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 TM
SureShift Transmission

How ZF Meritor’s SureShift How to Clear Active and Inactive Fault

Transmission Works
ZF Meritor’s SureShift transmission shift module enables
you to easily shift gears by moving a joystick FORWARD to
upshift or BACKWARD to downshift. The joystick signals
the transmission control unit (TCU) to activate solenoids to
r Break driveline torque
r Shift into neutral
r Complete a range shift, if necessary
r Synchronize engine speed to match the
vehicle’s road speed
r Shift into a selected gear
Fault Code Diagnostics
ZF Meritor’s SureShift transmission control unit (TCU) uses
a series of fault codes to identify system malfunctions that
the TCU detects and stores into memory. Each fault code
that the TCU lists on the instrument panel display is
preceded by either “ “ for an active fault or “:” for an
inactive fault.
After you retrieve a fault code from the instrument panel
display and identify the fault, use a Volt-ohm meter to test
the area where the fault code indicates that the malfunction
has occurred. An authorized ZF Meritor distributor or
dealer should repair the fault.
For complete maintenance and diagnostics procedures, as
well as information on how the SureShift transmission
works, refer to Maintenance Manual MM-9970. Call
Meritor’s Customer Service Center at 800-535-5560 to order
this publication, or visit the Technical Library section of
Meritor’s web site at www.meritorauto.com.
Codes From TCU Memory
NOTE: The vehicle must be stationary to clear fault codes.
1. Park the vehicle. Turn the engine OFF. Turn the
ignition OFF.
2. Press the NEUTRAL button and the FUNCTION button
at the same time and hold both buttons.
3. Turn the ignition ON. Do not start the engine.
4. Release both buttons about two seconds after you
turn the ignition ON. The fault codes will be cleared
from TCU memory.
Instrument Panel and Shift
Module Displays
WARNING
If a system malfunction occurs, the instrument
panel display illuminates “SM” for system
malfunction; and the shift module display
illuminates “F,“ “N” and “R” and emits a long,
repeating beep. When this warning occurs, you will
be unable to shift the transmission. Do not
continue to operate the vehicle. Serious personal
injury and damage to components can result.
Safely move the vehicle to the side of the road and
call for assistance.

