008 Allison Transmission, Inc.
H15/H16
3000 AND 4000 PRODUCT FAMILIES TROUBLESHOOTING MANUALALLISON 4th GENERATION CONTROLS
LUBE
FILTER
COOLER
CONVERTER OUT
LUBE
LUBE
CONVERTER IN
TORQUE
CONVERTER
Orifice
EX
EX
CONVERTER
REGULATOR
CONVERTER
FLOW
EX
LUBE
REGULATOR
REAR
SPLITLINE
TCC *
EX
EX
PCS1
N/O
N/C
EX
PCS2
N/O
EX
EX
PCS3
N/C
EX
PCS4
N/C
EX
EX
EX
MAIN
Accumulator
Accumulator
Accumulator
EX
EX
CONTROL
MAIN
Accumulator
EX
EX
EX
EX
MAIN
FILTER
SS1
N/C
Pressure
Relief
EX
Orifice
***
PS1
EX
DIAGNOSTIC
PCS6
N/C
EX
EX
SS2
N/C
EX
MAIN
REGULATOR
PUMP
EX
6-Speed
Only
EX
EXHAUST
BACKFILL
Accumulator
MAIN
MOD **
N/C
EX
C2
LATCH
EX
EX
C1
LATCH
EX
SUCTION
FILTER
EX
C1
C2
C1
C3
C2
C4
C3
C5
C4
SUMP
C6
C5
C6
NOTES:
LEGEND:
* TCC Solenoid is generally ON from 2nd-range thru 6th-range
MAIN
** Main Mod Solenoid may be ON in Reverse, Neutral, Low (7-speed),
CONTROL MAIN
1st, or 2nd as determined by calibration.
EXHAUST
*** PS1 = Diagnostic Pressure Switch
SUCTION
FWD. KDN.
= 7-Speed Transmissions only
LOCKUP
COOLER/LUBE
EX. BACKFILL
CONVERTER
C1
C2
V09258.00.00
Figure H8. 3000 and 4000 Product Families Hydraulic SchematicFourth Range
Copyright 2008 Allison Transmission, Inc.
H17/H18
3000 AND 4000 PRODUCT FAMILIES TROUBLESHOOTING MANUALALLISON 4th GENERATION CONTROLS
LUBE
FILTER
COOLER
CONVERTER OUT
LUBE
LUBE
CONVERTER IN
TORQUE
CONVERTER
Orifice
EX
EX
CONVERTER
REGULATOR
CONVERTER
FLOW
EX
LUBE
REGULATOR
REAR
SPLITLINE
TCC *
EX
EX
PCS1
N/O
N/C
EX
PCS2
N/O
EX
EX
PCS3
N/C
EX
PCS4
N/C
EX
EX
EX
Accumulator
Accumulator
Accumulator
EX
EX
CONTROL
MAIN
Accumulator
EX
MAIN
EX
EX
EX
MAIN
FILTER
SS1
N/C
Pressure
Relief
EX
Orifice
***
PS1
DIAGNOSTIC
EX
PCS6
N/C
EX
EX
SS2
N/C
EX
MAIN
REGULATOR
PUMP
EX
6-Speed
Only
EX
EXHAUST
BACKFILL
Accumulator
MAIN
MOD **
N/C
EX
C2
LATCH
EX
EX
C1
LATCH
EX
SUCTION
FILTER
EX
C1
C2
C1
C3
C2
C4
C3
C5
C4
SUMP
C6
C5
C6
NOTES:
* TCC Solenoid is generally ON from 2nd-range thru 6th-range
** Main Mod Solenoid may be ON in Reverse, Neutral, Low (7-speed),
1st, or 2nd as determined by calibration.
*** PS1 = Diagnostic Pressure Switch
= 7-Speed Transmissions only
LEGEND:
MAIN
CONTROL MAIN
EXHAUST
SUCTION
FWD. KDN.
LOCKUP
COOLER/LUBE
EX. BACKFILL
CONVERTER
C2
C3
V09259.00.00
Figure H9. 3000 and 4000 Product Families Hydraulic SchematicFifth Range
Copyright 2008 Allison Transmission, Inc.
H19/H20
3000 AND 4000 PRODUCT FAMILIES TROUBLESHOOTING MANUALALLISON 4th GENERATION CONTROLS
LUBE
FILTER
COOLER
CONVERTER OUT
LUBE
LUBE
CONVERTER IN
TORQUE
CONVERTER
Orifice
EX
EX
CONVERTER
REGULATOR
CONVERTER
FLOW
EX
LUBE
REGULATOR
REAR
SPLITLINE
TCC *
EX
EX
PCS1
N/O
N/C
EX
PCS2
N/O
EX
PCS4
N/C
EX
PCS3
N/C
EX
EX
EX
EX
Accumulator
Accumulator
Accumulator
EX
EX
CONTROL
MAIN
Accumulator
EX
MAIN
EX
EX
EX
MAIN
FILTER
SS1
N/C
Pressure
Relief
EX
Orifice
***
PS1
EX
DIAGNOSTIC
PCS6
N/C
EX
EX
SS2
N/C
EX
MAIN
REGULATOR
PUMP
EX
6-Speed
Only
EX
EXHAUST
BACKFILL
Accumulator
C2
LATCH
EX
EX
C1
LATCH
SUCTION
FILTER
MAIN
MOD **
N/C
EX
EX
EX
C1
C2
C1
C3
C2
C4
C3
C5
C4
SUMP
C6
C5
C6
NOTES:
* TCC Solenoid is generally ON from 2nd-range thru 6th-range
** Main Mod Solenoid may be ON in Reverse, Neutral, Low (7-speed),
1st, or 2nd as determined by calibration.
*** PS1 = Diagnostic Pressure Switch
= 7-Speed Transmissions only
LEGEND:
MAIN
CONTROL MAIN
EXHAUST
SUCTION
FWD. KDN.
LOCKUP
COOLER/LUBE
EX. BACKFILL
CONVERTER
C2
C4
V09260.00.00
Figure H10. 3000 and 4000 Product Families Hydraulic SchematicSixth Range
Copyright 2008 Allison Transmission, Inc
H21/H22
3000 AND 4000 PRODUCT FAMILIES TROUBLESHOOTING MANUALALLISON 4th GENERATION CONTROLS
PCS5
N/C
TO RETARDER
EX
EX
RELAY
VALVE
LUBE
REGULATOR
VALVE
CONVERTER OUT
EX
EX
Retarder
Temp Sensor
Flow
Valve
EX
Sump
Cooler
Cooler
ON/OFF
Solenoid
SS2
Air Protection
Valve
(OEM supplied)
(Air)
EX
Accumulator
CONTROL MAIN
LUBE
MAIN PRESSURE
FROM COOLER
CONVERTER OUT
TO COOLER
EXHAUST
VEHICLE AIR
ORIFICE LUBE
V09280.02.00
H23/H24
3000 AND 4000 PRODUCT FAMILIES TROUBLESHOOTING MANUALALLISON 4th GENERATION CONTROLS
PCS5
N/C
EX
TO RETARDER
EX
RELAY
VALVE
LUBE
REGULATOR
VALVE
CONVERTER OUT
EX
EX
Retarder
Temp Sensor
Flow
Valve
EX
Sump
Cooler
CONTROL MAIN
TO RETARDER
MAIN PRESSURE
LUBE
RETARDER OUT
FROM COOLER
CONVERTER OUT
TO COOLER
EXHAUST
VEHICLE AIR
Cooler
ON/OFF
Solenoid
SS2
Air Protection
Valve
(OEM supplied)
EX
Accumulator
(Air)
V09281.02.00
H25/H26
3000 AND 4000 PRODUCT FAMILIES TROUBLESHOOTING MANUALALLISON 4th GENERATION CONTROLS
EX
PCS5
N/C
TO RETARDER
EXHAUST
BACKFILL
EX
RELAY
VALVE
LUBE
REGULATOR
VALVE
EX
CONVERTER OUT
EX
Retarder
Temp Sensor
Flow
Valve
EX
Sump
Cooler
Cooler
ON/OFF
Solenoid
SS2
Air Protection
Valve
(OEM supplied)
(Air)
EX
Accumulator
CONTROL MAIN
LUBE
MAIN PRESSURE
FROM COOLER
CONVERTER OUT
TO COOLER
EXHAUST
VEHICLE AIR
ORIFICE LUBE
V09279.02.00
H27/H28
3000 AND 4000 PRODUCT FAMILIES TROUBLESHOOTING MANUALALLISON 4th GENERATION CONTROLS
EX
PCS5
N/C
TO RETARDER
EXHAUST
BACKFILL
EX
RELAY
VALVE
LUBE
REGULATOR
VALVE
EX
CONVERTER OUT
EX
Retarder
Temp Sensor
Flow
Valve
EX
Sump
Cooler
Cooler
ON/OFF
Solenoid
SS2
Air Protection
Valve
(OEM supplied)
(Air)
EX
CONTROL MAIN
TO RETARDER
MAIN PRESSURE
LUBE
RETARDER OUT
FROM COOLER
CONVERTER OUT
TO COOLER
EXHAUST
VEHICLE AIR
Accumulator
V09278.02.00
H29/H30
3000 AND 4000 PRODUCT FAMILIES TROUBLESHOOTING MANUALALLISON 4th GENERATION CONTROLS
LUBE
FILTER
COOLER
CONVERTER OUT
LUBE
LUBE
CONVERTER IN
TORQUE
CONVERTER
Orifice
EX
EX
CONVERTER
REGULATOR
CONVERTER
FLOW
EX
LUBE
REGULATOR
REAR
SPLITLINE
TCC *
EX
EX
PCS1
N/O
N/C
EX
PCS2
N/O
EX
PCS4
N/C
EX
PCS3
N/C
EX
EX
EX
EX
Accumulator
Accumulator
Accumulator
EX
EX
EX
CONTROL
MAIN
Accumulator
MAIN
EX
EX
EX
MAIN
FILTER
SS1
N/C
MAIN
REGULATOR
Pressure
Relief
EX
Orifice
***
PS1
DIAGNOSTIC
EX
EX
EX
EX
PUMP
****
PS2
6-Speed
Only
EX
EXHAUST
BACKFILL
MAIN
MOD **
N/C
EX
C2
LATCH
SUCTION
FILTER
EX
C1
LATCH
EX
C1
C2
C1
C3
C2
C4
C3
SUMP
C5
C4
C5
NOTES:
* TCC Solenoid is generally ON from 2nd-range thru 6th-range
** Main Mod Solenoid may be ON in Reverse, Neutral, Low (7-speed),
1st, or 2nd as determined by calibration.
*** PS1 = Diagnostic Pressure Switch
**** PS2 = Filter Life Switch
LEGEND:
MAIN
CONTROL MAIN
EXHAUST
SUCTION
MAIN MOD
COOLER/LUBE
EX. BACKFILL
CONVERTER
C5
V09253.00.00.A
H31/H32
3000 AND 4000 PRODUCT FAMILIES TROUBLESHOOTING MANUALALLISON 4th GENERATION CONTROLS
LUBE
FILTER
COOLER
CONVERTER OUT
LUBE
LUBE
CONVERTER IN
TORQUE
CONVERTER
Orifice
EX
EX
CONVERTER
REGULATOR
CONVERTER
FLOW
EX
LUBE
REGULATOR
REAR
SPLITLINE
TCC *
EX
EX
PCS1
N/O
N/C
EX
PCS22
PCS
N/O
EX
EX
PCS3
N/C
EX
PCS4
N/C
EX
EX
EX
Accumulator
Accumulator
Accumulator
EX
EX
EX
CONTROL
MAIN
Accumulator
EX
MAIN
EX
EX
MAIN
FILTER
SS1
N/C
MAIN
REGULATOR
EX
Orifice
DIAGNOSTIC
***
PS1
Pressure
Relief
EX
EX
EX
EX
PUMP
****
PS2
6-Speed
Only
EX
EXHAUST
BACKFILL
MAIN
MOD **
N/C
EX
C2
LATCH
SUCTION
FILTER
EX
C1
LATCH
EX
C1
C2
C1
C3
C2
C4
C3
C5
C4
SUMP
C5
NOTES:
* TCC Solenoid is generally ON from 2nd-range thru 6th-range
** Main Mod Solenoid may be ON in Reverse, Neutral, Low (7-speed),
1st, or 2nd as determined by calibration.
*** PS1 = Diagnostic Pressure Switch
**** PS2 = Filter Life Switch
LEGEND:
MAIN
CONTROL MAIN
EXHAUST
SUCTION
MAIN MOD
COOLER/LUBE
EX. BACKFILL
CONVERTER
C3
C5
V09254.00.00.A
Figure H16. 3000 and 4000 Product Family Hydraulic SchematicReverse With Prognostics
Copyright 2008 Allison Transmission, Inc.
H33/H34
3000 AND 4000 PRODUCT FAMILIES TROUBLESHOOTING MANUALALLISON 4th GENERATION CONTROLS
Lube
Filter
Cooler
CONVERTER OUT
Lube
Lube
CONVERTER IN
TORQUE
CONVERTER
Orifice
EX
EX
CONVERTER
REGULATOR
CONVERTER
FLOW
EX
LUBE
REGULATOR
REAR
SPLITLINE
TCC *
EX
EX
PCS1
N/O
N/C
EX
PCS2
N/O
EX
EX
PCS3
N/C
EX
PCS4
N/C
EX
EX
EX
Accumulator
Accumulator
Accumulator
EX
EX
EX
CONTROL
MAIN
Accumulator
EX
EX
EX
MAIN
FILTER
SS1
N/C
MAIN
REGULATOR
Pressure
Relief
EX
Orifice
EX
DIAGNOSTIC
EX
EX
EX
PUMP
****
PS2
6-Speed
Only
EX
EXHAUST
BACKFILL
MAIN
MOD **
N/C
EX
C2
LATCH
SUCTION
FILTER
EX
EX
C1
LATCH
SUMP
C1
C2
C3
C4
C5
NOTES:
* TCC Solenoid is generally ON from 2nd-range thru 6th-range
** Main Mod Solenoid may be ON in Reverse, Neutral, Low (7-speed),
1st, or 2nd as determined by calibration.
*** PS1 = Diagnostic Pressure Switch
**** PS2 = Filter Life Switch
LEGEND:
MAIN
CONTROL MAIN
EXHAUST
SUCTION
FWD. KDN.
MAIN MOD
COOLER/LUBE
EX. BACKFILL
CONVERTER
C1
C5
V09255.01.00.A
Figure H17. 3000 and 4000 Product Family Hydraulic SchematicFirst Range With Prognostics
Copyright 2008 Allison Transmission, Inc.
H35/H36
3000 AND 4000 PRODUCT FAMILIES TROUBLESHOOTING MANUALALLISON 4th GENERATION CONTROLS
LUBE
FILTER
COOLER
CONVERTER OUT
LUBE
LUBE
CONVERTER IN
TORQUE
CONVERTER
Orifice
EX
EX
CONVERTER
REGULATOR
CONVERTER
FLOW
EX
LUBE
REGULATOR
REAR
SPLITLINE
TCC *
EX
EX
PCS1
N/O
N/C
EX
PCS2
N/O
EX
EX
PCS3
N/C
EX
PCS4
N/C
EX
EX
EX
Accumulator
Accumulator
Accumulator
EX
EX
EX
CONTROL
MAIN
Accumulator
EX
MAIN
EX
EX
MAIN
FILTER
SS1
N/C
EX
Orifice
MAIN
REGULATOR
***
PS1
DIAGNOSTIC
EX
EX
EX
EX
6-Speed
Only
EX
****
PS2
PUMP
EXHAUST
BACKFILL
MAIN
MOD **
N/C
EX
C2
LATCH
Pressure
Relief
SUCTION
FILTER
EX
C1
LATCH
EX
C1
C2
C1
C3
C2
C4
C3
C5
C4
SUMP
C5
NOTES:
LEGEND:
* TCC Solenoid is generally ON from 2nd-range thru 6th-range
MAIN
** Main Mod Solenoid may be ON in Reverse, Neutral, Low (7-speed),
CONTROL MAIN
EXHAUST
1st, or 2nd as determined by calibration.
SUCTION
*** PS1 = Diagnostic Pressure Switch
FWD. KDN.
**** PS2 = Filter Life Switch
MAIN MOD
LOCKUP
COOLER/LUBE
EX. BACKFILL
CONVERTER
C1
C4
V09256.00.00.A
Figure H18. 3000 and 4000 Product Family Hydraulic SchematicSecond Range With Prognostics
Copyright 2008 Allison Transmission, Inc.
H37/H38
3000 AND 4000 PRODUCT FAMILIES TROUBLESHOOTING MANUALALLISON 4th GENERATION CONTROLS
LUBE
FILTER
COOLER
CONVERTER OUT
LUBE
LUBE
CONVERTER IN
TORQUE
CONVERTER
Orifice
EX
EX
CONVERTER
REGULATOR
CONVERTER
FLOW
EX
LUBE
REGULATOR
REAR
SPLITLINE
TCC *
EX
EX
PCS1
N/O
N/C
EX
PCS2
N/O
EX
EX
PCS3
N/C
EX
PCS4
N/C
EX
EX
EX
MAIN
Accumulator
Accumulator
Accumulator
EX
EX
EX
CONTROL
MAIN
Accumulator
EX
EX
EX
MAIN
FILTER
SS1
N/C
EX
Orifice
MAIN
REGULATOR
***
PS1
DIAGNOSTIC
EX
EX
EX
EX
6-Speed
Only
EX
****
PS2
PUMP
EXHAUST
BACKFILL
MAIN
MOD **
N/C
EX
C2
LATCH
Pressure
Relief
SUCTION
FILTER
EX
C1
LATCH
EX
C1
C2
C1
C3
C2
C4
C3
SUMP
C5
C4
C5
NOTES:
* TCC Solenoid is generally ON from 2nd-range thru 6th-range
** Main Mod Solenoid may be ON in Reverse, Neutral, Low (7-speed),
1st, or 2nd as determined by calibration.
*** PS1 = Diagnostic Pressure Switch
**** PS2 = Filter Life Switch
LEGEND:
MAIN
CONTROL MAIN
EXHAUST
SUCTION
FWD. KDN.
LOCKUP
COOLER/LUBE
EX. BACKFILL
CONVERTER
C1
C3
V09257.00.00.A
Figure H19. 3000 and 4000 Product Family Hydraulic SchematicThird Range With Prognostics
Copyright 2008 Allison Transmission, Inc.
H39/H40
3000 AND 4000 PRODUCT FAMILIES TROUBLESHOOTING MANUALALLISON 4th GENERATION CONTROLS
LUBE
FILTER
COOLER
CONVERTER OUT
LUBE
LUBE
CONVERTER IN
TORQUE
CONVERTER
Orifice
EX
EX
CONVERTER
REGULATOR
CONVERTER
FLOW
EX
LUBE
REGULATOR
REAR
SPLITLINE
TCC *
EX
EX
PCS1
N/O
N/C
EX
PCS2
N/O
EX
EX
PCS3
N/C
EX
PCS4
N/C
EX
EX
EX
MAIN
Accumulator
Accumulator
Accumulator
EX
EX
EX
CONTROL
MAIN
Accumulator
EX
EX
EX
MAIN
FILTER
SS1
N/C
MAIN
REGULATOR
EX
Orifice
***
PS1
EX
EX
DIAGNOSTIC
EX
EX
6-Speed
Only
EX
****
PS2
PUMP
EXHAUST
BACKFILL
SUCTION
FILTER
MAIN
MOD **
N/C
EX
C2
LATCH
Pressure
Relief
EX
EX
C1
LATCH
C1
C2
C1
C3
C2
C4
C3
SUMP
C5
C4
C5
NOTES:
LEGEND:
* TCC Solenoid is generally ON from 2nd-range thru 6th-range
MAIN
** Main Mod Solenoid may be ON in Reverse, Neutral, Low (7-speed),
CONTROL MAIN
1st, or 2nd as determined by calibration.
EXHAUST
*** PS1 = Diagnostic Pressure Switch
SUCTION
FWD. KDN.
**** PS2 = Filter Life Switch
LOCKUP
COOLER/LUBE
EX. BACKFILL
CONVERTER
C1
C2
V09258.00.00.A
Figure H20. 3000 and 4000 Product Family Hydraulic SchematicFourth Range With Prognostics
Copyright 2008 Allison Transmission, Inc.
H41/H42
3000 AND 4000 PRODUCT FAMILIES TROUBLESHOOTING MANUALALLISON 4th GENERATION CONTROLS
LUBE
FILTER
COOLER
CONVERTER OUT
LUBE
CONVERTER IN
TORQUE
CONVERTER
LUBE
Orifice
EX
EX
CONVERTER
REGULATOR
CONVERTER
FLOW
EX
LUBE
REGULATOR
REAR
SPLITLINE
TCC *
EX
EX
PCS1
N/O
N/C
EX
PCS2
N/O
EX
EX
PCS3
N/C
EX
PCS4
N/C
EX
EX
EX
Accumulator
EX
Accumulator
Accumulator
EX
EX
CONTROL
MAIN
Accumulator
EX
MAIN
EX
EX
MAIN
FILTER
SS1
N/C
EX
Orifice
MAIN
REGULATOR
***
PS1
DIAGNOSTIC
EX
EX
EX
EX
6-Speed
Only
EX
****
PS2
PUMP
EXHAUST
BACKFILL
SUCTION
FILTER
MAIN
MOD **
N/C
EX
C2
LATCH
Pressure
Relief
EX
C1
LATCH
EX
C1
C2
C1
C3
C2
C4
C3
SUMP
C5
C4
C5
NOTES:
* TCC Solenoid is generally ON from 2nd-range thru 6th-range
** Main Mod Solenoid may be ON in Reverse, Neutral, Low (7-speed),
1st, or 2nd as determined by calibration.
*** PS1 = Diagnostic Pressure Switch
**** PS2 = Filter Life Switch
LEGEND:
MAIN
CONTROL MAIN
EXHAUST
SUCTION
FWD. KDN.
LOCKUP
COOLER/LUBE
EX. BACKFILL
CONVERTER
C2
C3
V09259.00.00.A
Figure H21. 3000 and 4000 Product Family Hydraulic SchematicFifth Range With Prognostic
Copyright 2008 Allison Transmission, Inc.
