AES-204 RevB - SBW & SBW II Re-Calibration Procedure 4-26-2013

Shift By Wire (SBW & SBW II) Actuator

Re-Calibration Procedure

For Allison 1000 - 2000 Series Transmissions

AES-204

Horizontally Mounted Actuator Vertically Mounted Actuator

14553 B Added Page 2 4/26/2013 John Maher

14355 A Released 5/1/2012 Don Krueger
ECN REV REVISION RECORD DATE ENGINEER

Actuator Re-Calibration Instructions

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 AES-204 RevB - SBW & SBW II Re-Calibration Procedure 4-26-2013

Hardware used during this Re-Calibration Procedure.

Actuator Re-Calibration Instructions

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 AES-204 RevB - SBW & SBW II Re-Calibration Procedure 4-26-2013

Bench Testing the Actuator:

CAUTION:
Do not connect the Actuator to a power supply unless it is completely installed on the transmission. If
power is connected to an Actuator that is not completely installed on the transmission, the sensor will not
function properly and the motor may be damaged.
Failure to do so may result in injury or death.

• The Actuator should not be removed from the

vehicle and “bench tested”.

• If the Actuator is removed from the vehicle and

power is applied the sensor will not function
properly and the motor may be damaged.

• All tests relating to the Actuator require it to be

completely installed on the vehicle, and all
connections securely made to the Controller.

Actuator Re-Calibration Instructions

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 AES-204 RevB - SBW & SBW II Re-Calibration Procedure 4-26-2013

There are two important points to note before re-calibrating:

1) Does the Horizontal or Vertical orientation matter?

Horizontal Mounting Vertical Mounting

The Procedure is the same for the Horizontal and Vertical Mounted Actuators. When there is a variation
or modification in the procedure, the steps are clearly identified as ‘Horizontal Mount’ or ‘Vertical
Mount’.

2) Some Allison Transmissions, known as Pre-Gen 4 Models,

have an external Neutral-Start-Backup (NSBU) Assembly.
Will this impact the Re-Calibration Procedure?
No, you will not need to adjust the NSBU Assembly
found on the Pre-Gen 4 versions of the Allison
Transmission.

NSBU Connector shown with Horizontal Mounting. NSBU Connector show with Vertical Mounting.

Actuator Re-Calibration Instructions

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 AES-204 RevB - SBW & SBW II Re-Calibration Procedure 4-26-2013

Re-Calibration Procedure
This is the SBW Re-Calibration Procedure for actuators that are already installed onto vehicles. Note: If this is
a “first time” installation or a replacement of a new actuator, please refer to Arens Controls AES-203
Installation Procedure.

WARNING
If the transmission is installed in a chassis, do the following:
a) Park the vehicle on level ground.
b) Set the emergency brake.
c) Chock/block the tires to prevent the vehicle from moving unexpectedly.
d) Turn off the engine.
Failure to follow these steps could result in serious injury or death.

1. Remove these three screws holding the

cover plate on the actuator, shown in
Figure #1. Set aside the cover, screws,
and O-Ring.

Figure # 1

2. Loosen the socket head cap screw,

located in the center of the cap nut, one
or two turns but do not remove it.

Figure #2

Actuator Re-Calibration Instructions

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 AES-204 RevB - SBW & SBW II Re-Calibration Procedure 4-26-2013

3. Loosen and remove the cap nut, as shown in Figure #3,

and set aside.

Figure #3

4. Remove these four socket head cap screws that hold the
Shift Shaft Adapter in place, as shown in Figure #4.

If the Shift Shaft Adapter is stuck on the Transmission

Selector Shaft, use two long #10-32 screws (not
supplied) to help with removal. Insert the two long #10-
32 screws into these holes on the Shift Shaft Adapter
(see Illustration #1). The screws will act as a “puller”,
and help remove the Shift Shaft Adapter from the
Transmission Selector Shaft. Remove these two screws
after the Shift Shaft Adapter has been removed.

Figure #4

Illustration #1

Actuator Re-Calibration Instructions

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 AES-204 RevB - SBW & SBW II Re-Calibration Procedure 4-26-2013

WARNING
Before moving on to the next part of the Re-Calibration Procedure, be sure that you have:
a) Parked the vehicle on level ground.
b) Set the emergency brake.
c) Chocked/blocked the tires to prevent the vehicle from moving unexpectedly.
d) Turned off the engine.
Failure to follow these steps could result in serious injury or death.