H43/H44
3000 AND 4000 PRODUCT FAMILIES TROUBLESHOOTING MANUALALLISON 4th GENERATION CONTROLS
LUBE
FILTER
COOLER
CONVERTER OUT
LUBE
CONVERTER IN
TORQUE
CONVERTER
LUBE
Orifice
EX
EX
CONVERTER
REGULATOR
CONVERTER
FLOW
EX
LUBE
REGULATOR
REAR
SPLITLINE
TCC *
PCS1
N/O
EX
N/C
EX
EX
PCS2
N/O
EX
PCS4
N/C
EX
PCS3
N/C
EX
EX
EX
EX
Accumulator
EX
Accumulator
Accumulator
EX
EX
CONTROL
MAIN
Accumulator
EX
MAIN
EX
EX
MAIN
FILTER
SS1
N/C
EX
Orifice
MAIN
REGULATOR
***
PS1
DIAGNOSTIC
EX
EX
EX
EX
6-Speed
Only
EX
****
PS2
PUMP
EXHAUST
BACKFILL
SUCTION
FILTER
MAIN
MOD **
N/C
EX
C2
LATCH
Pressure
Relief
EX
C1
LATCH
EX
C1
C2
C1
C3
C2
C4
C3
SUMP
C5
C4
C5
NOTES:
* TCC Solenoid is generally ON from 2nd-range thru 6th-range
** Main Mod Solenoid may be ON in Reverse, Neutral, Low (7-speed),
1st, or 2nd as determined by calibration.
*** PS1 = Diagnostic Pressure Switch
**** PS2 = Filter Life Switch
LEGEND:
MAIN
CONTROL MAIN
EXHAUST
SUCTION
FWD. KDN.
LOCKUP
COOLER/LUBE
EX. BACKFILL
CONVERTER
C2
C4
V09260.00.00.A
Figure H22. 4000 Product Family Hydraulic SchematicSixth Range With Prognostics
Copyright 2008 Allison Transmission, Inc.
H45/H46
3000 AND 4000 PRODUCT FAMILIES TROUBLESHOOTING MANUALALLISON 4th GENERATION CONTROLS
OUTPUT 2
OUTPUT 3
DIAGNOSTIC TOOL/
ENGINE INTERFACE
(J1708)
DIAGNOSTIC
TOOL/ENGINE
INTERFACE
ISO 9141
124
BLUE
164
PINK
150*
WHITE
113
YELLOW
104
ORANGE
145
WHITE
132
BLUE
172
24
GP0 6
CAN 1 HI
GP0 7
CAN 1 LO
GP0 8
OUTPUT 1
141
WHITE
130
GRAY
169
GRAY
10A OR 15A
10A
OR
15A
IGNITION
12V OR
24V
163
143
INPUT 2
YELLOW
102
INPUT 1
GREEN
123
YELLOW
L
R
WHITE
142
INPUT 6
BLUE
101
INPUT 7
ORANGE
161
ABS
GREEN
121
YELLOW
122
YELLOW
103
PINK
179
BLUE
117
INPUT 12
WHITE
157
SS-1
ORANGE
173
SS-2
GREEN
153
SS-4
BLUE
114
SS-P TAN
138
134
TAN
SPEEDOMETER
125
48
26
13
GP0 2
CAN 2 HI
27
GP0 3
45
SAE/ATA
DRIVER
(J1708)
32
72
CAN 2 LO
CAN 2.0B
J2284
DATA
LINK
CAN 2
CAN 2
SHIELD
47
12
V BAT
PWM
INPUT
56
58
BATTERY
POWER
70
10
IGNITION SENSE
63
16
76
TRANSID
77
PSI INPUT
GPI 9
18
GPI 5
42
11
HIGH SIDE
DRIVERS
HSD1
GPI 6
PCS4
PCS6
GPI 7
61
GPI 4
22
PWM
INPUT
GPI 11
GPI 10
3
D
79
17
78
MAIN MOD
74
HSD 2
V BAT
71
PCS1
36
PCS2
HSD 3
L
PCS3
52
33
SS 1
GPI 12
57
55
ABS INPUT
21
75
GPI 1
62
35
54
GPI 2
23
GPI 3
43
25
44
RMR
POWER
SUPPLY
34
YELLOW
108
GREEN
51
SS-1
31
SS-P
DIRECTIONAL SIGNAL
PWM
INPUT
VEHICLE SPEED
NZC
TCC
L
SS2
CAN 1
(CAN+)
148
YELLOW
168
GREEN
(CAN-)
126
YELLOW
(TERM)
106
YELLOW
(CAN+)
127
GREEN
(CAN-)
CAN 2
(SHIELD)
167
166
YELLOW
(CAN+)
147
GREEN
(CAN-)
112
PINK
16
RMR
144
BLUE
HALL EFFECT
PWM
THROTTLE
156
YELLOW
158
GREEN
135
BLUE
175
ORANGE
116
BLUE
154
TAN
176
YELLOW
177
GREEN
118
YELLOW
111
ORANGE
155
WHITE
178
174
BLUE
171
YELLOW
136
ORANGE
152
GREEN
133
YELLOW
151
WHITE
131
YELLOW
15
37
19
115
WHITE
137
WHITE
119
BLUE
RETARDER TEMP.
15
TRANSID
20
PS1
PS2
17
HSD1
PCS4
PCS6
MAIN MOD
HSD2
PCS1
PCS2
PCS3
SS1
10
HSD3
11
NC
NC
RETARDER AIR/
ACCUMULATOR
SOLENOID
TCC
12
3000 MODELS ONLY
NT HIGH
SS2
17
(7 SPEED MODELS)
13
TURBINE
SPEED
14
80
20
60
40
59
SUMP TEMP
18
NT LOW
39
ANALOG RETURN
19
WATER TEMP.
B
PCS5
SS-4
(CAN-)
(SHIELD)
149
SPEED
INTERFACE
SS-2
(TERM)
(CAN+)
TPS
BATTERY
RETURN
69
38
128
GP0 1
30
14
ALLISON
RECOMMENDATIONS
WIRE NO.
COLOR
107
YELLOW
SENSOR SUPPLY
NEUTRAL START
53
66
CAN 2 LO
41
73
67
CAN 2 HI
ISO 9141
DATA
LINK
INPUT 10
IGN
162
INPUT 5
STRIP
SHIFT
SELECTOR
110
BLUE
INPUT 11
170
PINK
YELLOW
INPUT 4
PINK
INPUT 3
INPUT 9
DIGITAL RETURN
109
49
68
50
TWISTED PAIRS
SEE NOTE ON SHEET 4
TAN
CAN 1
SHIELD
64
46
NEUTRAL START
CAN 1
GP0 5
CAN 1 LO
TURBINE SPEED-HI
OUTPUT 8
WHITE
CAN 2.0B
J1939
DATA
LINK
GP0 4
TURBINE SPEED-LO
OUTPUT 7
105
CAN 1 HI
ANALOG
INTERFACE
OUTPUT 6
ORANGE
28
REVERSE WARNING
65
OUTPUT SPEED-HI
OUTPUT 5
165
ENGINE SPEED-HI
OUTPUT 4
TAN
OUTPUT SPEED-LO
REVERSE WARNING
CHECK TRANS.
29
ENGINE SPEED-LO
CHECK TRANS.
DIGITAL INTERFACE
ALLISON
RECOMMENDATIONS
COLOR WIRE NO.
129
GREEN
SWITCHED
POWER
RETARDER OR
DIFF-LOCK (T-CASE)
PCS5
TRANSMISSION CONTROL
MODULE (TCM)
TWISTED PAIRS
180
ORANGE
NT HIGH
120
BLUE
NT LOW
160
YELLOW
NO HIGH
140
GREEN
NO LOW
159
TAN
NE HIGH
139
ORANGE
NE LOW
A
B
A
B
TURBINE
SPEED
OUTPUT
SPEED
ENGINE
SPEED
V09231.01.00.A
J1
3000 AND 4000 PRODUCT FAMILIES TROUBLESHOOTING MANUALALLISON 4th GENERATION CONTROLS
Solenoid Resistance
7.50
7.00
6.50
Max Ohms
Min Ohms
6.00
5.50
5.00
4.50
4.00
3.50
-4
32
68
104
140
176
212
248
284
Degrees F
-20
20
40
60
80
100
120
140
Degrees C
Temperature
V09264.00.00
Figure K1. 3000 and 4000 Product Families Variable Bleed SolenoidsMain Mod, TCC, And PCS1 through PCS6
K1
3000 AND 4000 PRODUCT FAMILIES TROUBLESHOOTING MANUALALLISON 4th GENERATION CONTROLS
ON/OFF Solenoid
Resistance Vs. Temperature
6.00
Solenoid Resistance
5.50
5.00
4.50
Max Ohms
Min Ohms
4.00
3.50
3.00
2.50
2.00
-4
32
68
104
140
176
212
248
284
Degrees F
-20
20
40
60
80
100
120
140
Degrees C
Temperature
V09263.00.00
Figure K2. 3000 and 4000 Product Families ON/OFF SolenoidsSS1 And SS2 (C6 Enable) in 7-Speed Models
35.00
30.00
Max Ohms
Min Ohms
25.00
20.00
15.00
-40 -22 -4
10 20 30 40 50 60 70 80
Temperature
Degrees F
Degrees C
V09265.00.00
Figure K3. 3000 and 4000 Product Families Retarder Accumulator Air SolenoidSS2 in
Retarder-Equipped Transmissions
K2
3000 AND 4000 PRODUCT FAMILIES TROUBLESHOOTING MANUALALLISON 4th GENERATION CONTROLS
Be sure that the TCM for the Allison Transmission Electronic Controls is properly grounded to prevent EMI
interference problems. The chassis frame must be connected to the negative post of the vehicle battery. A proper
connection to the chassis frame is required. The connection must be free from rust and paint. The electrical
integrity of this connection must not deteriorate with the age of the vehicle. If the TCM is cab-mounted, there must
be two 11 2 to 2 inch braided grounding straps connecting the cab structure to the chassis frame.
All electrical and electronic systems generate electromagnetic fields that can interfere with other electronic
systems. Allison Transmission electronic transmission controls comply with Federal Communications Commission
(FCC) regulations and other guidelines concerning emitted radio frequency interference for transportation
electronics. The position of Allison Transmission is that manufacturers and installers of EMI/RFI emitting
equipment are responsible for adhering to FCC regulations and other guidelines concerning emitted radio
frequency interference for transportation electronics.
Some radio-telephone or two-way communication radios (land-mobile radio), or the manner in which they are
installed, can adversely affect vehicle operation or be affected by other vehicle components. Expenses incurred to
protect vehicle-related systems from EMI/RFI emissions by radio-telephone or two-way communications radios
(land-mobile radio) or to integrate such devices into vehicles are not the responsibility of Allison Transmission.
L2.
The following general guidelines for installing radio-telephone or two-way communications radios (land-mobile
radio) in a vehicle supplement, but DO NOT replace, detailed instructions provided by the radio equipment
manufacturer. Detailed installation instructions are the sole responsibility of the radio equipment manufacturer.
Experience has shown that most EMI/RFI problems can be prevented or eliminated by following the guidelines.
If EMI/RFI problems persist after following the guidelines and after ensuring the installation conforms to the
guidelines, contact the vehicle and radio equipment manufacturers for additional installation or equipment
operation instructions.
A.
Transmitter Installation
1. Locate remote radio transmitters as far away from other electronic devices and as near to the side
of the vehicle body as possible.
2. Mount transceivers (transmitter and receiver in one box) under the dash so as not to interfere with
vehicle controls or passenger movement.
B.
Antenna Installation
Each vehicle and body style react differently to radio frequency energy. When dealing with an
unfamiliar vehicle, test various antenna locations by using a magnetic mount antenna and checking
for adverse effects. Antenna location is a major factor in EMI/RFI problems.
L1
3000 AND 4000 PRODUCT FAMILIES TROUBLESHOOTING MANUALALLISON 4th GENERATION CONTROLS
F.
Troubleshooting
The following are common causes of EMI/RFI problems:
L3.
NOTE:
If false speed signals were present at the previous shutdown, the TCM might still be on even though
the ignition is off. The Allison DOC For PCService Tool is powered by ignition power so the
ignition must be on to use the Allison DOC For PCService Tool to read the speed signals.
4. Read speed sensor signals.
5. If a speed sensor signal is other than one (1), then there is a short to another circuit that is carrying
an AC or PWM signal.
6. Measure the resistance of the sensor.
7. Test for shorts to other circuits within the harness or transmission connector.
8. Inspect to be sure there is no conductive material inside the connector.
L2
3000 AND 4000 PRODUCT FAMILIES TROUBLESHOOTING MANUALALLISON 4th GENERATION CONTROLS
L3
3000 AND 4000 PRODUCT FAMILIES TROUBLESHOOTING MANUALALLISON 4th GENERATION CONTROLS
L4
3000 AND 4000 PRODUCT FAMILIES TROUBLESHOOTING MANUALALLISON 4th GENERATION CONTROLS
INSTRUMENT
MAIN & C1C5
WITH 300 PSI
PRESSURE
GAUGES
SELECT
NEUTRAL
RANGE,
ENGINE @ IDLE,
ENABLE CLUTCH
TEST MODE
ALL OTHER
CONDITIONS
C2
CLUTCH
APPLIED,
PS1 OFF
C1
LATCH VALVE
STUCK UP
PCS3
SOLENOID
OFF
C2
CLUTCH
APPLIED,
PS1 ON
SELECT FIFTH
RANGE,
ENGINE @ IDLE
C3
CLUTCH
APPLIED,
PS1 ON
PCS2
SOLENOID
OFF**
ALL OTHER
SELECT FOURTH
RANGE,
ENGINE @ IDLE
C3
CLUTCH
APPLIED,
PS1 ON
SS1
SOLENOID
OFF
PCS4
SOLENOID
OFF
ALL OTHER
C1
CLUTCH
APPLIED,
PS1 ON
C5
CLUTCH
APPLIED,
PS1 ON
C1,
C2 & C3
CLUTCHES
APPLIED,
PS1 ON
PCS1
SOLENOID
ON
C2,
C3 & C4
CLUTCHES
APPLIED,
PS1 ON
C1 & C2
CLUTCHES
APPLIED,
PS1 OFF
CONDITIONS
PS1 SWITCH
FAILED ON
C1 & C3
CLUTCHES
APPLIED,
PS1 OFF
PCS4
SOLENOID
ON
PCS3
SOLENOID
ON
PS1 SWITCH
FAILED OFF
C2 LATCH
VALVE
STUCK UP
SELECT SECOND
RANGE,
ENGINE @ IDLE
ALL OTHER
SS1
SOLENOID
ON
PCS2
SOLENOID
ON
C1,
C2 & C3
CLUTCHES
APPLIED,
PS1 ON
C2
CLUTCH
APPLIED,
PS1 ON
PCS1
SOLENOID
OFF
CONDITIONS
C3 & C5
CLUTCHES
APPLIED,
PS1 ON
HYDRAULIC
CIRCUIT
LEAK
C3
CLUTCH
APPLIED,
PS1 ON
RESELECT
NEUTRAL
RANGE,
ENGINE @ IDLE
ALL OTHER
CONDITIONS
NO
CLUTCHES
APPLIED,
PS1 OFF
C2 LATCH
VALVE STUCK
DOWN
CONDITIONS
HYDRAULIC
SYSTEMS OKAY
Figure M1. Diagnostic Tree3000 and 4000 Product Families Hydraulic System
Using Pressure Gauges At Main and C1C5
M1
3000 AND 4000 PRODUCT FAMILIES TROUBLESHOOTING MANUALALLISON 4th GENERATION CONTROLS
SELECT
NEUTRAL
RANGE,
ENGINE @ IDLE,
ENABLE CLUTCH
TEST MODE
ALL OTHER
C1 LATCH
VALVE
STUCK UP
SELECT FOURTH
RANGE,
ENGINE @ IDLE
PCS3
SOLENOID
OFF
SS1
SOLENOID
OFF
IN
NEUTRAL
PSI ON
SELECT FIFTH
RANGE,
ENGINE @ IDLE
IN
NEUTRAL,
PS1 ON
CONDITIONS
IN GEAR,
LOCKED UP
PS1 ON
SELECT FOURTH
RANGE,
ENGINE @ IDLE
PCS2
SOLENOID
OFF
ALL OTHER
ALL OTHER
IN GEAR,
PS1 ON
ALL OTHER
CONDITIONS
IN
NEUTRAL,
PS1 ON
ATTAIN
RANGE,
PS1 OFF
PCS1
SOLENOID
OFF**
PS1
SWITCH
FAILED OFF
CONDITIONS
SELECT
REVERSE
RANGE,
ENGINE @ IDLE
ATTAIN
NEUTRAL
PS1 ON
PCS4
SOLENOID
ON
CONDITIONS
RESELECT
NEUTRAL
RANGE,
ENGINE @ IDLE
C2 LATCH
VALVE
STUCK UP
SELECT FOURTH
RANGE,
ENGINE @ IDLE
IN GEAR,
LOCKED UP
PS1 ON
IN
NEUTRAL
PS1 ON
ALL OTHER
PCS4
SOLENOID
OFF
PS1 SWITCH
FAILED ON
CONDITIONS
SELECT SECOND
RANGE,
ENGINE @ IDLE
IN
NEUTRAL,
PS1 ON
C5
CLUTCH
APPLIED
PS1 ON
PCS2
SOLENOID
ON
IN
NEUTRAL,
PS1 OFF
ALL OTHER
ATTAIN
RANGE,
PS1 ON
IN
REVERSE
PS1 ON
IN
NEUTRAL
PS1 OFF
ATTAIN
RANGE,
PS1 ON
PCS1
SOLENOID
ON
IN GEAR,
LOCKED UP
PS1 ON
PCS3
SOLENOID
ON
C2 LATCH
VALVE STUCK
DOWN
CONDITIONS
HYDRAULIC
SYSTEMS OKAY
Figure M2. Diagnostic Tree3000 and 4000 Product Families Hydraulic System Without Pressure Gauges
M2
N1
N2
3000 AND 4000 PRODUCT FAMILIES TROUBLESHOOTING MANUALALLISON 4th GENERATION CONTROLS
Description
Page
OUTPUT
A
B
C
C
C
D
E
F
G
H
H
H
H
I
I
J
J
J
J
L
L
Q
V
V
W
W
Y
Y
Z
AA
AF
AG
AG
P-3
P-4
P5
P6
P7
P8
P9
P10
P11
P12
P13
P14
P15
P16
P17
P18
P19
P20
P21
P22
P23
P24
P25
P26
P27
P28
P29
P30
P31
P32
P33
P34
P35
P1
3000 AND 4000 PRODUCT FAMILIES TROUBLESHOOTING MANUALALLISON 4th GENERATION CONTROLS
Description
Page
Kickdown
P36
Military Auxiliary Function Range Inhibit (Standard)
P37
Fourth Lockup Pump ModeOperator and Pump Activated (North America)
P38
Fourth Lockup Pump ModeOperator Only Activated (North America)
P39
Fourth Lockup Pump ModeOperator and Pump Activated (Non-North America)
P40
Fourth Lockup Pump ModeOperator Only Activated (Non-North America)
P41
Automatic NeutralDual Input With Service Brake StatusAutomated Side Loader Activated P42
Automatic NeutralDual Input With Service Brake StatusDash Switch Activated
P43
Automatic NeutralDual Input With Service Brake StatusPark Brake Activated
P44
Automatic NeutralDual Input With Service Brake StatusWork Brake Activated
P45
Automatic NeutralDual Input With Service Brake StatusEmergency Vehicle Option
P46
Shift Selector Transition and Secondary Shift Schedule Without Auto Neutral
P47
Shift Selector Transition and Secondary Shift Schedule With Auto Neutral
P48
Refuse Packer Step Switch
P49
Selector Display Blanking
P50
Reduced Engine Load at Stop (RELS)
P51
RELS With Service Brake Status
P52
Auto 21 Preselect for 7-Speed
P53
INPUT
A
B
C
D
D
E
G
I
I
J
K
N
N
O
Q
R
S
S
P2
P54
P55
P56
P57
P58
P59
P60
P61
P62
P63
P64
P65
P66
P67
P68
P69
P70
P71
3000 AND 4000 PRODUCT FAMILIES TROUBLESHOOTING MANUALALLISON 4th GENERATION CONTROLS
WARNING!
The schematics which follow were taken from the Sales Tech Data Book entitled Allison 4th Generation Controls.
These schematics provide detail information needed to correctly perform input and output function connections.
For an overview of Input/Output Functions, refer to Section 7 of this manual.
INPUT FUNCTION A.
USES: Provides operator selection of dual shift schedules. Can be used for performance/economy, loaded/empty,
or other shift schedule combinations.
VARIABLES TO SPECIFY: None
VOCATIONS: Various
See TABLE A
TCM
OPTIONAL
CUSTOMER-FURNISHED
VIW CONNECTOR(S)
6 1
OPTION 1
OPTION 2
DASH SWITCH
Open: PRIMARY
(usually PERFORMANCE)
Closed: SECONDARY
(usually ECONOMY)
MODE
TABLE A
PIN 22 WIRE 122
PIN 42 WIRE 142
V09154.00.00
P3
3000 AND 4000 PRODUCT FAMILIES TROUBLESHOOTING MANUALALLISON 4th GENERATION CONTROLS
WARNING!
These schematics show the intended use of the specified controls features which
have been validated in the configuration shown. Any miswiring or use of these
features which differs from that shown could result in damage to equipment or
property, personal injury, or loss of life. ALLISON TRANSMISSION IS NOT
LIABLE FOR THE CONSEQUENCES ASSOCIATED WITH MISWIRING
OR UNINTENDED USE OF THESE FEATURES.
INPUT FUNCTION B.
D1 SELECTION
USES: Provides a convenient means of attaining 1st range hold for pushbutton shift selectors. Range to select is
programmable for Primary and Secondary modes.
VARIABLES TO SPECIFY: Primary Mode selected range, Secondary Mode selected range (usually 1st range).
Can be used only on the MODE button.
VOCATIONS: Various
LOW
LOW
MODE
MODE
V09155.00.00
P4
3000 AND 4000 PRODUCT FAMILIES TROUBLESHOOTING MANUALALLISON 4th GENERATION CONTROLS
WARNING!
WARNING!
These
These schematics
schematics show
show the
the intended
intended use
use of
of the
the specified
specified controls
controls features
features which
which
have
been
validated
in
the
configuration
shown.
Any
miswiring
have been validated in the configuration shown. Any miswiring or
or use
use of
of these
these
features
operation
of the
features which
which differs
differs from
fromthat
thatshown
showncould
couldcause
resultunscheduled
in damage to
equipment
or
PTO
or other
unpredictable
operation
damage to equipment
or
property,
personal
injury, or loss
of life. resulting
ALLISONinTRANSMISSION
IS NOT
property,
personal
injury,
or
loss
of
life.
ALLISON
TRANSMISSION
IS
NOT
LIABLE FOR THE CONSEQUENCES ASSOCIATED WITH MISWIRING
LIABLE
FOR THEUSE
CONSEQUENCES
ASSOCIATED WITH MISWIRING
OR UNINTENDED
OF THESE FEATURES.
OR UNINTENDED USE OF THESE FEATURES.
INPUT FUNCTION C.
USES: Permits PTO to be engaged only when engine speed and output speed are in allowable range and throttle is
low. Also disengages PTO if speeds are exceeded.
VARIABLES TO SPECIFY: Minimum and maximum engine speed for engagement, maximum engine speed for
allowable operation, minimum and maximum output speed for engagement,
maximum output speed for allowable operation.
VOCATIONS: Various (with usage of PTO)
OPTIONAL
CUSTOMER-FURNISHED
VIW CONNECTOR(S)
43
SWITCHED
POWER
TCM
DASH
LIGHT
PTO
SWITCH
30
WIRE 143
PTO ENABLE INPUT
OPTIONAL VIM
NC
F2
PTO
PRESSURE
SWITCH
COM
NO
F3
PTO
D2
P5
3000 AND 4000 PRODUCT FAMILIES TROUBLESHOOTING MANUALALLISON 4th GENERATION CONTROLS
WARNING!
WARNING!
These
These schematics
schematics show
show the
the intended
intended use
use of
of the
the specified
specified controls
controls features
features which
which
have
been
validated
in
the
configuration
shown.
Any
miswiring
have been validated in the configuration shown. Any miswiring or
or use
use of
of these
these
features
operation
of the
features which
which differs
differs from
fromthat
thatshown
showncould
couldcause
resultunscheduled
in damage to
equipment
or
PTO
or other
unpredictable
operation
damage to equipment
or
property,
personal
injury, or loss
of life. resulting
ALLISONinTRANSMISSION
IS NOT
property,
personal
injury,
or
loss
of
life.
ALLISON
TRANSMISSION
IS
NOT
LIABLE FOR THE CONSEQUENCES ASSOCIATED WITH MISWIRING
LIABLE
FOR THEUSE
CONSEQUENCES
ASSOCIATED WITH MISWIRING
OR UNINTENDED
OF THESE FEATURES.
OR UNINTENDED USE OF THESE FEATURES.
INPUT FUNCTION C.
USES: Permits PTO to be engaged only when engine speed and output speed are in allowable range and throttle is
low. Also disengages PTO if speeds are exceeded.
VARIABLES TO SPECIFY: Minimum and maximum engine speed for engagement, maximum engine speed for
allowable operation, minimum and maximum output speed for engagement,
maximum output speed for allowable operation.
VOCATIONS: Various (with usage of PTO)
OPTIONAL
CUSTOMER-FURNISHED
VIW CONNECTOR(S)
3
42
SWITCHED
POWER
PTO
SWITCH
DASH
LIGHT
WIRE 103
SIGNAL RETURN
30
TCM
PTO
PRESSURE
SWITCH
COM
NO
F3
PTO
D2
P6
3000 AND 4000 PRODUCT FAMILIES TROUBLESHOOTING MANUALALLISON 4th GENERATION CONTROLS
WARNING!
WARNING!
These
These schematics
schematics show
show the
the intended
intended use
use of
of the
the specified
specified controls
controls features
features which
which
have
been
validated
in
the
configuration
shown.
Any
miswiring
have been validated in the configuration shown. Any miswiring or
or use
use of
of these
these
features
operation
of the
features which
which differs
differs from
fromthat
thatshown
showncould
couldcause
resultunscheduled
in damage to
equipment
or
PTO
or other
unpredictable
operation
damage to equipment
or
property,
personal
injury, or loss
of life. resulting
ALLISONinTRANSMISSION
IS NOT
property,
personal
injury,
or
loss
of
life.
ALLISON
TRANSMISSION
IS
NOT
LIABLE FOR THE CONSEQUENCES ASSOCIATED WITH MISWIRING
LIABLE
FOR THEUSE
CONSEQUENCES
ASSOCIATED WITH MISWIRING
OR UNINTENDED
OF THESE FEATURES.
OR UNINTENDED USE OF THESE FEATURES.
INPUT FUNCTION C.
USES: Permits PTO to be engaged only when engine speed and output speed are in allowable range and throttle is
low. Also disengages PTO if speeds are exceeded.
VARIABLES TO SPECIFY: Minimum and maximum engine speed for engagement, maximum engine speed for
allowable operation, minimum and maximum output speed for engagement,
maximum output speed for allowable operation.
VOCATIONS: Various (with usage of PTO)
30
OPTIONAL
SWITCHED
CUSTOMER-FURNISHED
POWER
VIW CONNECTOR(S)
WIRE 130 PTO ENABLE
DASH
LIGHT
6 1
PTO
F2
MODE
PTO
PRESSURE
SWITCH
OPTIONAL VIM
NC
TCM
MODE
BUTTON
COM
NO
F3
PTO
D2
P7
3000 AND 4000 PRODUCT FAMILIES TROUBLESHOOTING MANUALALLISON 4th GENERATION CONTROLS
WARNING!
These schematics show the intended use of the specified controls features which
have been validated in the configuration shown. Any miswiring or use of these
features which differs from that shown could result in damage to equipment or
property, personal injury, or loss of life. ALLISON TRANSMISSION IS NOT
LIABLE FOR THE CONSEQUENCES ASSOCIATED WITH MISWIRING
OR UNINTENDED USE OF THESE FEATURES.
INPUT FUNCTION D.
USES: When two shift selectors are used, to select which one is active.
VARIABLES TO SPECIFY: None
VOCATIONS: Various
WARNING!
If this function is enabled in the shift calibration, the function MUST be integrated
into the vehicle wiring. If the function is available in the shift calibration but will
not be used in the vehicle, it MUST be disabled in the calibration.
OPTIONAL
CUSTOMER-FURNISHED
VIW CONNECTOR(S)
1
WIRE 101
SHIFT SELECTOR
TRANSITION
DASH SWITCH
Open: Selector 1
Closed: Selector 2
WIRE 103
SIGNAL RETURN
SELECTOR
1
SELECTOR
2
TCM
MODE
MODE
V09158.00.00
P8
3000 AND 4000 PRODUCT FAMILIES TROUBLESHOOTING MANUALALLISON 4th GENERATION CONTROLS
WARNING!
WARNING!
These
These schematics
schematics show
show the
the intended
intended use
use of
of the
the specified
specified controls
controls features
features which
which
have
been
validated
in
the
configuration
shown.
Any
miswiring
have been validated in the configuration shown. Any miswiring or
or use
use of
of these
these
features
of range
features which
which differs
differsfrom
fromthat
thatshown
showncould
couldcause
resultunintended
in damageselection
to equipment
or
or
other unpredictable
operation
in damageTRANSMISSION
to equipment or property,
property,
personal injury,
or lossresulting
of life. ALLISON
IS NOT
personal
or loss
of life. ALLISONASSOCIATED
TRANSMISSION
IS NOT
LIABLE
LIABLE injury,
FOR THE
CONSEQUENCES
WITH
MISWIRING
FOR
THE
CONSEQUENCES
ASSOCIATED
WITH
MISWIRING
OR
OR UNINTENDED USE OF THESE FEATURES.
UNINTENDED USE OF THESE FEATURES.
INPUT FUNCTION E.
USES: Prevents inadvertent range selection when auxiliary equipment is operating or prevents engagement of the
transmission unless brake pedal is depressed.
VARIABLES TO SPECIFY: None
VOCATIONS: Transit bus, school busauxiliary equipment input; various (brake pedal input)
WARNING!
If this function is enabled in the shift calibration, the function MUST be integrated
into the vehicle wiring. If the function is available in the shift calibration but will
not be used in the vehicle, it MUST be disabled in the calibration.
OPTIONAL
CUSTOMER-FURNISHED
VIW CONNECTOR(S)
1
3
OR
SWITCH IS OPENED
WHEN AUXILIARY
EQUIPMENT
IS OPERATING
WIRE 101
WIRE 103
NORMALLY-OPEN
SWITCH IS CLOSED
WHEN BRAKES
ARE APPLIED
BRAKE
PRESSURE
SWITCH
TCM
NOTE: TCMs with this function activated must have wire 101
permanently connected to wire 103 if the function is not being used.
V09160.00.00
P9
3000 AND 4000 PRODUCT FAMILIES TROUBLESHOOTING MANUALALLISON 4th GENERATION CONTROLS
WARNING!
WARNING!
These
These schematics
schematics show
show the
the intended
intended use
use of
of the
the specified
specified controls
controls features
features which
which
have
been
validated
in
the
configuration
shown.
Any
miswiring
have been validated in the configuration shown. Any miswiring or
or use
use of
of these
these
features
of range
features which
which differs
differsfrom
fromthat
thatshown
showncould
couldcause
resultunintended
in damageselection
to equipment
or
or
other unpredictable
operation
in damageTRANSMISSION
to equipment or property,
property,
personal injury,
or lossresulting
of life. ALLISON
IS NOT
personal
or loss
of life. ALLISONASSOCIATED
TRANSMISSION
IS NOT
LIABLE
LIABLE injury,
FOR THE
CONSEQUENCES
WITH
MISWIRING
FOR
THE
CONSEQUENCES
ASSOCIATED
WITH
MISWIRING
OR
OR UNINTENDED USE OF THESE FEATURES.
UNINTENDED USE OF THESE FEATURES.
INPUT FUNCTION F.
USES: Prevents inadvertent range selection when auxiliary equipment is operating. Used in emergency equipment
to prevent inadvertent range selection from NEUTRAL.
VARIABLES TO SPECIFY: None
VOCATIONS: Emergency equipment
TABLE A
PIN 64 WIRE 164
PIN 13 WIRE 113
NORTH AMERICAN
NON-NORTH AMERICAN
SEE TABLE A
1
3
42
SWITCHED
POWER
WIRE 164 OR 113
SERVICE INDICATOR
WIRE 101
AUX. FUNCTION RANGE
INHIBIT INPUT 1
WIRE 103 SIGNAL RETURN
9
69
TCM
WIRE 142
AUX. FUNCTION
RANGE INHIBIT INPUT 2
OPTIONAL
CUSTOMER-FURNISHED
VIW CONNECTOR(S)
* Switch is closed when
auxiliary equipment is
operating.
AUXILIARY
FUNCTION
SENSE SWITCH 2*
WIRE 109
WIRE 169
SERVICE
TRANS
If current in lamp
circuit exceeds
SERVICE
0.5 amp, ground
TRANS
lamp through a relay
SWITCHED
POWER
WIRE 164 OR 113
AUXILIARY
FUNCTION
SELECT NOTE: Both input signals must turn on
SWITCH 1* within 120 seconds. If the state of the
two input signals is different for longer
than this time period, the SERVICE
TRANS light will be illuminated, a code
will be stored in memory, and
neutral-to-range shifts will NOT be
inhibited.
A2
A1
COM
NO
K2
OPTIONAL
VIM
K1
P10
NC
BATTERY
GROUND
V09161.00.00
3000 AND 4000 PRODUCT FAMILIES TROUBLESHOOTING MANUALALLISON 4th GENERATION CONTROLS
WARNING!
INPUT FUNCTION G.
AUXILIARY HOLD
SEE TABLE A
OPTIONAL
CUSTOMER-FURNISHED
VIW CONNECTOR(S)
OPTION 1
OPTION 2
SEE TABLE A
AUXILIARY HOLD
WIRE 103
SIGNAL RETURN
TABLE A
PIN 42 WIRE 142
PIN 17 WIRE 117
MOMENTARY
SWITCH
Function is activated when
switch is depressed.
Function is de-activated when
switch is released.
TCM
HOLD
HOLD
MODE
MODE
V09162.00.00
P11
3000 AND 4000 PRODUCT FAMILIES TROUBLESHOOTING MANUALALLISON 4th GENERATION CONTROLS
WARNING!
These schematics show the intended use of the specified controls features which
have been validated in the configuration shown. Any miswiring or use of these
features which differs from that shown could result in damage to equipment or
property, personal injury, or loss of life. ALLISON TRANSMISSION IS NOT
LIABLE FOR THE CONSEQUENCES ASSOCIATED WITH MISWIRING
OR UNINTENDED USE OF THESE FEATURES.
INPUT FUNCTION H.
USES: Used with engine brakes to signal the TCM that the brake is active and to provide increased braking by
preselecting a lower range. Also prevents engagement of engine brake with throttle > 0 or lockup OFF.
VARIABLES TO SPECIFY: Preselect range. Standard value is second range.
VOCATIONS: Various
SWITCHED
POWER
4
TCM
WIRE 104
ENGINE BRAKE
ENABLE OUPUT
OPTIONAL
CUSTOMER-FURNISHED
VIW CONNECTOR(S)
ENGINE BRAKE
DASH SWITCH
NC
2
WIRE 102
ENGINE BRAKE AND
PRESELECT REQUEST
E2
B1
COM
D2
NO
SWITCHED
POWER
OPTIONAL VIM
DASH
LIGHT
BRAKE
ON
**ENGINE
BRAKE
Figure P10. Engine Brake Enable And Preselect Request Plus Engine Brake Enable Output Using Exhaust Brakes
P12
3000 AND 4000 PRODUCT FAMILIES TROUBLESHOOTING MANUALALLISON 4th GENERATION CONTROLS
WARNING!
These schematics show the intended use of the specified controls features which
have been validated in the configuration shown. Any miswiring or use of these
features which differs from that shown could result in damage to equipment or
property, personal injury, or loss of life. ALLISON TRANSMISSION IS NOT
LIABLE FOR THE CONSEQUENCES ASSOCIATED WITH MISWIRING
OR UNINTENDED USE OF THESE FEATURES.
INPUT FUNCTION H.
USES: Used with exhaust brakes controlled by electronic engines to signal the TCM that the brake is active and to
provide increased braking by preselecting a lower range. Also prevents engagement of engine brake with
throttle > 0 or lockup OFF.
VARIABLES TO SPECIFY: Preselect range. Standard value is second range.
VOCATIONS: Various
SWITCHED
POWER
4
TCM
** ENGINE BRAKE
DASH SWITCH
NO
EXHAUST BRAKE
HIGH SIDE DRIVER
MAXIMUM CURRENT PER
ENGINE MANUFACTURER
WIRE 104
ENGINE BRAKE
ENABLE OUPUT
OPTIONAL
CUSTOMER-FURNISHED
VIW CONNECTOR(S)
D2
NC
E2
B1
ECM
WIRE 102
ENGINE BRAKE AND
PRESELECT REQUEST
COM
NO
SWITCHED
POWER
OPTIONAL VIM
Relay shown de-energized
DASH
LIGHT
(Optional)
BRAKE
ON
ENGINE
BRAKE
SOLENOID*
Figure P11. Engine Brake Enable And Preselect Request Plus Engine Brake Enable Output
Using ECM Controlled Exhaust Brakes
P13
3000 AND 4000 PRODUCT FAMILIES TROUBLESHOOTING MANUALALLISON 4th GENERATION CONTROLS
WARNING!
These schematics show the intended use of the specified controls features which
have been validated in the configuration shown. Any miswiring or use of these
features which differs from that shown could result in damage to equipment or
property, personal injury, or loss of life. ALLISON TRANSMISSION IS NOT
LIABLE FOR THE CONSEQUENCES ASSOCIATED WITH MISWIRING
OR UNINTENDED USE OF THESE FEATURES.
INPUT FUNCTION H.
USES: Used with engine brakes to signal the TCM that the brake is active and to provide increased braking by
preselecting a lower range. Also prevents engagement of engine brake with throttle > 0 or lockup OFF.
VARIABLES TO SPECIFY: Preselect range. Standard value is fourth range.
VOCATIONS: Various
SWITCHED
POWER
* ENGINE THROTTLE
SWITCH
NC
TCM
WIRE 104
ENGINE BRAKE
ENABLE OUPUT
OPTIONAL
CUSTOMER-FURNISHED
VIW CONNECTOR(S)
57
WIRE 157
ENGINE BRAKE AND
PRESELECT REQUEST
50
WIRE 158
SIGNAL RETURN
SEE NOTE ON INSTALLATION
DRAWING AS07-027
E2
B1
COM
D2
NO
DASH
LIGHT
BRAKE
ON
** ENGINE
BRAKE
SWITCHED
POWER
OPTIONAL VIM
Figure P12. Engine Brake Enable And Preselect Request Plus Engine Brake Enable Output
With Single Level Compression Brakes
P14
3000 AND 4000 PRODUCT FAMILIES TROUBLESHOOTING MANUALALLISON 4th GENERATION CONTROLS
WARNING!
These schematics show the intended use of the specified controls features which
have been validated in the configuration shown. Any miswiring or use of these
features which differs from that shown could result in damage to equipment or
property, personal injury, or loss of life. ALLISON TRANSMISSION IS NOT
LIABLE FOR THE CONSEQUENCES ASSOCIATED WITH MISWIRING
OR UNINTENDED USE OF THESE FEATURES.
INPUT FUNCTION H.
USES: Used with multiple-level compression brakes to signal the TCM that the brake is active and to provide
increased braking by preselecting a lower range. Also prevents engagement of engine brake with
throttle > 0 or lockup OFF.
VARIABLES TO SPECIFY: Preselect range. Standard value is fourth range.
VOCATIONS: Various
WIRE 104
B1
ENGINE BRAKE
ENABLE OUPUT
WIRE 158
OPTIONAL
CUSTOMER-FURNISHED
SIGNAL RETURN
VIW CONNECTOR(S)
COM
58
57
2
ECM
NO
TCM
D2
* ENGINE BRAKE
Med/High
Low/High
VIM
Low/Med/High
On/Off
WIRE 157
ENGINE BRAKE AND
PRESELECT REQUEST
WIRE 102
ENGINE BRAKE AND
PRESELECT REQUEST
SWITCHED
POWER
V09166.00.00
Figure P13. Engine Brake Enable and Preselect Request Plus Engine Brake Enable Output
With Multi-Level Compression Brakes
P15
3000 AND 4000 PRODUCT FAMILIES TROUBLESHOOTING MANUALALLISON 4th GENERATION CONTROLS
WARNING!
These schematics show the intended use of the specified controls features which
have been validated in the configuration shown. Any miswiring or use of these
features which differs from that shown could result in damage to equipment or
property, personal injury, or loss of life. ALLISON TRANSMISSION IS NOT
LIABLE FOR THE CONSEQUENCES ASSOCIATED WITH MISWIRING
OR UNINTENDED USE OF THESE FEATURES.
INPUT FUNCTION I.
Used with engine brakes to provide a signal to the TCM that the brake is active and to provide increased braking by
preselecting a lower range. Also prevents engagement of engine brake with throttle > 0 or lockup OFF.
VARIABLES TO SPECIFY: Preselect range. Standard value is second range.
VOCATIONS: Various
SWITCHED
POWER
4
TCM
WIRE 104
ENGINE BRAKE
ENABLE OUPUT
OPTIONAL
CUSTOMER-FURNISHED
VIW CONNECTOR(S)
ENGINE BRAKE
DASH SWITCH
NC
2
WIRE 102
ENGINE BRAKE AND
PRESELECT REQUEST
E2
B1
COM
NO
E3
SWITCHED
POWER
OPTIONAL VIM
DASH
LIGHT
(OPTIONAL)
BRAKE
ON
**ENGINE
BRAKE
Figure P14. European Engine Brake Enable and Preselect Request Plus Engine Brake Enable Output
Using Exhaust Brakes
P16
3000 AND 4000 PRODUCT FAMILIES TROUBLESHOOTING MANUALALLISON 4th GENERATION CONTROLS
WARNING!
These schematics show the intended use of the specified controls features which
have been validated in the configuration shown. Any miswiring or use of these
features which differs from that shown could result in damage to equipment or
property, personal injury, or loss of life. ALLISON TRANSMISSION IS NOT
LIABLE FOR THE CONSEQUENCES ASSOCIATED WITH MISWIRING
OR UNINTENDED USE OF THESE FEATURES.
INPUT FUNCTION I.
USES: Used with engine brakes to provide a signal to the TCM that the brake is active and to provide increased
braking by preselecting a lower range. Also prevents engagement of engine brake with throttle > 0 or
lockup off.
VARIABLES TO SPECIFY: Preselect range. Standard value is fourth range.
VOCATIONS: Various
SWITCHED
POWER
* ENGINE THROTTLE
SWITCH
NC
TCM
WIRE 104
ENGINE BRAKE
ENABLE OUPUT
OPTIONAL
CUSTOMER-FURNISHED
VIW CONNECTOR(S)
E2
B1
COM
E3
NO
SWITCHED
POWER
OPTIONAL VIM
DASH
LIGHT
(OPTIONAL)
BRAKE
ON
** ENGINE
BRAKE
57
WIRE 157
ENGINE BRAKE AND
PRESELECT REQUEST
58
WIRE 158
SIGNAL RETURN
SEE NOTE ON INSTALLATION
DRAWING AS07-027
Figure P15. European Engine Brake Enable and Preselect Request Plus Engine Brake Enable Output
With Single Level Compression Brakes
P17
3000 AND 4000 PRODUCT FAMILIES TROUBLESHOOTING MANUALALLISON 4th GENERATION CONTROLS
WARNING!