5. Move up into the cab of the vehicle and turn the ignition ON, but do not engage the starter, leaving the
engine OFF. Select NEUTRAL, then REVERSE, then NEUTRAL again. This will ensure that the Actuator
is in the Neutral position.
6. Check that the Transmission is in NEUTRAL by “bumping’ the starter with the ignition switch. If the
transmission is in NEUTRAL the starter will engage. If the Transmission is not in NEUTRAL the starter will
not engage.
7. If the transmission is not in NEUTRAL, perform the following steps:
A. IMPORTANT – The following steps are to confirm that the transmission is truly in NEUTRAL.
Performing these steps incorrectly will result in calibrating the transmission in a position other than
NEUTRAL.
B. Make sure that the four Socket Head Cap Screws that hold the Shift Shaft Adapter in place have
been removed as described in step 6. Again, place the two long (1-3/4” to 2-1/2”) #10-32 screws
(not supplied) in the two threaded holes (not the slot) of the Shift Shaft Adapter. And place the shift
shaft Adapter back into the actuator engaging the Transmission’s Selector Shaft.
C. Using a long substantial screwdriver wedged between the 2 long screws, rotate the shift shaft
adapter clockwise. Do not force the selector shaft when it reaches the end of its travel. This could
damage the transmission. The transmission is now in *PARK detent position
D. Next, slowly and carefully rotate the selector shaft back counterclockwise two detents. The
transmission is now in NEUTRAL. Once NEUTRAL has been obtained on the transmission,
Remove the two #10-32 screws for the Shift Shaft Adapter and remove the Shift Shaft Adapter from
the Actuator.

*NOTE – All Allison 1000 and 2000 series transmission have a PARK detent position regardless if
they have a PARK pawl or not.

IMPORTANT - When moving the selector shaft in the counterclockwise direction from PARK, the
tendency is to move it too fast. This may result in moving past the NEUTRAL (the 2 detents)
position. The transmission MUST be in NEUTRAL for proper calibration
8. Double check that the transmission is in NEUTRAL by repeating step #6.
9. Turn the Ignition OFF. The Push Button Shift Selector will react in different ways, depending on which Push
Button Shift Selector is installed. Check the next page for more details.

Actuator Re-Calibration Instructions

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 AES-204 RevB - SBW & SBW II Re-Calibration Procedure 4-26-2013

Push Button Shift Selector with P Button Push Button Shift Selector without P Button

7-Button Shifter 6-Button Shifter

Illustration #2 Illustration #3

The engine should turn off when the ignition is Both the engine and the Push Button Shift Selector
turned off, though the Push Button Shift Selector should turn off when the key is turned off. This is
will remain on. The Push Button Shift Selector will the desired condition for this shift selector.
stay ON supplying power to the Actuator, holding it
in NEUTRAL. This is the desired condition with this The Re-Calibration Procedure continues on the
Push Button Shift Selector. next page.

The Re-Calibration Procedure continues on the

next page.

Actuator Re-Calibration Instructions

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 AES-204 RevB - SBW & SBW II Re-Calibration Procedure 4-26-2013

Horizontal Mount – Loosen Mounting Bolts Vertical Mount – Loosen Mounting Bolts

Figure #5a
Figure #5b
10. Loosen the 3 bolts that hold the actuator to the
transmission 1 to 3 turns. These bolts include 10. Loosen the 4 bolts that hold the actuator to the
the 2 rear cover bolts and the single front bolt. transmission 1 to 3 turns. These bolts include
11. Wiggle the actuator to make sure that it is the 2 rear-cover bolts and the 2 front bolts.
loose. 11. Wiggle the actuator to make sure that it is
12. Press the SBW Actuator Alignment Tool into loose.
the Actuator until it is flush with the actuator 12. Press the SBW Actuator Alignment Tool into
face. the Actuator until is it flush with the actuator
face.

Figure #6a
Figure #6b
13. Next, while holding Actuator, re-tighten bolt
#1 first (shown in Figure #5a above), then 13. Next, while holding up on the bottom Actuator,
tighten the two rear bolts. It is important that re-tighten the front bolt #1 first (shown in
the front bolt #1 be tightened first. Figure #5b above), then tighten the other
14. The actuator should now be in the correct bolts. It is important that the front bolt be
position over the transmission selector shaft. tightened first.
14. The actuator should now be in the correct
position over the transmission selector shaft.

Actuator Re-Calibration Instructions

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 AES-204 RevB - SBW & SBW II Re-Calibration Procedure 4-26-2013

These steps apply to both Horizontal and Vertical Mount

Systems
15. Remove the SBW Actuator Alignment Tool and set
aside. When removing the Alignment Tool make sure
that the Actuator does not move. Lube the O-Ring on
the outer face of the Actuator

16. Place a long #10-32 screw into one of the slotted holes in
the lost motion wheel, shown in Figure #7a. Grasp the
head of the socket head cap screw with a pair of pliers
and pull the lost motion wheel outward; it should move
outward above 1/8” to 3/16”. This places the actuator
into the “calibration” position. See Figures #7b and #7c
for correct positing.