These schematics show the intended use of the specified controls features which
have been validated in the configuration shown. Any miswiring or use of these
features which differs from that shown could result in damage to equipment or
property, personal injury, or loss of life. ALLISON TRANSMISSION IS NOT
LIABLE FOR THE CONSEQUENCES ASSOCIATED WITH MISWIRING
OR UNINTENDED USE OF THESE FEATURES.
INPUT FUNCTION J.
USES: Facilitates engagement of split shaft PTO and shifts transmission to fourth range lockup.
VARIABLES TO SPECIFY: None
VOCATIONS: Fire Truck Pumpers
WARNING!
If this function is enabled in the shift calibration, the function MUST be integrated
into the vehicle wiring. If the function is available in the shift calibration but will
not be used in the vehicle, it MUST be disabled in the calibration.
SYSTEM OPERATION
OPERATOR ACTIONSystem Response
TO ENGAGE:
1. SELECT NEUTRALTransmission shifts to Neutral.
2. APPLY PARK BRAKENone
3. SELECT PUMPTurns on Pump Mode Requested light. Turns on input signal to TCM (wire 123) which
activates fire truck mode. When split-shaft shifts, wire 122 is activated and Pump Engaged light is turned on.
4. SELECT DRIVETransmission shifts to fourth lockup. OK To Pump light is turned on.
TO DISENGAGE:
1. SELECT NEUTRALTransmission shifts to Neutral if output shaft speed is less than 1000 rpm.
2. SELECT ROAD MODEPTO disengages. If output shaft rotation continues, press the Momentary Trans. Brake
Switch before selecting Road Mode. This will cause the transmission output shaft to stop if transmission is in
Neutral and output shaft speed is less than 175 rpm.
OPTIONAL
CUSTOMER-FURNISHED
VIW CONNECTOR(S)
23
3
22
WIRE 123
FIRE TRUCK
PUMP MODE INPUT
PARKING BRAKE DASH SWITCH
PRESSURE SWITCH Open: Road
Closed: Pump
Switch is closed
when brakes are on
SWITCHED
POWER
OPTIONAL VIM
Relay shown
de-energized
NC
AIR
45
TCM
POSITIVE PUMP
ENGAGEMENT
(PPE) SWITCH
Switch is closed
when pump
is engaged
MOMENTARY
TRANS.
BRAKE
SWITCH
OK TO
PUMP
PUMP MODE
REQUESTED
A2
SPLITSHAFT
PTO
COM
NO
A3
F3
PUMP
ENGAGED
SWITCHED
POWER
Figure P16. Fire Truck Pump ModeOperator and Pump Activated (North American)
P18
3000 AND 4000 PRODUCT FAMILIES TROUBLESHOOTING MANUALALLISON 4th GENERATION CONTROLS
WARNING!
These schematics show the intended use of the specified controls features which
have been validated in the configuration shown. Any miswiring or use of these
features which differs from that shown could result in damage to equipment or
property, personal injury, or loss of life. ALLISON TRANSMISSION IS NOT
LIABLE FOR THE CONSEQUENCES ASSOCIATED WITH MISWIRING
OR UNINTENDED USE OF THESE FEATURES.
INPUT FUNCTION J.
USES: Facilitates engagement of split shaft PTO and shifts transmission to fourth range lockup.
VARIABLES TO SPECIFY: None
VOCATIONS: Fire Truck Pumpers
WARNING!
If this function is enabled in the shift calibration, the function MUST be integrated
into the vehicle wiring. If the function is available in the shift calibration but will
not be used in the vehicle, it MUST be disabled in the calibration.
SYSTEM OPERATION
OPERATOR ACTIONSystem Response
TO ENGAGE:
1. SELECT NEUTRALTransmission shifts to Neutral.
2. APPLY PARK BRAKENone
3. SELECT PUMPTurns on Pump Mode Requested light. Turns on both input signals to TCM (wires 122
and 123) which activates fire truck mode. When split-shaft shifts, Pump Engaged light is turned on.
4. SELECT DRIVETransmission shifts to fourth lockup. OK To Pump light is turned on.
TO DISENGAGE:
1. SELECT NEUTRALTransmission shifts to Neutral if output shaft speed is less than 1000 rpm.
2. SELECT ROAD MODEPTO disengages. If output shaft rotation continues, press the Momentary Trans.
Brake Switch before selecting road mode. This will cause the transmission output shaft to stop if transmission
is in Neutral and output shaft speed is less than 175 rpm.
OPTIONAL
CUSTOMER-FURNISHED
VIW CONNECTOR(S)
SWITCHED
POWER
WIRE 122 PUMP ENABLE
DASH SWITCH
Open: Road
Closed: Pump
POSITIVE PUMP
ENGAGEMENT
(PPE) SWITCH
Switch is closed
when pump
is engaged
22
3
23
45
TCM
MOMENTARY
TRANS.
PARKING BRAKE
BRAKE
PRESSURE SWITCH
SWITCH
Switch is closed
WIRE 123
when brakes are on
FIRE TRUCK
PUMP
PUMP MODE
MODE INPUT
REQUESTED
OPTIONAL VIM
Relay shown
de-energized
NC
OK TO
PUMP
SPLITSHAFT
PTO
A2
COM
A3
NO
F3
PUMP
ENGAGED
SWITCHED
POWER
Figure P17. Fire Truck Pump ModeOperator Only Activated (North American)
P19
3000 AND 4000 PRODUCT FAMILIES TROUBLESHOOTING MANUALALLISON 4th GENERATION CONTROLS
WARNING!
These schematics show the intended use of the specified controls features which
have been validated in the configuration shown. Any miswiring or use of these
features which differs from that shown could result in damage to equipment or
property, personal injury, or loss of life. ALLISON TRANSMISSION IS NOT
LIABLE FOR THE CONSEQUENCES ASSOCIATED WITH MISWIRING
OR UNINTENDED USE OF THESE FEATURES.
INPUT FUNCTION J.
USES: Facilitates engagement of split shaft PTO and shifts transmission to fourth range lockup.
VARIABLES TO SPECIFY: None
VOCATIONS: Fire Truck Pumpers
WARNING!
If this function is enabled in the shift calibration, the function MUST be integrated
into the vehicle wiring. If the function is available in the shift calibration but will
not be used in the vehicle, it MUST be disabled in the calibration.
SYSTEM OPERATION
OPERATOR ACTIONSystem Response
TO ENGAGE:
1. SELECT NEUTRALTransmission shifts to Neutral.
2. APPLY PARK BRAKENone
3. SELECT PUMPTurns on Pump Mode Requested light. Turns on both input signals to TCM (wire 143)
which activates fire truck mode. When split-shaft shifts, WIRE 117 IS ACTIVE AND Pump Engaged light
is turned on.
4. SELECT DRIVETransmission shifts to fourth lockup. OK To Pump light is turned on.
TO DISENGAGE:
1. SELECT NEUTRALTransmission shifts to Neutral if output shaft speed is less than 1000 rpm.
2. SELECT ROAD MODEPTO disengages. If output shaft rotation continues, press the Momentary Trans.
Brake Switch before selecting road mode. This will cause the transmission output shaft to stop if transmission
is in Neutral and output shaft speed is less than 175 rpm.
OPTIONAL
CUSTOMER-FURNISHED
VIW CONNECTOR(S)
43
3
17
WIRE 143
FIRE TRUCK
PUMP MODE INPUT
PARKING BRAKE DASH SWITCH
PRESSURE SWITCH Open: Road
Closed: Pump
Switch is closed
when brakes are on
SWITCHED
POWER
OPTIONAL VIM
Relay shown
de-energized
NC
AIR
45
TCM
POSITIVE PUMP
ENGAGEMENT
(PPE) SWITCH
Switch is closed
when pump
is engaged
MOMENTARY
TRANS.
BRAKE
SWITCH
OK TO
PUMP
PUMP MODE
REQUESTED
A2
SPLITSHAFT
PTO
COM
NO
A3
F3
PUMP
ENGAGED
SWITCHED
POWER
P20
3000 AND 4000 PRODUCT FAMILIES TROUBLESHOOTING MANUALALLISON 4th GENERATION CONTROLS
WARNING!
These schematics show the intended use of the specified controls features which
have been validated in the configuration shown. Any miswiring or use of these
features which differs from that shown could result in damage to equipment or
property, personal injury, or loss of life. ALLISON TRANSMISSION IS NOT
LIABLE FOR THE CONSEQUENCES ASSOCIATED WITH MISWIRING
OR UNINTENDED USE OF THESE FEATURES.
INPUT FUNCTION J.
USES: Facilitates engagement of split shaft PTO and shifts transmission to fourth range lockup.
VARIABLES TO SPECIFY: None
VOCATIONS: Fire Truck Pumpers
WARNING!
If this function is enabled in the shift calibration, the function MUST be integrated
into the vehicle wiring. If the function is available in the shift calibration but will
not be used in the vehicle, it MUST be disabled in the calibration.
SYSTEM OPERATION
OPERATOR ACTIONSystem Response
TO ENGAGE:
1. SELECT NEUTRALTransmission shifts to Neutral.
2. APPLY PARK BRAKENone
3. SELECT PUMPTurns on Pump Mode Requested light. Turns on both input signals to TCM (wires 117
and 143) which activates fire truck mode. When split-shaft shifts, Pump Engaged light is turned on.
4. SELECT DRIVETransmission shifts to fourth lockup. OK To Pump light is turned on.
TO DISENGAGE:
1. SELECT NEUTRALTransmission shifts to Neutral if output shaft speed is less than 1000 rpm.
2. SELECT ROAD MODEPTO disengages. If output shaft rotation continues, press the Momentary Trans.
Brake Switch before selecting road mode. This will cause the transmission output shaft to stop if transmission
is in Neutral and output shaft speed is less than 175 rpm.
OPTIONAL
CUSTOMER-FURNISHED
VIW CONNECTOR(S)
SWITCHED
POWER
WIRE 117 PUMP ENABLE
DASH SWITCH
Open: Road
Closed: Pump
POSITIVE PUMP
ENGAGEMENT
(PPE) SWITCH
Switch is closed
when pump
is engaged
17
3
43
45
TCM
MOMENTARY
TRANS.
PARKING BRAKE
BRAKE
PRESSURE SWITCH
SWITCH
Switch is closed
WIRE 143
when brakes are on
FIRE TRUCK
PUMP
PUMP MODE
MODE INPUT
REQUESTED
OPTIONAL VIM
OK TO
PUMP
SPLITSHAFT
PTO
NC
A2
COM
NO
A3
F3
PUMP
ENGAGED
P21
3000 AND 4000 PRODUCT FAMILIES TROUBLESHOOTING MANUALALLISON 4th GENERATION CONTROLS
WARNING!
These schematics show the intended use of the specified controls features which
have been validated in the configuration shown. Any miswiring or use of these
features which differs from that shown could result in damage to equipment or
property, personal injury, or loss of life. ALLISON TRANSMISSION IS NOT
LIABLE FOR THE CONSEQUENCES ASSOCIATED WITH MISWIRING
OR UNINTENDED USE OF THESE FEATURES.
INPUT FUNCTION L.
USES: Provides for automatic selection of NEUTRAL when PTO is operated regardless of range selected.
Requires re-selecting range to shift out of NEUTRAL. Shown with range indicator output.
VARIABLES TO SPECIFY: Maximum output speed for activating this function. Range indicator = neutral.
VOCATIONS: Various (with usage of PTO)
WARNING!
If this function is enabled in the shift calibration, the function MUST be integrated
into the vehicle wiring. If the function is available in the shift calibration but will
not be used in the vehicle, it MUST be disabled in the calibration.
This function must not be used with Neutral Indicator For PTO (Output S).
OPTIONAL
CUSTOMER-FURNISHED
VIW CONNECTOR(S)
17
SWITCHED
POWER
WIRE 117
AUTOMATIC
NEUTRAL FOR
PTO (STD)
3
45
DASH
LIGHT
DASH
SWITCH
WIRE 103
SIGNAL RETURN
TCM
PTO
PRESSURE
SWITCH
OPTIONAL VIM
NC
A2
13
WIRE 113
(Alternate)
COM
NO
A3
PTO
F3
SWITCHED
POWER
Relay shown de-energized
P22
V09173.00.00
3000 AND 4000 PRODUCT FAMILIES TROUBLESHOOTING MANUALALLISON 4th GENERATION CONTROLS
WARNING!
These schematics show the intended use of the specified controls features which
have been validated in the configuration shown. Any miswiring or use of these
features which differs from that shown could result in damage to equipment or
property, personal injury, or loss of life. ALLISON TRANSMISSION IS NOT
LIABLE FOR THE CONSEQUENCES ASSOCIATED WITH MISWIRING
OR UNINTENDED USE OF THESE FEATURES.
INPUT FUNCTION L.
USES: Provides for automatic selection of NEUTRAL when PTO is operated regardless of range selected.
Requires re-selecting range to shift out of NEUTRAL. Shown with range indicator output.
VARIABLES TO SPECIFY: Maximum output speed for activating this function. Range indicator = neutral.
VOCATIONS: Various (with usage of PTO)
WARNING!
If this function is enabled in the shift calibration, the function MUST be integrated
into the vehicle wiring. If the function is available in the shift calibration but will
not be used in the vehicle, it MUST be disabled in the calibration.
This function must not be used with Neutral Indicator For PTO (Output S).
SWITCHED POWER
45
WIRE 145
RANGE INDICATOR
(Neutral)
OPTIONAL
CUSTOMER-FURNISHED
VIW CONNECTOR(S)
DASH
LIGHT
DASH SWITCH
NC
A2
TCM
13
WIRE 113
RANGE INDICATOR
(Neutral) ALTERNATE
CONFIGURATION
COM
PTO
PRESSURE
SWITCH
A3
NO
SWITCHED
POWER
F3
OPTIONAL VIM
PTO
TABLE A
PIN 23 WIRE 123
PIN 2
WIRE 102
V09172.00.00
Figure P21. Automatic NeutralSingle Input Switched to Power (Wire 123 or 102)
P23
3000 AND 4000 PRODUCT FAMILIES TROUBLESHOOTING MANUALALLISON 4th GENERATION CONTROLS
WARNING!
These schematics show the intended use of the specified controls features which
have been validated in the configuration shown. Any miswiring or use of these
features which differs from that shown could result in damage to equipment or
property, personal injury, or loss of life. ALLISON TRANSMISSION IS NOT
LIABLE FOR THE CONSEQUENCES ASSOCIATED WITH MISWIRING
OR UNINTENDED USE OF THESE FEATURES.
INPUT FUNCTION Q.
USES: Provides output speed interlock for axle engagement, input to ECU, and input to speedometer to adjust for
axle ratio change.
VARIABLES TO SPECIFY: Output speed to activate, output speed to deactivate.
VOCATIONS: Dump truck, refuse packer, cement mixer, two-speed axle equipped vehicles.
See TABLE A
OPTIONAL
CUSTOMER-FURNISHED
VIW CONNECTOR(S)
SWITCHED
POWER
Low
Axle
High
Axle
TWO-SPEED
AXLE SWITCH
45
LOW
25
GND
TCM
WIRE 103
SIGNAL RETURN
WIRE 145 TWO-SPEED
AXLE ENABLE
OPTION 1
OPTION 2
OPTION 3
TABLE A
PIN 1
WIRE 101
PIN 17 WIRE 117
PIN 42 WIRE 142
OPTIONAL VIM
NC
A2
COM
NO
AUX +
A3
SIG GND
F3
SPEEDOMETER
SWITCHED
POWER
WIRE 125
SPEEDOMETER SIGNAL
B2
H2
WIRE
357
P24
3000 AND 4000 PRODUCT FAMILIES TROUBLESHOOTING MANUALALLISON 4th GENERATION CONTROLS
WARNING!
These schematics show the intended use of the specified controls features which
have been validated in the configuration shown. Any miswiring or use of these
features which differs from that shown could result in damage to equipment or
property, personal injury, or loss of life. ALLISON TRANSMISSION IS NOT
LIABLE FOR THE CONSEQUENCES ASSOCIATED WITH MISWIRING
OR UNINTENDED USE OF THESE FEATURES.
INPUT FUNCTION V.
USES: Provides for a separate instrument panel-mounted switch which must be pressed simultaneously with the
REVERSE button to achieve Reverse.
VARIABLES TO SPECIFY: None
VOCATIONS: European transit buses and tour buses
WARNING!
If this function is enabled in the shift calibration, the function MUST be integrated
into the vehicle wiring. If the function is available in the shift calibration but will
not be used in the vehicle, it MUST be disabled in the calibration.
OPTIONAL
CUSTOMER-FURNISHED
VIW CONNECTOR(S)
17
3
MOMENTARY
SWITCH
TCM
WIRE 117
REVERSE ENABLE
WIRE 3
SIGNAL RETURN
V09176.00.00
P25
3000 AND 4000 PRODUCT FAMILIES TROUBLESHOOTING MANUALALLISON 4th GENERATION CONTROLS
WARNING!
INPUT FUNCTION V.
USES: Provides for a separate instrument panel-mounted switch which must be pressed simultaneously with the
REVERSE button to achieve Reverse.
VARIABLES TO SPECIFY: None
VOCATIONS: European transit buses and tour buses
If this function is enabled in the shift calibration, the function MUST be integrated
into the vehicle wiring. If the function is available in the shift calibration but will
not be used in the vehicle, it MUST be disabled in the calibration.
WARNING!
MOMENTARY
SWITCH
SWITCHED POWER
TCM
WIRE 143
REVERSE ENABLE
43
OPTIONAL
CUSTOMER-FURNISHED
VEHICLE INTERFACE
WIRING CONNECTOR
V09177.00.00
P26
3000 AND 4000 PRODUCT FAMILIES TROUBLESHOOTING MANUALALLISON 4th GENERATION CONTROLS
WARNING!
These schematics show the intended use of the specified controls features which
have been validated in the configuration shown. Any miswiring or use of these
features which differs from that shown could result in damage to equipment or
property, personal injury, or loss of life. ALLISON TRANSMISSION IS NOT
LIABLE FOR THE CONSEQUENCES ASSOCIATED WITH MISWIRING
OR UNINTENDED USE OF THESE FEATURES.
WARNING!
If this function is enabled in the shift calibration, the function MUST be integrated
into the vehicle wiring. If the function is available in the shift calibration but will
not be used in the vehicle, it MUST be disabled in the calibration.
SEE TABLE A
SEE TABLE A
DIRECTION CHANGE ENABLE
TCM
DIRECTION
CHANGE
SWITCH
WIRE 103
SIGNAL RETURN
3
OPTIONAL
CUSTOMER-FURNISHED
VIW CONNECTOR(S)
OPTION
OPTION
OPTION
OPTION
1
2
3
4
TABLE A
PIN 1
WIRE
PIN 17 WIRE
PIN 22 WIRE
PIN 42 WIRE
101
117
122
142
V09178.00.00
P27
3000 AND 4000 PRODUCT FAMILIES TROUBLESHOOTING MANUALALLISON 4th GENERATION CONTROLS
WARNING!
These schematics show the intended use of the specified controls features which
have been validated in the configuration shown. Any miswiring or use of these
features which differs from that shown could result in damage to equipment or
property, personal injury, or loss of life. ALLISON TRANSMISSION IS NOT
LIABLE FOR THE CONSEQUENCES ASSOCIATED WITH MISWIRING
OR UNINTENDED USE OF THESE FEATURES.
WARNING!
If this function is enabled in the shift calibration, the function MUST be integrated
into the vehicle wiring. If the function is available in the shift calibration but will
not be used in the vehicle, it MUST be disabled in the calibration.
WIRE 143
DIRECTION CHANGE ENABLE
43
OPTIONAL
CUSTOMER-FURNISHED
VIW CONNECTOR(S)
TCM
DIRECTION
CHANGE
SWITCH
SWITCHED POWER
V09179.00.00
P28
3000 AND 4000 PRODUCT FAMILIES TROUBLESHOOTING MANUALALLISON 4th GENERATION CONTROLS
WARNING!
INPUT FUNCTION Y.
USES: Signals the TCM when ABS function is active, so that lockup clutch and retarder will be disabled.
VARIABLES TO SPECIFY: None
VOCATIONS: Various
ABS INPUT ()
NO ABS
TCM
ANTI-LOCK
BRAKE
CONTROLS
WIRE 103
SIGNAL RETURN
BRAKE
PRESSIRE
SWITCH
(See Note)
21
TCM
OPTIONAL
CUSTOMER-FURNISHED
VEHICLE INTERFACE
WIRING CONNECTOR
WIRE 121
ABS
RESPONSE
21
WIRE 121
ABS
RESPONSE
OPTIONAL
CUSTOMER- FURNISHED
VEHICLE INTERFACE
WIRING CONNECTOR
ABS INPUT ()
ANTI-LOCK
BRAKE
CONTROLS
WIRE 103
SIGNAL RETURN
BRAKE
PRESSURE
SWITCH
WIRE 103
SIGNAL RETURN
BRAKE
PRESSURE
SWITCH
N.C.
WIRE 121
ABS RESPONSE
SWITCHED
POWER
ANTI-LOCK
BRAKE
CONTROLS
COM N.O.
N.C.
WIRE 121
ABS RESPONSE
RELAY
SHOWN
DE-ENERGIZED
COM N.O.
RELAY
SHOWN
DE-ENERGIZED
V09341.00.00
Figure P27. Anti-Lock Brake Response With Input From ABS Controller
P29
3000 AND 4000 PRODUCT FAMILIES TROUBLESHOOTING MANUALALLISON 4th GENERATION CONTROLS
WARNING!
INPUT FUNCTION Y.
USES: Signals the TCM when ABS function is active so that the lockup clutch and retarder will be disabled.
Signals the TCM during hard braking even if ABS is not activated, so that the lockup clutch and retarder
will be disabled.
VARIABLES TO SPECIFY: None
VOCATIONS: Various
TCM
SAE J1939
VEHICLE COMMUNICATION
INTERFACE
See appropriate
Installation Schematic
installation drawing for
wire and pin numbers.
OPTIONAL
CUSTOMER- FURNISHED
VEHICLE INTERFACE
WIRING CONNECTOR
SAE J1939
VEHICLE COMMUNICATION
INTERFACE
See appropriate
Installation Schematic
installation drawing for
wire and pin numbers.
TCM
21
OPTIONAL
CUSTOMER- FURNISHED
VEHICLE INTERFACE
WIRING CONNECTOR
WIRE 121
ABS RESPONSE
ALL ITEMS SHOWN,
EXCEPT TCM,
ARE CUSTOMER-FURNISHED
V09073.00.00
P30
3000 AND 4000 PRODUCT FAMILIES TROUBLESHOOTING MANUALALLISON 4th GENERATION CONTROLS
WARNING!
These schematics show the intended use of the specified controls features which
have been validated in the configuration shown. Any miswiring or use of these
features which differs from that shown could result in damage to equipment or
property, personal injury, or loss of life. ALLISON TRANSMISSION IS NOT
LIABLE FOR THE CONSEQUENCES ASSOCIATED WITH MISWIRING
OR UNINTENDED USE OF THESE FEATURES.
INPUT FUNCTION Z.
RETARDER ENABLE
USES: Provides for operator ON/OFF control of the retarder, transmission temperature indication, and brake
lights during retarder operation.
USES: None
VOCATIONS: Various. This function is required for retarder-equipped transmissions.
SWITCHED
POWER
OPTIONAL
CUSTOMER-FURNISHED
VIW CONNECTOR(S)
64
62
3
24
TCM
COM
COM
WIRE 161
RETARDER ENABLE
WIRE 158
SIGNAL RETURN
RETARDER
DASH SWITCH
Closed = On
NO
WIRE 164
WIRE 124
RETARDER INDICATOR
NC
E1
CRUISE
+ CONTROL
BRAKE
STATUS
INPUT
NO
RETARDER
ON
61
58
UNSWITCHED
POWER
BRAKE
LIGHTS
SWITCH
** CUSTOMERFURNISHED
RELAY
NC
COM
NO
C2
**OPTIONAL VIM
** Relays shown
de-energized
D1
BRAKE
LIGHTS
SWITCHED
POWER
V09180.00.00
P31
3000 AND 4000 PRODUCT FAMILIES TROUBLESHOOTING MANUALALLISON 4th GENERATION CONTROLS
WARNING!
BRAKE PEDAL
SWITCH
62
WIRE 162
SERVICE BRAKE STATUS
WIRE 103
SIGNAL RETURN
CLOSED = BRAKES ON
TCM
OPTIONAL
CUSTOMER-FURNISHED
VIW CONNECTOR(S)
V09181.00.00
P32
3000 AND 4000 PRODUCT FAMILIES TROUBLESHOOTING MANUALALLISON 4th GENERATION CONTROLS
WARNING!
These schematics show the intended use of the specified controls features which
have been validated in the configuration shown. Any miswiring or use of these
features which differs from that shown could result in damage to equipment or
property, personal injury, or loss of life. ALLISON TRANSMISSION IS NOT
LIABLE FOR THE CONSEQUENCES ASSOCIATED WITH MISWIRING
OR UNINTENDED USE OF THESE FEATURES.
USES: Provides for operator ON/OFF control of the differential locking clutch in the 3000 Product Family
7-speed transmission transfer case.
VARIABLES TO SPECIFY: None
VOCATIONS: Various. This function is required for all 3000 Product Family 7-speed transmissions and used
only with this transmission.
SWITCHED
POWER
24
TCM
WIRE 124
DIFFERENTIAL CLUTCH ENABLE
OPTIONAL
CUSTOMER-FURNISHED
VIW CONNECTOR(S)
61
58
WIRE 161
DIFFERENTIAL
CLUTCH REQUEST
WIRE 158
SIGNAL RETURN
DASH
SWITCH
NC
E1
COM
NO
C2
D1
SWITCHED
POWER
DIFF
CLUTCH
OPTIONAL VIM
Relay shown de-energized
V09182.00.00
P33
3000 AND 4000 PRODUCT FAMILIES TROUBLESHOOTING MANUALALLISON 4th GENERATION CONTROLS
WARNING!
These schematics show the intended use of the specified controls features which
have been validated in the configuration shown. Any miswiring or use of these
features which differs from that shown could result in damage to equipment or
property, personal injury, or loss of life. ALLISON TRANSMISSION IS NOT
LIABLE FOR THE CONSEQUENCES ASSOCIATED WITH MISWIRING
OR UNINTENDED USE OF THESE FEATURES.
OPTIONAL
CUSTOMER-FURNISHED
VIW CONNECTOR(S)
SWITCHED
POWER
WIRE 143
PTO ENABLE INPUT
WIRE 103
SIGNAL RETURN
WIRE 117 or 101
PACK ENABLE
43
3
42
F2
COM
SEE TABLE A
FAST IDLE
NEUTRAL SOLENOID
INDICATOR
(GREEN DASH LIGHT)
Indicates neutral &
park brake on
PRESSURE
SWITCH #2
(520 psi)
NC
A2
COM
NO
F3
NO
WIRE 142
AUTO NEUTRAL
PACKER INPUT
F3
D2
NO
AUTO
NEUTRAL
CAB SWITCH
45
NO
NC COM
PARK BRAKE
SWITCHED
POWER
PTO
PRESSURE
SWITCH
FAST IDLE
CONTROL
NC
PRESSURE
SWITCH #1
(520 psi)
NC COM
30
TCM
PTO
SWITCH
DASH
LIGHT
A3
PTO
NOTE: The fast idle
solenoid must be
diode suppressed.
SEE NOTE*
OPTIONAL
VIM
OPTION 1
OPTION 2
TABLE A
PIN 17 WIRE 117
PIN 1
WIRE 101
CUSTOMER
SUPPLIED RELAY
NC
COM
NO
SWITCHED
POWER
NOTE*: Typical engine "Fast Idle" control system. Actual configuration may vary from that shown.
Consult the engine manufacturer.
NOTE: Transmission shifts to Neutral when either rail switch or arm switch is closed (if other conditions are satisfied). Transmission shifts back to Drive
if both switches open and engine speed drops below 900 rpm within 2.5 seconds of both switches closing.
V09183.00.00
P34
3000 AND 4000 PRODUCT FAMILIES TROUBLESHOOTING MANUALALLISON 4th GENERATION CONTROLS
WARNING!
These schematics show the intended use of the specified controls features which
have been validated in the configuration shown. Any miswiring or use of these
features which differs from that shown could result in damage to equipment or
property, personal injury, or loss of life. ALLISON TRANSMISSION IS NOT
LIABLE FOR THE CONSEQUENCES ASSOCIATED WITH MISWIRING
OR UNINTENDED USE OF THESE FEATURES.
OPTIONAL
CUSTOMER-FURNISHED
VIW CONNECTOR(S)
SWITCHED
POWER
WIRE 143
PTO ENABLE INPUT
WIRE 103
SIGNAL RETURN
WIRE 117 or 101
PACK ENABLE
43
3
42
45
F2
COM
NO
SEE TABLE A
FAST IDLE
NEUTRAL SOLENOID
INDICATOR
(GREEN DASH LIGHT)
Indicates neutral &
park brake on
NC
A2
COM
NO
F3
NO
WIRE 142
AUTO NEUTRAL
PACKER INPUT
F3
D2
NO
NC COM
WORK BRAKE
SWITCHED
POWER
PTO
PRESSURE
SWITCH
FAST IDLE
CONTROL
NC
PRESSURE
SWITCH #1
(520 psi)
AUTO
NC COM
NEUTRAL
CAB SWITCH
PRESSURE
SWITCH #2
(520 psi)
30
TCM
PTO
SWITCH
DASH
LIGHT
A3
PTO
NOTE: The fast idle
solenoid must be
diode suppressed.
SEE NOTE*
OPTIONAL
VIM
OPTION 1
OPTION 2
TABLE A
PIN 17 WIRE 117
PIN 1
WIRE 101
CUSTOMER
SUPPLIED RELAY
NC
COM
NO
SWITCHED
POWER
NOTE*: Typical engine Fast Idle control system. Actual configuration may vary from that shown.
Consult the engine manufacturer.
NOTE: Transmission shifts to Neutral when either rail switch or arm switch is closed (if other conditions are satisfied). Transmission shifts back to Drive
if both switches open and engine speed drops below 900 rpm within 2.5 seconds of both switches closing.
V09184.00.00
P35
3000 AND 4000 PRODUCT FAMILIES TROUBLESHOOTING MANUALALLISON 4th GENERATION CONTROLS
WARNING!
These schematics show the intended use of the specified controls features which
have been validated in the configuration shown. Any miswiring or use of these
features which differs from that shown could result in damage to equipment or
property, personal injury, or loss of life. ALLISON TRANSMISSION IS NOT
LIABLE FOR THE CONSEQUENCES ASSOCIATED WITH MISWIRING
OR UNINTENDED USE OF THESE FEATURES.
OPTIONAL
CUSTOMER-FURNISHED
VIW CONNECTOR(S)
CLOSED THROTTLE
22
3
ENGINE
OPERATING
RANGE
FULL THROTTLE
ECONOMY SHIFT POINTS
FULL THROTTLE
KICKDOWN SHIFT POINTS
THROTTLE
PEDAL
MOMENTARY
SWITCH
TCM
WIRE 122
KICKDOWN
NOTE: Full throttle economy shift points position on the pedal should
coincide with full stroke of the Allison throttle position sensor (if used) and/or
full fuel setting of the engine controls. Thus, pedal movement beyond
full throttle economy shift points must not change fuel setting of the engine
or the throttle position signal to the transmission controls system.
WIRE 103
SIGNAL RETURN
V09185.00.00
P36
3000 AND 4000 PRODUCT FAMILIES TROUBLESHOOTING MANUALALLISON 4th GENERATION CONTROLS
WARNING!
WARNING!
WARNING!
SEE TABLE A
WIRE 103
SIGNAL RETURN
3
TCM
OPTIONAL
CUSTOMER-FURNISHED
VIW CONNECTOR(S)
OPTION 1
OPTION 2
TABLE A
PIN 42 WIRE 142
PIN 2
WIRE 101
V09186.00.00
P37
3000 AND 4000 PRODUCT FAMILIES TROUBLESHOOTING MANUALALLISON 4th GENERATION CONTROLS
WARNING!
WARNING!
SYSTEM OPERATION
OPERATOR ACTIONSystem Response
TO ENGAGE:
1. SELECT NEUTRALTransmission shifts to Neutral.
2. APPLY PARKING BRAKENone
3. SELECT PUMPTurns on Pump Mode Requested light. Turns on input signal to TCM (wire 123) which
activates pump mode. When split-shaft shifts, wire 122 is activated and Pump Engaged light is turned on.
4. SELECT DRIVETransmission shifts to fourth lockup. OK To Pump light is turned on.
TO DISENGAGE:
1. SELECT NEUTRALTransmission shifts to Neutral if output rpm is less than 1000.
2. SELECT ROAD MODEPTO disengages. If output shaft rotation continues, press the Momentary Trans. Brake
switch before selecting Road Mode. This will cause the transmission output shaft to stop if transmission is in
Neutral and output shaft speed is less than 175 rpm.
MOMENTARY PARKING BRAKE
TRANSMISSION PRESSURE
BRAKE
SWITCH
SWITCH
Switch is
closed when
brakes are on
WIRE 103
AIR
SIGNAL
RETURN
WIRE 123
4th LOCKUP PUMP
MODE INPUT
23
3
22
PUMP MODE
REQUESTED
45
TCM
OPTIONAL
CUSTOMERFURNISHED
VIW
CONNECTOR(S)
DASH SWITCH
Open: Road
Closed: Pump
SWITCHED POWER
Relay shown de-energized
Switch is closed
OPTIONAL VIM
when pump is
engaged
NC
SPLITSHAFT
PTO
A2
COM
NO
F3
WIRE 122
PUMP ENABLE
PUMP
ENGAGED
OK TO
PUMP
SWITCHED
POWER
WIRE 145
RANGE INDICATOR (4th)
Figure P36. Fourth Lockup Pump ModeOperator and Pump Activated (North America)
P38
A3
V09187.00.00
3000 AND 4000 PRODUCT FAMILIES TROUBLESHOOTING MANUALALLISON 4th GENERATION CONTROLS
WARNING!
These schematics show the intended use of the specified controls features which
have been validated in the configuration shown. Any miswiring or use of these
features which differs from that shown could result in damage to equipment or
property, personal injury, or loss of life. ALLISON TRANSMISSION IS NOT
LIABLE FOR THE CONSEQUENCES ASSOCIATED WITH MISWIRING
OR UNINTENDED USE OF THESE FEATURES.
USES: Facilitates engagement of split shaft PTO and shifts transmission to fourth range lockup for driving a
vehicle-mounted pump.
VARIABLES TO SPECIFY: None
VOCATIONS: Street cleaners, sewer cleaners
WARNING!
SYSTEM OPERATION
OPERATOR ACTIONSystem Response
TO ENGAGE:
1. SELECT NEUTRALTransmission shifts to Neutral.
2. APPLY PARKING BRAKENone
3. SELECT PUMPTurns on Pump Mode Requested light. Turns on both input signals to TCM (wires 122 and
123) which activates pump mode. When split-shaft shifts, Pump Engaged light is turned on.
4. SELECT DRIVETransmission shifts to fourth lockup. OK To Pump light is turned on.
TO DISENGAGE:
1. SELECT NEUTRALTransmission shifts to Neutral if output rpm is less than 1000.
2. SELECT ROAD MODEPTO disengages. If output shaft rotation continues, press the Momentary Trans.
Brake switch before selecting Road Mode. This will cause the transmission output shaft to stop if transmission is
in Neutral and output shaft speed is less than 175 rpm.
SWITCHED
OPTIONAL
POWER
CUSTOMER-FURNISHED
VIW CONNECTOR(S)
WIRE 122
PUMP ENABLE
22
WIRE 103 SIGNAL RETURN
3
DASH SWITCH
Open: Road
Closed: Pump
Switch closes when
pump is engaged
AIR
Relay shown
de-energized
23
45
TCM
MOMENTARY
TRANSMISSION PARKING BRAKE
BRAKE
PRESSURE SWITCH
SWITCH
Switch is closed
when brakes are on
WIRE 123
4th LOCKUP PUMP
PUMP MODE
MODE INPUT
REQUESTED
OK TO
PUMP
SPLITSHAFT
PTO
OPTIONAL VIM
NC
A2
COM
NO
A3
F3
PUMP
ENGAGED
SWITCHED
POWER
Figure P37. Fourth Lockup Pump ModeOperator Only Activated (North America)
P39
3000 AND 4000 PRODUCT FAMILIES TROUBLESHOOTING MANUALALLISON 4th GENERATION CONTROLS
WARNING!
WARNING!
SYSTEM OPERATION
OPERATOR ACTIONSystem Response
TO ENGAGE:
1. SELECT NEUTRALTransmission shifts to Neutral.
2. APPLY PARKING BRAKENone
3. SELECT PUMPTurns on Pump Mode Requested light. Turns on both input signals to TCM (wires 143 and
123) which activates pump mode. When split-shaft shifts, Pump Engaged light is turned on.
4. SELECT DRIVETransmission shifts to fourth lockup. OK To Pump light is turned on.
TO DISENGAGE:
1. SELECT NEUTRALTransmission shifts to Neutral if output rpm is less than 1000.
2. SELECT ROAD MODEPTO disengages. If output shaft rotation continues, press the Momentary Trans.
Brake switch before selecting Road Mode. This will cause the transmission output shaft to stop if transmission is
in Neutral and output shaft speed is less than 175 rpm.
MOMENTARY PARKING BRAKE
TRANSMISSION PRESSURE
BRAKE
SWITCH
SWITCH
Switch is
closed when
brakes are on
WIRE 103
AIR
SIGNAL
RETURN
WIRE 143
4th LOCKUP PUMP
MODE INPUT
43
3
17
PUMP MODE
REQUESTED
45
TCM
OPTIONAL
CUSTOMERFURNISHED
VIW
CONNECTOR(S)
DASH SWITCH
Open: Road
Closed: Pump
SWITCHED POWER
Relay shown de-energized
Switch is closed
OPTIONAL VIM
when pump is
engaged
NC
SPLITSHAFT
PTO
A2
COM
NO
F3
WIRE 117
PUMP ENABLE
PUMP
ENGAGED
OK TO
PUMP
SWITCHED
POWER
WIRE 145
RANGE INDICATOR (4th)
Figure P38. Fourth Lockup Pump ModeOperator and Pump Activated (Non-North America)
P40
A3
V09189.00.00
3000 AND 4000 PRODUCT FAMILIES TROUBLESHOOTING MANUALALLISON 4th GENERATION CONTROLS
WARNING!
These schematics show the intended use of the specified controls features which
have been validated in the configuration shown. Any miswiring or use of these
features which differs from that shown could result in damage to equipment or
property, personal injury, or loss of life. ALLISON TRANSMISSION IS NOT
LIABLE FOR THE CONSEQUENCES ASSOCIATED WITH MISWIRING
OR UNINTENDED USE OF THESE FEATURES.
USES: Facilitates engagement of split shaft PTO and shifts transmission to fourth range lockup for driving a
vehicle-mounted pump.
VARIABLES TO SPECIFY: None
VOCATIONS: Street cleaners, sewer cleaners
WARNING!
SYSTEM OPERATION
OPERATOR ACTIONSystem Response
TO ENGAGE:
1. SELECT NEUTRALTransmission shifts to Neutral.
2. APPLY PARKING BRAKENone
3. SELECT PUMPTurns on Pump Mode Requested light. Turns on both input signals to TCM (wires 117 and
143) which activates pump mode. When split-shaft shifts, Pump Engaged light is turned on.
4. SELECT DRIVETransmission shifts to fourth lockup. OK To Pump light is turned on.
TO DISENGAGE:
1. SELECT NEUTRALTransmission shifts to Neutral if output rpm is less than 1000.
2. SELECT ROAD MODEPTO disengages. If output shaft rotation continues, press the Momentary Trans.
Brake switch before selecting Road Mode. This will cause the transmission output shaft to stop if transmission is
in Neutral and output shaft speed is less than 175 rpm.
SWITCHED
OPTIONAL
POWER
CUSTOMER-FURNISHED
VIW CONNECTOR(S)
WIRE 117
PUMP ENABLE
17
WIRE 103 SIGNAL RETURN
3
DASH SWITCH
Open: Road
Closed: Pump
Switch closes when
pump is engaged
Relay shown de-energized
AIR
43
45
TCM
MOMENTARY
TRANSMISSION PARKING BRAKE
BRAKE
PRESSURE SWITCH
SWITCH
Switch is closed
when brakes are on
WIRE 143
4th LOCKUP PUMP
PUMP MODE
MODE INPUT
REQUESTED
OPTIONAL
VIM
OK TO
PUMP
SPLITSHAFT
PTO
NC
A2
COM
NO
A3
F3
PUMP
ENGAGED
SWITCHED
POWER
Figure P39. Fourth Lockup Pump ModeOperator Only Activated (Non-North America)
P41
3000 AND 4000 PRODUCT FAMILIES TROUBLESHOOTING MANUALALLISON 4th GENERATION CONTROLS
WARNING!
These schematics show the intended use of the specified controls features which
have been validated in the configuration shown. Any miswiring or use of these
features which differs from that shown could result in damage to equipment or
property, personal injury, or loss of life. ALLISON TRANSMISSION IS NOT
LIABLE FOR THE CONSEQUENCES ASSOCIATED WITH MISWIRING
OR UNINTENDED USE OF THESE FEATURES.
WARNING!
This feature is meant to be used in applications where the vehicle operator remains
in the cab. If the operator leaves the vehicle, the park brake must be engaged and
Neutral must be selected prior to the operator exiting the cab. In addition, vehicles
using this feature must have the following Warning sticker visible in the vehicle
cab: WARNING: Set Park Brake and select Neutral before exiting cab!
OPTIONAL
CUSTOMER-FURNISHED
VIW CONNECTOR(S)
43
62
3
17
42
TCM
30
45
SWITCHED
POWER
WIRE 143
PTO ENABLE INPUT
PTO
SWITCH
BRAKE PEDAL
SWITCH
WIRE 162
SERVICE BRAKE STATUS
Closed = Brakes On
WIRE 103
SIGNAL RETURN
WIRE 117
PACK ENABLE
1
AUTO NEUTRAL
DASH SWITCH
WIRE 142
AUTO NEUTRAL
PACKER INPUT
2
WIRE 136
PTO ENABLE OUTPUT
WIRE 145 NEUTRAL INDICATOR FOR PTO
PTO
PRESSURE
SWITCH
NC
F2
COM
NO
F3
D2
DASH
LIGHT
SEE NOTE *
NC
A2
COM
NO
F3
SWITCHED
POWER
A3
PTO
FAST IDLE
CONTROL
FAST IDLE
SOLENOID
OPTIONAL
VIM
NOTE: The fast idle solenoid must be diode suppressed.
NOTE: Transmission shifts to Neutral when dash switch is closed (if other
conditions are satisfied). Transmission shifts back to Drive when switch is
opened, service brake switch is closed, and engine speed drops below
900 rpm within 2.5 sec. Otherwise, transmission stays in Neutral.
NOTE*: Typical engine Fast Idle control system. Actual configuration
may vary from that shown. Consult the engine manufacturer.
V09191.00.00
Figure P40. Automatic NeutralDual Input With Service Brake StatusAutomated Side Loader Activated
P42
3000 AND 4000 PRODUCT FAMILIES TROUBLESHOOTING MANUALALLISON 4th GENERATION CONTROLS
WARNING!
WARNING!
OPTIONAL
CUSTOMER-FURNISHED
VIW CONNECTOR(S)
43
SWITCHED
POWER
WIRE 143
PTO ENABLE INPUT
62
3
17
42
TCM
30
45
PTO
SWITCH
BRAKE PEDAL
SWITCH
WIRE 162
SERVICE BRAKE STATUS
Closed = Brakes On
WIRE 103
SIGNAL RETURN
WIRE 117
PACK ENABLE
1
AUTO NEUTRAL
DASH SWITCH
WIRE 142
AUTO NEUTRAL
PACKER INPUT
2
WIRE 136
PTO ENABLE OUTPUT
WIRE 145 NEUTRAL INDICATOR FOR PTO
PTO
PRESSURE
SWITCH
NC
F2
COM
NO
F3
D2
DASH
LIGHT
SEE NOTE *
NC
A2
COM
NO
F3
SWITCHED
POWER
A3
PTO
FAST IDLE
CONTROL
FAST IDLE
SOLENOID
OPTIONAL
VIM
NOTE: The fast idle solenoid must be diode suppressed.