Figure #7a

Calibration Position, pulled outward Operating Position, pushed inward

Figure #7b Figure #7c

Actuator Re-Calibration Instructions

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 AES-204 RevB - SBW & SBW II Re-Calibration Procedure 4-26-2013

Horizontal Mount, Shift Shaft Adapter Vertical Mount, Shift Shaft Adapter
with or without the NSBU Assembly with or without the NSBU Assembly

17. Lube the O-ring on the Shift Shaft Adapter. 17. Lube the O-Ring on the Shift Shaft Adapter.
Align the witness marks on the Shift Shaft Align the witness marks on the Shift Shaft
Adapter with the witness marks on the actuator Adapter with the witness marks on the actuator
housing. Use the single groove witness mark housing. Use the double witness mark on the
on the Shift Shaft Adapter as shown in Figure Shift Shaft Adapter as shown in Figure #8c.
#8a. Place the shift shaft adapter into the center Place the shift shaft adapter into the center of
of the actuator, shown in Figure #8b. Be sure the actuator, shown in Figure #8d. Be sure that
that the Shift Shaft Adapter properly engages the Shift Shaft Adapter properly engages the
the end of Selector Shaft of the transmission. end of Selector Shaft of the transmission.

Figure #8a Figure #8c

Figure #8b

Figure #8d

Actuator Re-Calibration Instructions

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 AES-204 RevB - SBW & SBW II Re-Calibration Procedure 4-26-2013

These steps apply to both Horizontal and Vertical Mount Systems

18. Insert the (Qty 4) #10-32 x ½” long Socket Head Cap Screws into the Shift Shaft Adapter.

19. Place your thumb over the center of the Shift Shaft
Adapter. Press the Shift Shaft Adapter inward while
tightening all 4 screws that secure the shift shaft adapter
to 20 lbs.-in, as shown in Figure #9.

Figure #9

20. IMPORTANT – First, lube the O-Ring on the Cap Nut.

Place the Cap Nut through the Shift Shaft Adapter and
thread on to the end of the Transmission Selector Shaft.
Tighten to 18 lbs.-in, and then loosen the Cap Nut 1/2
to 1 full turn. Holding the cap nut with a wrench,
tighten the socket head cap screw that goes through
the center of the cap nut to 5 lbs.-ft, shown in Figure
#11. The Actuator will not work if you do not loosen the
Cap Nut as described above.

Figure #10

21. Install the O-Ring, shown in Figure #11, then attach the Cover Plate with the 3 Cover Plate Screws, shown
in Figure #12. Tighten the 3 screws to 20 lbs.-in.

Figure #11 Figure #12

SBW – Re-Calibration Instructions

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 AES-204 RevB - SBW & SBW II Re-Calibration Procedure 4-26-2013

System Checks:
CAUTION:
When performing the following system checks, make sure that the vehicle’s emergency brake is set, the
wheels are chocked, and foot pressure is maintained on the service brake pedal.
Failure to do so may result in injury or death.

i. The recalibration of the SBW system was done with the transmission in NEUTRAL; as such, the
transmission should still be in NEUTRAL. To confirm this, power-up the system with the ignition switch
without starting the engine. The “Monitor” side (right hand side) of the display should indicate “N” for
NEUTRAL. If it does not, select NEUTRAL by depressing the “N” button on the PBSS (Push Button Shift
Selector). The display should now show “NN” for NEUTRAL. Attempt to start the engine. If the
recalibration was done correctly the engine should start. Turn OFF the engine and proceed to the next
system check.
ii. If chassis/vehicle is equipped with PARK, power-up the system with the ignition switch without starting
the engine. Select “P” for PARK. The “Monitor” side (right hand side) of the display should indicate “P”
for PARK. Attempt to start the engine. If the recalibration was done correctly the engine should start.
Turn OFF the engine and proceed to the next system check.
iii. Power-up the system with the ignition switch without starting the engine. Select DRIVE, the SBW (Shift
By Wire) system will place the transmission in the DRIVE position. The display should indicate “DN” for
CAN equipped vehicles or “DD” for non-CAN equipped vehicles for DRIVE position.
i. NOTE: With the ignition ON, and the engine not running, the CAN message from the
Allison TCM (Transmission Control Module) to the Arens Controls PBSS (Push Button Shift
Selector) will result in an “N” indication on the “Monitor” side of the display for any gear
(e.g.: DRIVE, REVERSE, etc.). This is normal. Once the engine is running the Display for
DRIVE will indicate “D1” through “D5”, depending on the vehicles speed, or “DD” if CAN
is not utilized; for REVERSE the display will indicate “RR”.
b. Attempt to start the engine. If the recalibration was done correctly the engine should not start.

If any of these system checks fail to function as described above, see Arens Controls Trouble Shooting
Guide AES-125.

This completes the Installation of the Arens Controls SBW Actuator.

For help with Troubleshooting, be sure to download the AES-125-C, the SBW II Troubleshooting Guide.

SBW – Re-Calibration Instructions

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