NOTE: Transmission shifts to Neutral when dash switch is closed (if other
conditions are satisfied). Transmission shifts back to Drive when switch is
opened, service brake switch is closed, and engine speed drops below
900 rpm within 2.5 sec. Otherwise, transmission stays in Neutral.
NOTE*: Typical engine Fast Idle control system. Actual configuration
may vary from that shown. Consult the engine manufacturer.
V09191.00.00
Figure P41. Automatic NeutralDual Input With Service Brake StatusDash Switch Activated
P43
3000 AND 4000 PRODUCT FAMILIES TROUBLESHOOTING MANUALALLISON 4th GENERATION CONTROLS
WARNING!
62
43
BRAKE PEDAL
SWITCH
WIRE 162
SERVICE BRAKE
PTO
(Closed = Brakes On)
STATUS
SWITCH
WIRE 143 PTO ENABLE INPUT
3
17
WIRE 103
SIGNAL RETURN
WIRE 117
PACK ENABLE
42
45
OPTIONAL
CUSTOMERFURNISHED
VIW
CONNECTOR(S)
AUTO
NEUTRAL
CAB SWITCH
COM
NC
NC
A2
PRESSURE
SWITCH #2
(520 psi)
NO
WIRE 142
AUTO NEUTRAL
PACKER INPUT
NO
F3
GROUND
NO
30
TCM
COM
D2
PRESSURE
SWITCH #1
(520 psi)
FAST IDLE
CONTROL
NC
F2
NC COM
PARK BRAKE
WIRE 130 PTO ENABLE OUTPUT
WIRE 145 NEUTRAL INDICATOR FOR PTO
F3
COM
NO
SWITCHED
POWER
SEE NOTE *
OPTIONAL
VIM
FAST IDLE
PTO
PRESSURE
SWITCH
SOLENOID
NEUTRAL
INDICATOR
(GREEN DASH LIGHT)
Indicates neutral &
park brake on
DASH
LIGHT
A3
PTO
SWITCHED
POWER NOTE: The fast idle
solenoid must be
diode suppressed.
CUSTOMER
SUPPLIED RELAY
NC
COM
NO
SWITCHED
POWER
NOTE*: Typical engine Fast Idle control system. Actual configuration may
vary from that shown. Consult the engine manufacturer.
V09192.00.00
Figure P42. Automatic NeutralDual Input With Service Brake StatusPark Brake Activated
P44
3000 AND 4000 PRODUCT FAMILIES TROUBLESHOOTING MANUALALLISON 4th GENERATION CONTROLS
WARNING!
62
43
BRAKE PEDAL
SWITCH
WIRE 162
SERVICE BRAKE
PTO
(Closed = Brakes On)
STATUS
SWITCH
WIRE 143 PTO ENABLE INPUT
3
17
WIRE 117
PACK ENABLE
42
30
TCM
WIRE 103
SIGNAL RETURN
45
OPTIONAL
CUSTOMERFURNISHED
VIW
CONNECTOR(S)
COM
AUTO
NEUTRAL
CAB SWITCH
WIRE 142
AUTO NEUTRAL
PACKER INPUT
COM
NO
D2
PRESSURE
SWITCH #1
(520 psi)
FAST IDLE
CONTROL
NC
F2
F3
GROUND
NC
NO
A2
NC PRESSURE
SWITCH #2
(520 psi)
NO
NC COM
WORK BRAKE
WIRE 130 PTO ENABLE OUTPUT
WIRE 145 NEUTRAL INDICATOR FOR PTO
F3
COM
NO
SWITCHED
POWER
SEE NOTE *
OPTIONAL
VIM
FAST IDLE
PTO
PRESSURE
SWITCH
SOLENOID
NEUTRAL
INDICATOR
(GREEN DASH LIGHT)
Indicates neutral &
park brake on
DASH
LIGHT
A3
PTO
SWITCHED
POWER NOTE: The fast idle
solenoid must be
diode suppressed.
CUSTOMER
SUPPLIED RELAY
NC
COM
NO
SWITCHED
POWER
NOTE*: Typical engine "Fast Idle" control system. Actual configuration may
vary from that shown. Consult the engine manufacturer.
V09193.00.00
Figure P43. Automatic NeutralDual Input With Service Brake StatusWork Brake Activated
P45
3000 AND 4000 PRODUCT FAMILIES TROUBLESHOOTING MANUALALLISON 4th GENERATION CONTROLS
WARNING!
45
62
WIRE 145
LEAVE OPEN
(NIPTO logic is timed out)
Do not use for fast idle.
WIRE 103
SIGNAL RETURN
PRESSURE
SWITCH #1
(520 psi)
AUTO NEUTRAL
CAB SWITCH
OPTIONAL
CUSTOMER
FURNISHED
VIW
CONNECTOR(S)
64
COM
WIRE 117
AUTO NEUTRAL ENABLE
TCM
WIRE 164
RANGE INDICATOR (N)
NO
A3
SWITCHED
POWER
NEUTRAL
INDICATOR
NO
PRESSURE
SWITCH #2
(520 psi)
WIRE 142
AUTO NEUTRAL
PACKER INPUT
CUSTOMER
SUPPLIED
RELAY
NC
42
OPTIONAL
SWITCHED POWER
WIRE 162
SERVICE BRAKE STATUS
3
17
BRAKE PEDAL
SWITCH
(Closed =
Brakes On)
COM
NC
NO
COM NC
NC
PARK BRAKE
PB Shown On
COM
NO
SWITCHED POWER
V09194.00.00
Figure P44. Automatic NeutralDual Input With Service Brake StatusEmergency Vehicle Option
P46
3000 AND 4000 PRODUCT FAMILIES TROUBLESHOOTING MANUALALLISON 4th GENERATION CONTROLS
WARNING!
These schematics show the intended use of the specified controls features which
have been validated in the configuration shown. Any miswiring or use of these
features which differs from that shown could result in damage to equipment or
property, personal injury, or loss of life. ALLISON TRANSMISSION IS NOT
LIABLE FOR THE CONSEQUENCES ASSOCIATED WITH MISWIRING
OR UNINTENDED USE OF THESE FEATURES.
WARNING!
If this function is enabled in the shift calibration, the function MUST be integrated
into the vehicle wiring. If the function is available in the shift calibration but will
not be used in the vehicle, it MUST be disabled in the calibration.
OPTIONAL
CUSTOMER-FURNISHED
VIW CONNECTOR(S)
WIRE 101
SHIFT SELECTOR
TRANSITION
WIRE 103
SIGNAL RETURN
SELECTOR
1
SELECTOR
2*
DASH SWITCH
Open: Selector 1 and primary
mode shift schedule
Closed: Selector 2 and secondary
mode shift schedule
When TCM is turned on, active shift selector is
determined by current switch position.
Inactive selector displays for range selected.
TCM
MODE
MODE
Figure P45. Shift Selector Transition and Secondary Shift Schedule Without Auto Neutral
P47
3000 AND 4000 PRODUCT FAMILIES TROUBLESHOOTING MANUALALLISON 4th GENERATION CONTROLS
WARNING!
These schematics show the intended use of the specified controls features which
have been validated in the configuration shown. Any miswiring or use of these
features which differs from that shown could result in damage to equipment or
property, personal injury, or loss of life. ALLISON TRANSMISSION IS NOT
LIABLE FOR THE CONSEQUENCES ASSOCIATED WITH MISWIRING
OR UNINTENDED USE OF THESE FEATURES.
WARNING!
If this function is enabled in the shift calibration, the function MUST be integrated
into the vehicle wiring. If the function is available in the shift calibration but will
not be used in the vehicle, it MUST be disabled in the calibration.
OPTIONAL
CUSTOMER-FURNISHED
WIRE 161
VIW CONNECTOR(S) SHIFT SELECTOR TRANSITION AND
SECONDARY SHIFT SCHEDULE
1
3
62
TCM
13
DASH SWITCH
Open: Selector 1 and primary mode shift schedule
Closed: Selector 2 and secondary mode shift schedule
When TCM is turned on,
active shift selector is
WIRE 103
determined by current
SIGNAL RETURN
switch position.
LEFT
WIRE 162
SELECTOR
BRAKE
SELECTOR
SERVICE
1
2*
Display of the inactive
BRAKE
NC
RIGHT
selector displays
STATUS
BRAKE
for range selected .
COM
To switch between
NO
WIRE 113
selector 1 and selector 2,
SWITCHED
Neutral must be selected
SECONDARY MODE
POWER
and attained, and output
INDICATOR
CUSTOMER-SUPPLIED
speed must be below
RELAY SHOWN
60 rpm.
DE-ENERGIZED
MODE
MODE
Figure P46. Shift Selector Transition and Secondary Shift Schedule With Auto Neutral
P48
V09196.00.00
3000 AND 4000 PRODUCT FAMILIES TROUBLESHOOTING MANUALALLISON 4th GENERATION CONTROLS
WARNING!
These schematics show the intended use of the specified controls features which
have been validated in the configuration shown. Any miswiring or use of these
features which differs from that shown could result in damage to equipment or
property, personal injury, or loss of life. ALLISON TRANSMISSION IS NOT
LIABLE FOR THE CONSEQUENCES ASSOCIATED WITH MISWIRING
OR UNINTENDED USE OF THESE FEATURES.
USES: Limit operation of transmission to first range and inhibit reverse with presence of personnel on rear
of vehicle.
VARIABLES TO SPECIFY: None
VOCATIONS: Refuse
SWITCHED
POWER
23
TCM
MOMENTARY
SWITCH
OPTIONAL
CUSTOMER-FURNISHED
VIW CONNECTOR(S)
WIRE 123
REFUSE PACKER STEP SWITCH
P49
3000 AND 4000 PRODUCT FAMILIES TROUBLESHOOTING MANUALALLISON 4th GENERATION CONTROLS
WARNING!
These schematics show the intended use of the specified controls features which
have been validated in the configuration shown. Any miswiring or use of these
features which differs from that shown could result in damage to equipment or
property, personal injury, or loss of life. ALLISON TRANSMISSION IS NOT
LIABLE FOR THE CONSEQUENCES ASSOCIATED WITH MISWIRING
OR UNINTENDED USE OF THESE FEATURES.
USES: Blanks the digital display and mode on indicator on the lever or pushbutton shift selectors.
VARIABLES TO SPECIFY: None
VOCATIONS: Specialty vehicles
SWITCHED
POWER
23
WIRE 123
SELECTOR DISPLAY BLANKING
DASH SWITCH
Open: NORMAL
Closed: BLANK
Display and indicator
are blanked when switch
is closed
TCM
MODE
P50
V09198.00.00
3000 AND 4000 PRODUCT FAMILIES TROUBLESHOOTING MANUALALLISON 4th GENERATION CONTROLS
WARNING!
USES: Automatically activates Reduced Engine Load at Stop (RELS) when vehicle service brakes are applied,
vehicle is stopped, and throttle is closed. RELS deactivates when the service brakes are released, or the
throttle is advanced, or Drive is selected at the shift selector. If an Automatic Neutral input is activated,
RELS will be deactivated.
VARIABLES TO SPECIFY: None
VOCATIONS: Buses, coach, and on-highway trucks. Use of this function is not permitted in refuse vehicles,
concrete mixers, or emergency vehicles. This feature is also not available in applications that
utilize second-range start shift calibrations.
43
WIRE 123
RELS
23
TCM
OPTIONAL
CUSTOMER- FURNISHED
VEHICLE INTERFACE
WIRING CONNECTOR
DOOR SWITCH
(OPTIONAL)
SERVICE BRAKE
PRESSURE
SWITCH
SWITCH CLOSES
WHEN DOOR
IS OPENED
SWITCH CLOSES
WHEN BRAKES
ARE APPLIED
RELS
ENABLE
(OPTIONAL)
SWITCHED
POWER
NOTE: The vehicle interface circuit must be designed such that this function is deactivated
at least 250 milliseconds before the service brakes on the drive axle are released.
This may be accomplished by the following:
a)
Selecting a service brake pressure switch which activates at a pressure which is near,
but less than, the service brake apply pressure. Typically a 10-15 psi pressure switch.
b)
If the front service brakes release before the rear service brakes, install the activation
pressure switch in the front service brake circuit.
c)
Place the pressure switch as near as possible to the quickest releasing side of the
service brake foot pedal (usually the front brake line).
ALL ITEMS SHOWN, EXCEPT TCM, ARE CUSTOMER-FURNISHED
V09199.00.01
P51
3000 AND 4000 PRODUCT FAMILIES TROUBLESHOOTING MANUALALLISON 4th GENERATION CONTROLS
WARNING!
These schematics show the intended use of the specified controls features which
have been validated in the configuration shown. Any miswiring or use of these
features which differs from that shown could result in damage to equipment or
property, personal injury, or loss of life. ALLISON TRANSMISSION IS NOT
LIABLE FOR THE CONSEQUENCES ASSOCIATED WITH MISWIRING
OR UNINTENDED USE OF THESE FEATURES.
BRAKE PEDAL
SWITCH
62
WIRE 162
SERVICE BRAKE STATUS
WIRE 103
SIGNAL RETURN
CLOSED = BRAKES ON
TCM
OPTIONAL
CUSTOMER-FURNISHED
VIW CONNECTOR(S)
V09200.00.00
P52
3000 AND 4000 PRODUCT FAMILIES TROUBLESHOOTING MANUALALLISON 4th GENERATION CONTROLS
WARNING!
These schematics show the intended use of the specified controls features which
have been validated in the configuration shown. Any miswiring or use of these
features which differs from that shown could result in damage to equipment or
property, personal injury, or loss of life. ALLISON TRANSMISSION IS NOT
LIABLE FOR THE CONSEQUENCES ASSOCIATED WITH MISWIRING
OR UNINTENDED USE OF THESE FEATURES.
USES: Specialty vehicles and commercial heavy equipment transporters (HET) to help prevent transmission
overheating. Allows an automatic 21 shift in a 7-speed if conditions are conducive to successfully
completing the shift.
VARIABLES TO SPECIFY: None
VOCATIONS: Various
TCM
LOW
MODE
LOW
MODE
P53
3000 AND 4000 PRODUCT FAMILIES TROUBLESHOOTING MANUALALLISON 4th GENERATION CONTROLS
WARNING!
These schematics show the intended use of the specified controls features which
have been validated in the configuration shown. Any miswiring or use of these
features which differs from that shown could result in damage to equipment or
property, personal injury, or loss of life. ALLISON TRANSMISSION IS NOT
LIABLE FOR THE CONSEQUENCES ASSOCIATED WITH MISWIRING
OR UNINTENDED USE OF THESE FEATURES.
OUTPUT FUNCTION A.
USES: Used with engine brakes to signal the ECU that the brake is active and to provide increased braking by
preselecting a lower range. Also prevents engagement of engine brake with throttle > 0 or lockup OFF.
VARIABLES TO SPECIFY: Preselect range. Standard value is second range.
VOCATIONS: Various
Refer to Inputs H and I: Engine Brake Enable and Preselect Request. This
output is inverted when used with Input H.
P54
3000 AND 4000 PRODUCT FAMILIES TROUBLESHOOTING MANUALALLISON 4th GENERATION CONTROLS
WARNING!
These schematics show the intended use of the specified controls features which
have been validated in the configuration shown. Any miswiring or use of these
features which differs from that shown could result in damage to equipment or
property, personal injury, or loss of life. ALLISON TRANSMISSION IS NOT
LIABLE FOR THE CONSEQUENCES ASSOCIATED WITH MISWIRING
OR UNINTENDED USE OF THESE FEATURES.
OUTPUT FUNCTION B.
USES: Turn on dash indicator when transmission sump or retarder-out temperature has exceeded specified limits.
VARIABLES TO SPECIFY: None
VOCATIONS: Various
SWITCHED
POWER
64
TCM
OPTIONAL
CUSTOMER-FURNISHED
VIW CONNECTOR(S)
WIRE 164
SUMP / RETARDER
TEMPERATURE
TRANSMISSION
TEMP
NC
TRANS
TEMP
COM
NO
WIRE 164
V09202.00.00
P55
3000 AND 4000 PRODUCT FAMILIES TROUBLESHOOTING MANUALALLISON 4th GENERATION CONTROLS
WARNING!
OUTPUT FUNCTION C.
RANGE INDICATOR
USES: Used with auxiliary vehicle systems to permit operation only in specified transmission range(s).
VARIABLES TO SPECIFY: Range or ranges to be indicated
VOCATIONS: Various
See TABLE A
SWITCHED
POWER
TCM
OPTIONAL
CUSTOMER-FURNISHED
VIW CONNECTOR(S)
OPTION 1
OPTION 2
OPTIONAL
VIM*
NC
A2
COM
NO
F3
TABLE A
PIN 45 WIRE 145
PIN 13 WIRE 113
SWITCHED
POWER
AUXILIARY
VEHICLE
SYSTEM
P56
3000 AND 4000 PRODUCT FAMILIES TROUBLESHOOTING MANUALALLISON 4th GENERATION CONTROLS
WARNING!
These schematics show the intended use of the specified controls features which
have been validated in the configuration shown. Any miswiring or use of these
features which differs from that shown could result in damage to equipment or
property, personal injury, or loss of life. ALLISON TRANSMISSION IS NOT
LIABLE FOR THE CONSEQUENCES ASSOCIATED WITH MISWIRING
OR UNINTENDED USE OF THESE FEATURES.
OUTPUT FUNCTION D.
USES: To signal that the transmission output shaft has exceeded a specified value.
VARIABLES TO SPECIFY: Rpm to turn output ON and to turn output OFF. The ON value must be higher than
the OFF value.
VOCATIONS: Various
SWITCHED
POWER
CUSTOMERNC FURNISHED
RELAY
COM
TCM
WIRE 105
OUTPUT SPEED INDICATOR A
OPTIONAL
CUSTOMER-FURNISHED
VIW CONNECTOR(S)
NO
Relay shown
de-energized
TRANSMISSION
OR VEHICLE
OVERSPEED
INDICATOR
V09205.00.00
P57
3000 AND 4000 PRODUCT FAMILIES TROUBLESHOOTING MANUALALLISON 4th GENERATION CONTROLS
WARNING!
These schematics show the intended use of the specified controls features which
have been validated in the configuration shown. Any miswiring or use of these
features which differs from that shown could result in damage to equipment or
property, personal injury, or loss of life. ALLISON TRANSMISSION IS NOT
LIABLE FOR THE CONSEQUENCES ASSOCIATED WITH MISWIRING
OR UNINTENDED USE OF THESE FEATURES.
OUTPUT FUNCTION D.
USES: To signal that the transmission output shaft has exceeded a specified value.
VARIABLES TO SPECIFY: Rpm to turn ON output and to turn OFF output. The ON value must be higher than
the OFF value.
VOCATIONS: Various
OPTIONAL
VIM
NC
SWITCHED
POWER
F2
30
TCM
WIRE 130
OUTPUT SPEED INDICATOR A
COM
NO
F3
D2
TRANSMISSION
OR VEHICLE
OVERSPEED
INDICATOR
OPTIONAL
CUSTOMER-FURNISHED
VIW CONNECTOR(S)
V09204.00.00
P58
3000 AND 4000 PRODUCT FAMILIES TROUBLESHOOTING MANUALALLISON 4th GENERATION CONTROLS
WARNING!
These schematics show the intended use of the specified controls features which
have been validated in the configuration shown. Any miswiring or use of these
features which differs from that shown could result in damage to equipment or
property, personal injury, or loss of life. ALLISON TRANSMISSION IS NOT
LIABLE FOR THE CONSEQUENCES ASSOCIATED WITH MISWIRING
OR UNINTENDED USE OF THESE FEATURES.
OUTPUT FUNCTION E.
USES: To signal that the transmission output shaft has exceeded a specified value.
VARIABLES TO SPECIFY: Rpm to turn ON output and to turn OFF output. The ON value must be higher than
the OFF value.
VOCATIONS: Various
SWITCHED
POWER
CUSTOMERNC FURNISHED
RELAY
COM
TCM
NO
TRANSMISSION
OR VEHICLE
OVERSPEED
INDICATOR
Relay shown
de-energized
OPTIONAL
CUSTOMER-FURNISHED
VIW CONNECTOR(S)
NOTE: The ON and OFF control values for this function may
be specified within the same range of values which are
permitted for Output Speed Indicator A. However, the
control values for this function may not be adjusted using the
Allison DOC Diagnostic Tool. Therefore, if adjustment of these
values is a desirable feature, the Output Speed Indicator A
function must be used.
V09206.00.00
P59
3000 AND 4000 PRODUCT FAMILIES TROUBLESHOOTING MANUALALLISON 4th GENERATION CONTROLS
WARNING!
WARNING!
These
These schematics
schematics show
show the
the intended
intended use
use of
of the
the specified
specified controls
controls features
features which
which
have
been
validated
in
the
configuration
shown.
Any
miswiring
have been validated in the configuration shown. Any miswiring or
or use
use of
of these
these
features
operation
of the
features which
which differs
differs from
fromthat
thatshown
showncould
couldcause
resultunscheduled
in damage to
equipment
or
PTO
or other
unpredictable
operation
damage to equipment
or
property,
personal
injury, or loss
of life. resulting
ALLISONinTRANSMISSION
IS NOT
property,
personal
injury,
or
loss
of
life.
ALLISON
TRANSMISSION
IS
NOT
LIABLE FOR THE CONSEQUENCES ASSOCIATED WITH MISWIRING
LIABLE
FOR THEUSE
CONSEQUENCES
ASSOCIATED WITH MISWIRING
OR UNINTENDED
OF THESE FEATURES.
OR UNINTENDED USE OF THESE FEATURES.
INPUT FUNCTION G.
PTO ENABLE
USES: Used with PTO Enable Input C. Permits PTO to be engaged only when engine speed and output speed are
in allowable range and throttle is low. Also disengages PTO if speeds are exceeded.
VARIABLES TO SPECIFY: Minimum and maximum engine speed for engagement, maximum engine speed for
allowable operation, minimum and maximum output speed for engagement,
maximum output speed for allowable operation.
VOCATIONS: Various (with usage of PTO)
P60
3000 AND 4000 PRODUCT FAMILIES TROUBLESHOOTING MANUALALLISON 4th GENERATION CONTROLS
WARNING!
These schematics show the intended use of the specified controls features which
have been validated in the configuration shown. Any miswiring or use of these
features which differs from that shown could result in damage to equipment or
property, personal injury, or loss of life. ALLISON TRANSMISSION IS NOT
LIABLE FOR THE CONSEQUENCES ASSOCIATED WITH MISWIRING
OR UNINTENDED USE OF THESE FEATURES.
OUTPUT FUNCTION I.
OPTIONAL
CUSTOMER-FURNISHED
VIW CONNECTOR(S)
SWITCHED
POWER
30
NC
F2
TCM
WIRE 130
ENGINE OVERSPEED
INDICATOR
COM
NO
F3
GROUND
D2
VIM
ENGINE
OVERSPEED
V09207.00.00
P61
3000 AND 4000 PRODUCT FAMILIES TROUBLESHOOTING MANUALALLISON 4th GENERATION CONTROLS
WARNING!
These schematics show the intended use of the specified controls features which
have been validated in the configuration shown. Any miswiring or use of these
features which differs from that shown could result in damage to equipment or
property, personal injury, or loss of life. ALLISON TRANSMISSION IS NOT
LIABLE FOR THE CONSEQUENCES ASSOCIATED WITH MISWIRING
OR UNINTENDED USE OF THESE FEATURES.
OUTPUT FUNCTION I.
SWITCHED
POWER
NC
COM
NO
ENGINE
OVERSPEED
SWITCHED
POWER
OPTIONAL
CUSTOMER-FURNISHED
VIW CONNECTOR(S)
WIRE 113
ENGINE OVERSPEED INDICATOR
ENGINE
OVERSPEED
13
V09208.00.00
P62
3000 AND 4000 PRODUCT FAMILIES TROUBLESHOOTING MANUALALLISON 4th GENERATION CONTROLS
WARNING!
These schematics show the intended use of the specified controls features which
have been validated in the configuration shown. Any miswiring or use of these
features which differs from that shown could result in damage to equipment or
property, personal injury, or loss of life. ALLISON TRANSMISSION IS NOT
LIABLE FOR THE CONSEQUENCES ASSOCIATED WITH MISWIRING
OR UNINTENDED USE OF THESE FEATURES.
OUTPUT FUNCTION J.
USES: Used with Two Speed Axle Enable input to provide a speed protected engagement of low axle.
VARIABLES TO SPECIFY: None
VOCATIONS: Various
P63
3000 AND 4000 PRODUCT FAMILIES TROUBLESHOOTING MANUALALLISON 4th GENERATION CONTROLS
WARNING!
OUTPUT FUNCTION K.
LOCKUP INDICATOR
USES: Turn on dash indicator when transmission lockup clutch is engaged. Used to indicate when maximum
engine braking is available.
VARIABLES TO SPECIFY: None
VOCATIONS: Various
NC
TRANSMISSION
COM
NO
SWITCHED
POWER
SWITCHED
POWER
WIRE 113
TCM
OPTIONAL
CUSTOMER-FURNISHED
VIW CONNECTOR(S)
WIRE 113
LOCKUP INDICATOR
TRANSMISSION
LOCKUP
13
NOTE: Economy legend is shown for illustrative purposes only.
Actual legend in each vehicle should describe the special characteristics
of the secondary mode shift calibration.
V09210.01.00
P64
3000 AND 4000 PRODUCT FAMILIES TROUBLESHOOTING MANUALALLISON 4th GENERATION CONTROLS
WARNING!
OUTPUT FUNCTION N.
NC
ECONOMY
COM
SWITCHED
POWER
NO
SWITCHED
POWER
WIRE 113
TCM
OPTIONAL
CUSTOMER-FURNISHED
VIW CONNECTOR(S)
WIRE 113
SECONDARY MODE INDICATOR
ECONOMY
13
NOTE: Economy legend is shown for illustrative purposes only.
Actual legend in each vehicle should describe the special characteristics
of the secondary mode shift calibration.
V09210.00.00
P65
3000 AND 4000 PRODUCT FAMILIES TROUBLESHOOTING MANUALALLISON 4th GENERATION CONTROLS
WARNING!
These schematics show the intended use of the specified controls features which
have been validated in the configuration shown. Any miswiring or use of these
features which differs from that shown could result in damage to equipment or
property, personal injury, or loss of life. ALLISON TRANSMISSION IS NOT
LIABLE FOR THE CONSEQUENCES ASSOCIATED WITH MISWIRING
OR UNINTENDED USE OF THESE FEATURES.
OUTPUT FUNCTION N.
SWITCHED
POWER
If current in lamp
circuit exceeds
0.5 amp, ground
lamp through a relay.
F2
WIRE 130
NC
COM
F3
NO
GROUND
D2
ECONOMY
OPTIONAL
VIM
Relay shown de-energized
TCM
OPTIONAL
CUSTOMER-FURNISHED
VIW CONNECTOR(S)
30
WIRE 130
SECONDARY MODE INDICATOR
ECONOMY
P66
V09211.00.00
3000 AND 4000 PRODUCT FAMILIES TROUBLESHOOTING MANUALALLISON 4th GENERATION CONTROLS
WARNING!
OUTPUT FUNCTION O.
SERVICE INDICATOR
USES: This function is required with Input Function F: Dual Input Auxiliary Function Range Inhibit to
indicate that there is a problem with the vehicle wiring for the input signal. This output signal is typically
used to turn on a dash-mounted light to indicate to the operator or service personnel to check for DTCs
stored in the ECU.
VARIABLES TO SPECIFY: None
VOCATIONS: Various
P67
3000 AND 4000 PRODUCT FAMILIES TROUBLESHOOTING MANUALALLISON 4th GENERATION CONTROLS
WARNING!
These schematics show the intended use of the specified controls features which
have been validated in the configuration shown. Any miswiring or use of these
features which differs from that shown could result in damage to equipment or
property, personal injury, or loss of life. ALLISON TRANSMISSION IS NOT
LIABLE FOR THE CONSEQUENCES ASSOCIATED WITH MISWIRING
OR UNINTENDED USE OF THESE FEATURES.
OUTPUT FUNCTION Q.
RETARDER INDICATOR
USES: Signals that the retarder is active. Typically used to turn on the vehicle brake lights when the retarder
is in use.
VARIABLES TO SPECIFY: None
VOCATIONS: Various
This function is used in conjunction with Input Function Z, Retarder Enable. Refer to
schematic for Input Function Z, noting the use of wire 125.
P68
3000 AND 4000 PRODUCT FAMILIES TROUBLESHOOTING MANUALALLISON 4th GENERATION CONTROLS
WARNING!
These schematics show the intended use of the specified controls features which
have been validated in the configuration shown. Any miswiring or use of these
features which differs from that shown could result in damage to equipment or
property, personal injury, or loss of life. ALLISON TRANSMISSION IS NOT
LIABLE FOR THE CONSEQUENCES ASSOCIATED WITH MISWIRING
OR UNINTENDED USE OF THESE FEATURES.
OUTPUT FUNCTION R.
USES: Signals the status of the differential clutch in the 3000 Product Family 7-Speed transfer case.
VARIABLES TO SPECIFY: None
VOCATIONS: Various. This function is required for all 3000 Product Family 7-Speed transmissions and used
only with that model.
P69
3000 AND 4000 PRODUCT FAMILIES TROUBLESHOOTING MANUALALLISON 4th GENERATION CONTROLS
WARNING!
WARNING!
These
These schematics
schematics show
show the
the intended
intended use
use of
of the
the specified
specified controls
controls features
features which
which
have
been
validated
in
the
configuration
shown.
Any
miswiring
have been validated in the configuration shown. Any miswiring or
or use
use of
of these
these
features
operation
of the
features which
which differs
differs from
fromthat
thatshown
showncould
couldcause
resultunscheduled
in damage to
equipment
or
PTO
or other
unpredictable
operation
damage to equipment
or
property,
personal
injury, or loss
of life. resulting
ALLISONinTRANSMISSION
IS NOT
property,
personal
injury,
or
loss
of
life.
ALLISON
TRANSMISSION
IS
NOT
LIABLE FOR THE CONSEQUENCES ASSOCIATED WITH MISWIRING
LIABLE
FOR THEUSE
CONSEQUENCES
ASSOCIATED WITH MISWIRING
OR UNINTENDED
OF THESE FEATURES.
OR UNINTENDED USE OF THESE FEATURES.
OUTPUT FUNCTION S.
USES: Provides for fast idle operation in neutral, pack-on-the-fly, and PTO engagement with overspeed
protection.
VARIABLES TO SPECIFY: Max engine rpm for PTO engagement, max engine rpm for PTO operation, max
output rpm for PTO engagement, max output rpm for PTO operation.
VOCATIONS: Refuse packer, recycling truck.
SYSTEM OPERATION
Operator selects NEUTRAL to enable fast idle.
Transmission shifts to neutral if throttle and output speed are low.
When DRIVE is re-selected, fast idle is interrupted and transmission shifts to drive if engine speed drops below
900 rpm within approximately two seconds.
SWITCHED
POWER
PTO DASH
SWITCH
WIRE 143
PTO ENABLE INPUT
WIRE 130
30
PTO ENABLE OUTPUT
WIRE 145
45
NEUTRAL INDICATOR
FOR PTO
OPTIONAL
CUSTOMER-FURNISHED
VIW CONNECTOR(S)
OPTIONAL
VIM
NC
43
TCM
F2
COM
NO
PTO
PRESSURE
SWITCH
F3
SEE NOTE **
D2
NC
A2
COM
NO
A3
FAST IDLE
CONTROL
PTO
F3
*NOTE: The fast idle solenoid must
be diode suppressed.
DASH
LIGHT
SWITCHED
POWER
* FAST IDLE
SOLENOID
Relays shown
de-energized
V09212.00.00
Figure P62. Neutral Indicator for PTO and PTO EnablePack-On-The-Fly Option
P70
3000 AND 4000 PRODUCT FAMILIES TROUBLESHOOTING MANUALALLISON 4th GENERATION CONTROLS
WARNING!
WARNING!
These
These schematics
schematics show
show the
the intended
intended use
use of
of the
the specified
specified controls
controls features
features which
which
have
been
validated
in
the
configuration
shown.
Any
miswiring
have been validated in the configuration shown. Any miswiring or
or use
use of
of these
these
features
operation
of the
features which
which differs
differs from
fromthat
thatshown
showncould
couldcause
resultunscheduled
in damage to
equipment
or
PTO
or other
unpredictable
operation
damage to equipment
or
property,
personal
injury, or loss
of life. resulting
ALLISONinTRANSMISSION
IS NOT
property,
personal
injury,
or
loss
of
life.
ALLISON
TRANSMISSION
IS
NOT
LIABLE FOR THE CONSEQUENCES ASSOCIATED WITH MISWIRING
LIABLE
FOR THEUSE
CONSEQUENCES
ASSOCIATED WITH MISWIRING
OR UNINTENDED
OF THESE FEATURES.
OR UNINTENDED USE OF THESE FEATURES.
OUTPUT FUNCTION S.
USES: Provides for fast idle operation in neutral, and PTO engagement with overspeed protection.
VARIABLES TO SPECIFY: Max engine rpm for PTO engagement, max engine rpm for PTO operation, max
output rpm for PTO engagement, max output rpm for PTO operation.
VOCATIONS: Refuse packer, recycling truck.
SYSTEM OPERATION
Operator selects NEUTRAL to enable fast idle.
Transmission shifts to neutral if throttle and output speed are low.
When DRIVE is re-selected, fast idle is interrupted and transmission shifts to drive if engine speed drops below
900 rpm within approximately two seconds.
43
30
SWITCHED POWER
WIRE 143
PTO ENABLE INPUT
PTO
PRESSURE
SWITCH
PTO SWITCH
WIRE 130
PTO ENABLE OUTPUT
OPTIONAL VIM
NC
F2
45
TCM
OPTIONAL
CUSTOMER-FURNISHED
VIW CONNECTOR(S)
WIRE 145
NEUTRAL
INDICATOR
FOR PTO
COM
F3
NO
D2
GROUND
* FAST IDLE
SOLENOID
NC
A2
F3
FAST
IDLE
CONTROL
PTO
COM
A3
NO
SWITCHED
POWER
SEE NOTE *
NOTE*: Typical engine "Fast Idle" control system. Actual configuration may
vary from that shown. Consult the engine manufacturer.
V09213.00.00
Figure P63. Neutral Indicator for PTO and PTO EnableNeutral Operation Only
P71
3000 AND 4000 PRODUCT FAMILIES TROUBLESHOOTING MANUALALLISON 4th GENERATION CONTROLS
P72
3000 AND 4000 PRODUCT FAMILIES TROUBLESHOOTING MANUALALLISON 4th GENERATION CONTROLS
RESISTANCE-TEMPERATURE
CHARACTERISTIC CHART
1,000,000
SENSOR RESISTANCE ()
100,000
10,000
1,000
100
10
1
40
10
20
50
40
14
68
122
80
110
140
170
200
176
230
284
338
392
TEMPERATURE
Negative Temperature Coefficient Sensor Retarder
Negative Temperature Coefficient Sensor Sump
V04711.01.00
NOTE:
Look carefully at the graph. The scale for the resistance (on the left side) is not constant (linear). It is
logarithmic which means it can display a great range of values within a small space. Each section of
the graph is ten units, but the units vary from 1 to 100,000 Ohms. The range of resistance for the old
thermistor is very small when compared with that of the new thermistors.
The following table shows the range of resistance values that correspond to either retarder or sump fluid
temperature shown in one degree increments over the operating range of the thermistors.
Q1
3000 AND 4000 PRODUCT FAMILIES TROUBLESHOOTING MANUALALLISON 4th GENERATION CONTROLS
40
39
38
37
36
35
34
33
32
31
30
29
28
27
26
25
24
23
22
21
20
19
18
17
16
15
14
Q2
40
38.2
36.4
34.6
32.8
31
29.2
27.4
25.6
23.8
22
20.2
18.4
16.6
14.8
13
11.2
9.4
7.6
5.8
4
2.2
0.4
1.4
3.2
5
6.8
Lo
Ohms
352399
329878
308936
289453
271318
254431
238698
224033
210358
197600
185693
174574
164188
154480
145404
136915
128971
121534.6
114569.9
108044.7
101928.7
96194
90814.8
85767
81028.5
76578.5
72397.9
Nom
Ohms
402392
376270
352005
329454
308486
288981
270827
253923
238177
223501
209817
197053
185140
174018
163630
153923
144848
136360.5
128419.6
120987
114027.2
107507.5
101397.8
95669.8
90297.8
85257.7
80527.1
Sump Thermistor
Hi
Ohms
452385
422662
395074
369456
345655
323531
302956
283814
265995
249402
233941
219531
206093
193556
181856
170930
160724
151188
142269.4
133929.3
126125.7
118821
111980.7
105572.7
99567.2
93937
88656.4
Degree Degree
C
F
50
49
48
47
46
45
44
43
42
41
40
39
38
37
36
35
34
33
32
31
30
29
28
27
26
25
24
23
22
21
20
19
18
17
16
15
14
58
56.2
54.4
52.6
50.8
49
47.2
45.4
43.6
41.8
40
38.2
36.4
34.6
32.8
31
29.2
27.4
25.6
23.8
22
20.2
18.4
16.6
14.8
13
11.2
9.4
7.6
5.8
4
2.2
0.4
1.4
3.2
5
6.8
Lo
Ohms
Nom
Ohms
Hi
Ohms
182288
169859
158357
147708
137844
128702
120224
112359
105057
98276
95956
89769
84019
78674
73701
69073
64764
60749
57008
53520
50266
47229
44394
41746
39271
36958
34794
32770
30875
29101
27439
25881
24420
23051
21766
20660
19427
202642
188561
175549
163519
152390
142089
132550
123711
115517
107917
100865
94317
88235
82582
77326
72437
67886
63649
59702
56024
52594
49394
46408
43620
41016
38583
36308
34181
32190
30327
28582
26948
25417
23981
22634
21371
20185
226183
210206
195459
181840
169255
157621
146860
136900
127678
119134
107181
100181
93681
87642
82030
76811
71956
67497
63228
59308
55654
52247
49069
46102
43332
40745
38328
36088
33954
31976
30125
28391
26767
25245
23818
22480
21225
3000 AND 4000 PRODUCT FAMILIES TROUBLESHOOTING MANUALALLISON 4th GENERATION CONTROLS
8.6
10.4
12.2
14
15.8
17.6
19.4
21.2
23
24.8
26.6
28.4
30.2
32
33.8
35.6
37.4
39.2
41
42.8
44.6
46.4
48.2
50
51.8
53.6
55.4
57.2
59
60.8
62.6
64.4
66.2
68
69.8
71.6
73.4
75.2
Sump Thermistor
Lo
Ohms
Nom
Ohms
Hi
Ohms
68469
64775.3
61301.3
58033
54956.9
52060.8
49333.13
46763.28
44341.27
42057.81
39904.26
37872.55
35955
34145.1
32430
30810
29282
27838
26474
25184
23965
22813
21722
20690
19712
18787
17910
17079
16292
15545
14836.8
14164.8
13527
12921.4
12346.4
11800.1
11281
10787.6
76085.4
71913.4
67993.3
64308.5
60843.6
57584.4
54517.51
51630.64
48912.25
46351.65
43938.84
41664.54
39520
37497.4
35590
33790
32092
30490
28976
27547
26197
24920
23713
22572
21492
20469
19502
18585
17717
16894
16113.8
15374.1
14672.6
14006.9
13375.1
12775.3
12205.7
11664.6
83701.9
79051.6
74685.3
70584
66730.3
63108
59701.9
56498
53483.24
50645.49
47973.42
45456.53
43085
40850
38750
36770
34903
33142
31479
29910
28428
27028
25704
24454
23271
22152
21093
20091
19141
18242
17391
16583.5
15818.2
15092.4
14403.8
13750.5
13130.3
12541
Degree Degree
C
F
13
12
11
10
9
8
7
6
5
4
3
2
1
0
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
8.6
10.4
12.2
14
15.8
17.6
19.4
21.2
23
24.8
26.6
28.4
30.2
32
33.8
35.6
37.4
39.2
41
42.8
44.6
46.4
48.2
50
51.8
53.6
55.4
57.2
59
60.8
62.6
64.4
66.2
68
69.8
71.6
73.4
75.2
Lo
Ohms
Nom
Ohms
Hi
Ohms
18363
17363
16424
15540
14709
13927
13190
12497
11844
11228
10648
10101
9585
9098
8638
8203
7793
7406
7041
6696
6369
6061
5769
5493
5231
4984
4750
4528
4318
4118
3929
3750
3580
3418
3265
3120
2981
2850
19072
18026
17043
16120
15251
14434
13666
12942
12261
11619
11014
10444
9906
9399
8921
8470
8044
7643
7263
6905
6567
6247
5944
5658
5387
5131
4888
4659
4441
4235
4039
3854
3678
3511
3353
3202
3060
2924
20046
18940
17900
16924
16006
15143
14331
13567
12848
12171
11533
10932
10365
9831
9329
8854
8407
7985
7587
7211
6855
6519
6202
5902
5618
5349
5095
4854
4626
4410
4205
4011
3827
3653
3487
3330
3180
3039
Q3
3000 AND 4000 PRODUCT FAMILIES TROUBLESHOOTING MANUALALLISON 4th GENERATION CONTROLS
77
78.8
80.6
82.4
84.2
86
87.8
89.6
91.4
93.2
95
96.8
98.6
100.4
102.2
104
105.8
107.6
109.4
111.2
113
114.8
116.6
118.4
120.2
122
123.8
125.6
127.4
129.2
131
132.8
134.6
136.4
138.2
140
141.8
143.6
Sump Thermistor
Lo
Ohms
Nom
Ohms
Hi
Ohms
10318.5
9872.4
9448
9755.2
8659.8
8293.8
7945.3
7613.3
7296.91
6995.38
6707.92
6433.8
6172.32
5922.86
5685
5457.5
5241
5033
4835
4646
4465
4293
4127
3969
3818
3673
3535
3403
3276
3155
3039
2928
2821
2718.9
2621.1
2527.2
2437.3
2351
11150.4
10661.7
10197.1
9755.2
9334.9
8934.9
8554.2
8191.7
7846.57
7517.77
7204.5
6905.92
6621.29
6349.87
6091
5844
5608
5383
5169
4963
4768
4580
4402
4231
4067
3911
3761
3619
3482
3352
3227
3107
2992
2882.4
2777.3
2676.5
2579.9
2487.3
11982.3
11451
10946.1
10466.2
10009.9
9575.9
9163.1
8770.2
8396.2
8040.17
7701.07
7378.04
7070.25
6776.89
6497
6231
5976
5733
5502
5281
5070
4868
4676
4492
4316
4148
3988
3835
3688
3548
3414
3286
3163
3046
2933.5
2825.7
2722.5
2623.6
Degree Degree
C
F
25
26
27
28
29
30
31
32
33
34
35
36
37
38
39
40
41
42
43
44
45
46
47
48
49
50
51
52
53
54
55
56
57
58
59
60
61
62
77
78.8
80.6
82.4
84.2
86
87.8
89.6
91.4
93.2
95
96.8
98.6
100.4
102.2
104
105.8
107.6
109.4
111.2
113
114.8
116.6
118.4
120.2
122
123.8
125.6
127.4
129.2
131
132.8
134.6
136.4
138.2
140
141.8
143.6
Lo
Ohms
Nom
Ohms
Hi
Ohms
2725
2606
2493
2385
2282
2185
2092
2003
1919
1839
1763
1690
1620
1554
1491
1430
1373
1318
1265
1215
1167
1122
1078
1036
996.3
958.1
921.6
886.7
853.3
821.4
790.8
761.5
733.5
706.6
680.9
656.2
632.6
609.9
2795
2673
2556
2445
2340
2240
2144
2053
1967
1884
1806
1731
1660
1592
1527
1465
1406
1349
1296
1244
1195
1148
1103
1060
1019
980.3
942.9
907.1
872.9
840.1
808.8
778.8
750
722.5
696.2
670.9
646.7
623.5
2904
2776
2655
2540
2430
2326
2227
2132
2043
1957
1875
1797
1723
1653
1585
1521
1459
1401
1345
1291
1240
1192
1145
1100
1058
1017
978.4
941.4
905.9
871.9
839.4
808.3
778.5
750
722.7
696.5
671.4
647.3
3000 AND 4000 PRODUCT FAMILIES TROUBLESHOOTING MANUALALLISON 4th GENERATION CONTROLS
145.4
147.2
149
150.8
152.6
154.4
156.2
158
159.8
161.6
163.4
165.2
167
168.8
170.6
172.4
174.2
176
177.8
179.6
181.4
183.2
185
186.8
188.6
190.4
192.2
194
195.8
197.6
199.4
201.2
203
204.8
206.6
208.4
210.2
212
Sump Thermistor
Lo
Ohms
Nom
Ohms
Hi
Ohms
2268.2
2188.8
2112.5
2039.3
1969.1
1901.6
1836.8
1774.5
1714.6
1657.1
1601.8
1548.65
1497.52
1448.33
1401.01
1355.47
1311.65
1269
1228.3
1190
1152
1116
1081
1047
1015
983
953
924
896
869
843
817
793
769
747
725
703.6
683.2
2398.5
2313.4
2231.7
2153.3
2078.1
2005.9
1936.6
1870
1806.1
1744.6
1685.6
1628.89
1574.36
1521.94
1471.52
1423.03
1376.38
1331
1288.3
1247
1207
1168
1131
1095
1061
1028
996
965
935
906
879
852
826
801
777
754
731.8
710.2
2528.8
2438
2350.8
2267.3
2187.1
2110.2
2036.4
1965.5
1897.5
1832.2
1769.4
1709.1
1651.21
1595.54
1542.03
1490.58
1441.11
1394
1348
1304
1261
1220
1181
1143
1107
1072
1038
1005
974
944
915
886
859
833
808
784
760
737.3
Degree Degree
C
F
63
64
65
66
67
68
69
70
71
72
73
74
75
76
77
78
79
80
81
82
83
84
85
86
87
88
89
90
91
92
93
94
95
96
97
98
99
100
145.4
147.2
149
150.8
152.6
154.4
156.2
158
159.8
161.6
163.4
165.2
167
168.8
170.6
172.4
174.2
176
177.8
179.6
181.4
183.2
185
186.8
188.6
190.4
192.2
194
195.8
197.6
199.4
201.2
203
204.8
206.6
208.4
210.2
212
Lo
Ohms
Nom
Ohms
Hi
Ohms
588.2
567.4
547.4
528.2
509.8
492.1
475.2
458.9
443.2
428.2
413.7
399.8
386.5
373.6
361.3
349.4
338
327
316.4
306.2
296.4
288.9
277.8
269
260.5
253.3
244.3
236.7
229.4
222.3
215.5
208.9
202.5
196.4
190.5
184.8
179.2
173.9
601.2
579.9
559.4
539.8
520.9
502.8
485.4
468.7
452.7
437.3
422.5
408.3
394.6
381.5
368.9
356.7
345
333.8
322.9
312.5
302.5
292.8
283.5
274.5
265.9
257.6
249.5
241.8
234.4
227.2
220.2
213.5
207.1
200.9
194.8
189
183.4
178
624.2
602.1
580.8
560.5
540.9
522.2
504.1
486.8
470.2
454.2
438.9
424.1
410
396.3
383.2
370.6
358.5
346.8
335.6
324.7
314.3
304.3
294.6
285.4
276.5
268
259.7
251.7
244
236.6
229.5
222.6
215.9
209.5
203.3
197.3
191.5
185.9
Q5
3000 AND 4000 PRODUCT FAMILIES TROUBLESHOOTING MANUALALLISON 4th GENERATION CONTROLS
213.8
215.6
217.4
219.2
221
222.8
224.6
226.4
228.2
230
231.8
233.6
235.4
237.2
239
240.8
242.6
244.4
246.2
248
249.8
251.6
253.4
255.2
257
258.8
260.6
262.4
264.2
266
267.8
269.6
271.4
273.2
275
276.8
278.6
280.4
Sump Thermistor
Lo
Ohms
Nom
Ohms
Hi
Ohms
663.4
644.4
626
608.2
591
574.3
558.2
542.6
527.6
513
498.8
485.2
471.9
459.1
446.73
434.72
423.08
411.8
400.88
390.29
380
370.1
360
351
342
333
325
316
308
301
293
286
279
272
265
258
252
246
689.4
669.3
649.8
631.1
612.9
595.4
578.4
562.1
546.2
530.9
516.1
501.8
487.9
474.5
461.51
448.95
436.79
425.02
413.61
402.57
392
381.5
371
362
352
343
334
326
317
309
302
294
287
279
272
266
259
253
715.3
694.1
673.7
653.9
634.9
616.5
598.7
581.5
564.9
548.8
533.3
518.3
503.9
489.8
476.3
463.18
450.5
438.23
426.35
414.86
404
393
383
372
363
353
344
335
326
318
310
302
294
287
280
273
266
260
Degree Degree
C
F
101
102
103
104
105
106
107
108
109
110
111
112
113
114
115
116
117
118
119
120
121
122
123
124
125
126
127
128
129
130
131
132
133
134
135
136
137
138
213.8
215.6
217.4
219.2
221
222.8
224.6
226.4
228.2
230
231.8
233.6
235.4
237.2
239
240.8
242.6
244.4
246.2
248
249.8
251.6
253.4
255.2
257
258.8
260.6
262.4
264.2
266
267.8
269.6
271.4
273.2
275
276.8
278.6
280.4
Lo
Ohms
Nom
Ohms
Hi
Ohms
168.8
163.8
159
154.4
149.9
145.6
141.4
137.4
133.5
129.7
126.1
122.6
119.2
115.9
112.7
109.6
106.6
103.7
100.91
98.2
95.58
93.04
90.58
88.2
85.89
83.65
81.49
79.38
77.35
75.37
73.46
71.6
69.8
68.05
66.35
64.7
63.11
61.56
172.8
167.8
162.9
158.2
159.6
149.2
145
140.9
136.9
133.1
129.4
125.8
122.3
118.9
115.7
112.5
109.5
106.5
103.7
100.9
98.23
95.63
93.12
90.68
88.32
86.03
83.8
81.65
79.56
77.54
75.58
73.67
71.82
70.03
68.29
66.6
64.96
63.37
180.5
175.3
170.3
165.4
160.7
156.2
151.8
147.5
143.4
139.4
135.6
131.9
128.2
124.8
121.4
118.1
114.9
111.9
108.9
106
103.2
100.5
97.9
95.36
92.9
90.51
88.19
85.95
83.77
81.65
79.6
77.61
75.68
73.8
71.98
70.21
68.5
66.83
3000 AND 4000 PRODUCT FAMILIES TROUBLESHOOTING MANUALALLISON 4th GENERATION CONTROLS
282.2
284
285.8
287.6
289.4
291.2
293
294.8
296.6
298.4
300.2
302
303.8
305.6
307.4
309.2
311
312.8
314.6
316.4
318.2
320
321.8
323.6
325.4
327.2
329
330.8
332.6
334.4
336.2
338
339.8
341.6
343.4
345.2
347
348.8
Sump Thermistor
Lo
Ohms
Nom
Ohms
Hi
Ohms
240
234.2
228.6
223.1
217.8
212.6
207.6
202.7
197.9
193.3
188.8
184.4
180.2
176
172
168.1
164.3
160.54
156.93
153.42
150.01
146.68
143.43
140
137.2
134
131
128
126
123
120
118
115
113
10
108
106
104
247
240.6
234.8
229.2
223.7
218.4
213.2
208.1
203.2
198.5
193.9
189.4
185
180.7
176.6
172.6
168.6
164.84
161.13
157.53
154.01
150.6
147.27
144
140.9
138
135
132
129
126
124
121
118
116
113
111
109
107
253
247
241.1
235.2
229.6
224.1
218.8
213.6
208.5
203.7
198.9
194.3
189.8
185.4
181.2
177.1
173
169.1
165.33
161.63
158.02
154.51
151.1
148
145
141
138
135
132
130
127
124
122
119
117
114
112
109
Degree Degree
C
F
139
140
141
142
143
144
145
146
147
148
149
150
282.2
284
285.8
287.6
289.4
291.2
293
294.8
296.6
298.4
300.2
302
Lo
Ohms
Nom
Ohms
Hi
Ohms
60.05
58.59
57.17
55.79
54.45
53.15
51.89
50.66
49.47
48.31
47.18
46.09
61.82
60.32
58.86
57.45
56.07
54.73
53.43
52.17
50.94
49.75
48.59
47.46
65.21
63.64
62.11
60.63
59.18
57.78
56.42
55.09
53.81
52.55
51.34
50.15
Q7
3000 AND 4000 PRODUCT FAMILIES TROUBLESHOOTING MANUALALLISON 4th GENERATION CONTROLS
Q8
350.6
352.4
354.2
356
357.8
359.6
361.4
363.2
365
366.8
368.6
370.4
372.2
374
375.8
377.6
379.4
381.2
383
384.8
386.6
388.4
390.2
392
393.8
395.6
397.4
399.2
Sump Thermistor
Lo
Ohms
Nom
Ohms
Hi
Ohms
101
99
97
95
93.4
91.5
89.6
87.8
86.1
84.3
82.7
81
79.4
77.8
76.3
74.8
73.4
71.9
70.5
69.2
67.84
66.54
65.27
64.03
62.82
61.64
60.00
59.30
104
102
100
98
96.1
94.1
92.3
90.4
88.6
86.8
85.1
83.4
81.8
80.2
78.7
77.1
75.6
74.2
72.8
71.4
70.02
68.70
67.41
66.14
64.91
63.70
63.00
61.40
107
105
103
101
99
96.8
94.9
93
91.1
89.4
87.6
85.9
84.2
82.6
81
79.4
77.9
76.4
75
73.6
72.20
70.86
69.54
68.25
65.99
65.76
65.00
63.00
Degree Degree
C
F
Lo
Ohms
Nom
Ohms
Hi
Ohms
3000 AND 4000 PRODUCT FAMILIES TROUBLESHOOTING MANUALALLISON 4th GENERATION CONTROLS
+
CAN
J1939
DATALINK
WIRE 128
28
(CAN +)
WIRE 108
(CAN )
WIRE 149
49
TCM
(TERMINATION
RESISTOR)
WIRE 107
(SHIELD)
WIRE 148
48
(CAN +)
WIRE 168
68
(CAN )
V09215.00.00
CAN LOW
(PIN A TYPICALLY GREEN)
INSULATION
FOIL SHIELD
OUTER COVER
DRAIN WIRE
(PIN C)
PIPING
(MAINTAINS WIRE TWIST)
CAN HIGH
(PIN B TYPICALLY YELLOW)
V08747.00.01
* NOTE: On Allison 4th Generation Controls Systems, off-board communications are only enabled via J1939.
R1
3000 AND 4000 PRODUCT FAMILIES TROUBLESHOOTING MANUALALLISON 4th GENERATION CONTROLS
J1939 networks are laid out in a linear fashion, consisting of a central backbone with stubs branching off to
individual controllers or nodes (refer to Figure R3).
Regardless of the cable used, two 120 Ohm termination resistors are required, one at each end of the backbone
cable (refer to Figure R4). These resistors may be built into a receptacle connector or plug connector that contains
a blue wedge lock.
Stubs must be
spaced at least
10 cm apart
UNUSED
STUB
R2
V08750.00.00
3000 AND 4000 PRODUCT FAMILIES TROUBLESHOOTING MANUALALLISON 4th GENERATION CONTROLS
V08749.00.00
Typically, all connectors on the backbone and stubs are of the plug type. However, receptacle connectors may
be used in some installations. Stubs and nodes use orange or green wedge locks.
The backbone may be no longer than 40 meters in length. A stub includes the length of wiring on the node, and the
length from the backbone to the node must be one meter or less.
Figure R3 shows a typical J1939-11 network cable configuration including controllers, or nodes. The connector
for the Allison controller is a 3-way connector configured as follows (refer to Figure R5):
Terminal A = CAN High
Terminal B = CAN Low
Terminal C = CAN Shield.
Typically CAN High is a yellow wire and CAN Low is a green wire.
A or H
B or L
C or S
V08751.00.00
R3
3000 AND 4000 PRODUCT FAMILIES TROUBLESHOOTING MANUALALLISON 4th GENERATION CONTROLS
F
G
C
A B
J
A =
B =
C =
D =
E =
F =
G =
H&J =
GROUND
+12 VOLT (UNSWITCHED)
J1939 HIGH (YELLOW)
J1939 LOW (GREEN)
J1939 SHIELD
JI587 + (TYP. BLUE)
J1587 (TYP. WHITE)
OEM USE
V08752.00.00
Troubleshooting
In terms of J1939 communication, Allison Transmission is only responsible for the Allison TCM hardware,
software, and calibration. Wiring issues belong solely to the vehicle manufacturer. The responsibility for putting
valid data on the datalink, and properly using the data obtained from the datalink, belongs to each component
supplier with a device connected to the datalink.
R4
3000 AND 4000 PRODUCT FAMILIES TROUBLESHOOTING MANUALALLISON 4th GENERATION CONTROLS
Termination Resistors
A J1939 network requires a 120 Ohm termination resistor at each end of the backbone (refer to Figure R3). With
all controllers powered off and both termination resistors in place, an ohmmeter should read 60 Ohms across
terminals A and B of the 3-way connector (refer to Figure R5), or Terminals C and D of the 9-way connector
(refer to Figure R6). The test can be performed with controllers connected to the backbone because the impedance
at the controllers is much higher than 60 Ohms and therefore does not affect the reading.
A measurement of 120 Ohms typically indicates that either one of the two termination resistors is not in place, or
there is an open somewhere in the backbone of the network.
A measurement of 0 (zero) Ohms indicates that there is a short between the CAN high and CAN low wires of the
network. The short may be in the backbone itself, or in one of the stubs connecting it to a controller.
Open Circuits
Open circuits in the CAN High (A) or CAN Low (B) sides of the backbone or in any of the stubs can affect one or
more controllers on the network. While an open circuit in a stub will have the most impact on the controller
attached to that stub, other devices on the network who normally receive information or expect a response from
that controller will be impacted as well.
When there are multiple nodes attached to the network, and their connectors are accessible, an open circuit can be
tracked by moving down the backbone from stub to stub looking at the datalink information present at each
connector. When there is a difference in the amount of datalink traffic between two connection points, there is
Copyright 2008 Allison Transmission, Inc.
R5
3000 AND 4000 PRODUCT FAMILIES TROUBLESHOOTING MANUALALLISON 4th GENERATION CONTROLS
Short Circuits
A short circuit can occur in the J1939 backbone or stubs between:
CAN high and CAN low
CAN high or CAN low and battery voltage
CAN high or CAN low and ground
When a short circuit is present, typically multiple controllers on the network indicate an error of some sort, due to
the loss of all communication between any of the nodes. For example, datalink-based instrument clusters will not
function properly. Short circuits typically fall into one of the following categories:
Mechanical failureInsulation cut or scraped through, wires pinched, etc.
Incorrectly wired pins on one or more of the controllers
Missing connector seal(s), allowing water intrusion.
Inducted Noise
Inducted noise tends to be a much greater issue when J1939-15 (unshielded) cable is used. While the following
routing tips are a good idea for shielded networks, they are critical when unshielded cable is used. J1939-15 cable
routing must avoid the following by a minimum of 3 to 4 inches of physical separation:
Solenoids
Alternator
Flasher modules
High output CB radio
Starter motor
Relays
Any high-current switching device.
Inducted noise is typically event driven, or associated with an activity that involves operation of a high-current
load near the network wiring. For example, everytime I use my left turn signal, the ABS lamp acts up...
To find noise sources, monitor datalink traffic under the following conditions:
With the key switch on: Operate every input the driver has access to, such as the CB, blower motors,
fans, air conditioning, flashers, turn signals, lights, horn, brakes, etc.
With the engine running: Exercise every function on the vehicle as is possible, such as engaging the
engine fan, turning on the air conditioning compressor, operating the dump bed, etc.
If errors or pauses in datalink traffic are noted during any specific activity, investigate the network wiring near the
associated component(s).
Calibrations
After wiring, calibrations are the number two cause of problems in the field. Inappropriate calibration changes in
the field can affect the operation of the Allison transmission, or the entire vehicle.
If a particular transmission or vehicle function worked prior to a calibration update of one of the controllers on the
J1939 datalink, but does not function properly afterwards, it is likely that a customer-programmable value was
changed on one or more controllers during the update. The same situation can exist for software upgrades, as well.
R6
3000 AND 4000 PRODUCT FAMILIES TROUBLESHOOTING MANUALALLISON 4th GENERATION CONTROLS
on the vehicle were connected to the J1939 datalink. In this case, Allison DOC For PCService Tool
can be used to reset the auto-detection process.
A calibration was constructed with an incorrect datalink package as specified in the Production
Calibration Configuration System (PCCS). In this case, a new calibration with the correct package will
have to be made. Table R1 illustrates Allison J1939 broadcast and receive parameters versus PCCS
datalink package.
Outside of the Allison TCM programming, engine TCM programming can have the greatest affect on transmission
operation. Electronic engines typically have many customer programmable items that can affect transmission
operation, such as:
Transmission type set incorrectly
Incompatible engine governor selected
Engine brake (compression or exhaust) options set incorrectly
J1939 communication not activated.
Tables R1 through R4, on the following pages, provide an overview of J1939 messages and parameters sent and
received by Allison 4th Generation Controller System. Support varies versus the datalink package in PCCS. Refer
to Datalink Tech Data for details.
Table R1. J1939 BroadcastsTCM
PGN
SA
Rate
Byte Bits
Parameters Sent
Remarks
ON
ON
00000 TSC1
03
12.5 MS
03
As Reqd
13
61184 Proprietary A
03
100 ms
18
61440 ERC1
16
100 ms
ON e
ON e
ON e
ON e
ON e
ON e
6,5
Shift in Progress
ON
4,3
ON
2,1
Driveline Engaged
ON
2,3
ON
61442 ETC1
03
12.5 ms
4,3
ON
6,7
ON
R7
3000 AND 4000 PRODUCT FAMILIES TROUBLESHOOTING MANUALALLISON 4th GENERATION CONTROLS
SA
03
Rate
100 ms
61452 ETC8
03
Varies2
65098 ETC7
03
100 ms
Byte Bits
03
65226 DM1
03 or 1000 ms
16 when
active
65242 SOFT
65249 RCFG
65250 TCFG
65259 CI
65272 TF
65275 RF
R8
03
16
03
03
03
16
Varies
Request
ON
2,3
ON
ON
5,6
ON
7,8
ON
1,2
8,7
ON
6,5
ON
8,7
ON
6,5
ON
4,3
ON
8,7
ON
6,5
ON
2,1
ON
8,7
ON
1,2
ON
4,3
ON
j
j
ON
ON
ON
2N
Software Identification
ON
At power
85 Retarder Location
1
up, on re41 Retarder Type
quest, and
2
Retarder Control Method
on 10%
j Torque and Speed Map (See text for details)
map
change
17,18 Reference Retarder Torque
Request
Request
Request
1000 ms
Remarks
65099 TCFG2
Parameters Sent
ONe
ONe
ONe
ONe
ONe
ON
ON
ON
15
Make
ON
Model
ON
5,6
ON
ONf
ONf
ONf
ONe
3000 AND 4000 PRODUCT FAMILIES TROUBLESHOOTING MANUALALLISON 4th GENERATION CONTROLS
Rate
Byte Bits
50 ms
3
6
61440 ERC1
100 ms
61444 EEC1
100 ms
Varies With
Engine
Speed
50 ms
05, 06
8,7
Transmission Mode 4
05, 06
4,3
Transmission Mode 2
33
8,7
05, 06
6,5
15, 41, 33
33
6,5
11
2,1
11
33, 00g
4-1
00
00
00
00
8
61443 EEC2
Remarks
33, 17, 00, 11, 39i
7
61441 EBC1
Parameters Sent
1
2
00
6,5
00
4,3
AL Kickdown Switch
00
1,2
00
65214 EEC4
Request
1,2
Rated Power
00
65247 EEC3
250 ms
00
00
65249 RCFG
Request
17,18
65251 ECFG
5000 ms
and on
request
20,21
00
31,32
Engine Inertia
00
33,34
00
Request
15
Make
00
Model
00
00
65259 C1
65262 ET
1S
65265 CCVS
100 ms
2, 3
00
6, 5 Brake Switch
51 PTO State
00
R9
3000 AND 4000 PRODUCT FAMILIES TROUBLESHOOTING MANUALALLISON 4th GENERATION CONTROLS
SA
05
06
Rate
Byte Bits
50 ms
7
60928 Address
Claimed
05
06
As Reqd
652421 Soft
05
06
Request
Parameters Sent
Transmission Requested Gear
ON
8,7
Transmission Mode 4
ON
8,7
ON
th
Remarks
2N
ON
ON
Software Identification
ON
Byte
Bits
Varies
13
03
61184 Proprietary A
100 ms
18
65098 ETC7
100 ms
Rate
Parameters Sent
Remarks
03
4,3
03
2,1
03
Footnotes:
c
d
Only broadcast in applications where the presence of an Allison driveline retarder has been auto-detected or
forced ON via calibration.
Only broadcast in applications where the presence of an Allison oil level sensor has been auto-detected or
forced ON via calibration.
Of the listed acceptable source addresses, the TCM locks onto the most preferred source, as determined by
auto-detect logic.
h
i
j
This parameter is calibration dependent and may not be present on the Datalink.
R10
25 ms when torque converter active, 100 ms when torque converter is in lockup. TCM does not support
SAE-specified broadcast rate of 20 ms.
TCM supports reception from all acceptable source addresses, not just one.
TCM can support reception from more than one acceptable source address in a given installation.