How to Retrieve Active and Inactive Fault Instrument Shift Module

Status Panel Display Display
Codes From the Instrument Panel Display Gear selector position L, 1-10, N, R, N, or F
RL or RH
NOTE: The vehicle must be stationary to retrieve fault Requested shift not CL (Clutch) Single beep
codes. available*
Torque lock** CL (Clutch) Fast, repeating
1. Park the vehicle. Turn the engine OFF, but leave the beep
ignition ON. Upshift or downshift being SH (Shift) F
executed
2. Prepare to write down the fault codes when the TCU Shifting from a forward gear SH (Shift) F and N
begins to list them on the instrument panel display. to neutral
Shifting from a reverse gear SH (Shift) R and N
3. Press the NEUTRAL button and the FUNCTION button to neutral
at the same time and then release both buttons. The
Shifting from neutral to a SH (Shift) N and F
transmission control unit (TCU) lists the fault codes forward gear
on the instrument panel display one at a time. Refer Shifting from neutral to a SH (Shift) N and R
to the table in this guide for a complete list of fault reverse gear
codes and fault code descriptions. System Malfunction SM (System F, N and R; plus a
4. When the TCU has listed all of the fault codes on the Malfunction) long, repeating
beep
instrument panel display, the list will stop.
Manual Override MO (Manual —
r To view the fault codes again: Press the NEUTRAL Override)
button and the FUNCTION button at the same time * The SureShift™ transmission control unit (TCU) will not allow shifts that
and then release both buttons. The TCU will list the require the engine to operate below 1000 rpm or above the engine
codes on the instrument panel display. rating.
** Torque lock occurs when the engine is unable to break torque, which
5. After you record the flash codes, turn the ignition usually occurs when the engine is turning faster than its governed
speed.
OFF.
SureShift Transmission Fault Code Diagnostics
SAE SAE
Fault Codes Fault Code Fault Codes Fault Code
Codes (PID/SID)a Descriptions Actions Required b Codes (PID/SID)a Descriptions Actions Required b
C2 SID 194 No Codes None 3A SID 58 Main Box Shift Inspect the main box for mechanical
A1 PID 161 Main Verify the resistance across the speed Engagement concerns.
Countershaft sensor. Inspect the wiring harness for cut System
Speed Sensor or damaged wires. 3B SID 59 Main Box Rail Inspect the top cover for mechanical
BF PID 191 Transmission Verify the resistance across the speed Selection concerns.
Output Shaft sensor. Inspect the wiring harness for cut System
Speed Sensor or damaged wires. E3 SID 227 Oil Temperature Verify the transmission oil temperature
1F PID 31 Transmission Verify the resistance across the range Out of Limits or and levels are to specification. Verify the
Range Position position sensor. Inspect the wiring Sensor resistance across the oil temperature
Sensor harness for cut or damaged wires. sensor. Inspect the wiring harness for cut
30 SID 48 X-Y Engage Fork Verify the resistance across the X-Y gear or damaged wires.
Position Sensor position sensor. Inspect the wiring E7 SID 231 SAE J-1939 Data Verify the J-1939 connections. Inspect the
harness for cut or damaged wires. Link wiring harness for cut or damaged wires.
3C PID 60 X-Y Rail Select Verify the resistance across the X-Y rail EE SID 238 Diagnostic Replace the diagnostic lamp.
Position Sensor position sensor. Inspect the wiring Lamp
harness for cut or damaged wires. FB SID 251 Power Supply Verify that the batteries are charged.
23 SID 35 High Range Verify the resistance across the high Inspect the wiring harness for cut or
Solenoid range solenoid. Inspect the wiring damaged wires.
harness for cut or damaged wires. FC SID 252 Transmission Contact ZF Meritor. b
24 SID 36 Low Range Verify the resistance across the low range Calibration
Solenoid solenoid. Inspect the wiring harness for Routine
cut or damaged wires. FD SID 253 Transmission Contact ZF Meritor. b
27 SID 39 X-Y Rail Select Verify the resistance across the X-Y rail Calibration
Solenoid #1 solenoid #1. Inspect the wiring harness Memory
for cut or damaged wires. FE SID 254 Transmission Contact ZF Meritor. b
32 SID 50 X-Y Rail Select Verify the resistance across the X-Y rail Controller
Solenoid #2 solenoid #2. Inspect the wiring harness 98 SID 152 Shift Lever Box Inspect the wiring harness connecting the
for cut or damaged wires. Supply Output shift lever box to the transmission control
28 SID 40 X-Y Engage Fork Verify the resistance across the X-Y gear unit (TCU).b
Solenoid #1 solenoid #1. Inspect the wiring harness 99 SID 153 Limp Home Shift lever box fault.b
for cut or damaged wires. Disable Output
33 SID 51 X-Y Engage Fork Verify the resistance across the X-Y gear 9A SID 154 Limp Home Shift lever box fault.b
Solenoid #2 solenoid #2. Inspect the wiring harness System/
for cut or damaged wires. Function
38 SID 56 Auxiliary Inspect the auxiliary section for 97 SID 151 Speed Sensor Verify the resistance across both speed
Section mechanical concerns. Plausibility sensors. Inspect the wiring harness for
Mechanical cut or damaged wires.
System a Parameter Identification; Subsystem Identification
39 SID 57 Shift Lever Inspect the wiring harness connecting the b If necessary, contact Meritor’s Customer Service Center at 800-535-5560.
Assembly shift lever box to the TCU.b
Communication
Seat-Mount Wiring Diagram
JOYSTICK SHIFT-N-CRUISETM
(SHIFT MODULE) KEYPAD A A
B B
1 2 3 4 5 6 7 8 9 10 11 12 1 2 3 4 5 6
J6 J7
INPUT (PTO GEAR) SPEED
1 2 3 4 5 6 7 8 9 10 11 12 1 2 3 4 5 6 SENSOR ASSEMBLY

ENGAGE FORK POSITION

SOLENOID SENSOR
SEAT
1 1
HARNESS 2
2 2
OEM WIRING HARNESS 3 3 S
7 8 9 10 11 12 13 14 15 16 1 2 3 4 5 6
(schematic omits OEM connectors) 1
J3
7 8 9 10 11 12 13 14 15 16 1 2 3 4 5 6 A A
B B

CRUISE CONTROL RAIL SELECT POSITION

SOLENOID SENSOR
BLACK — COMMON
1 1 2
WHITE — (SET)
2 2
GREEN — RESUME
3 3 S
YELLOW — PAUSE 1
BLUE — PAUSE
A A
OEM CONNECTORS A A
B B
B B
C C
D D X–Y ACTUATOR
E E
F F
G G HIGH POSITION
H H SOLENOID SENSOR
A A
B B
FUNCTION
BATTERY (+)
LOW
IGNITION (+) SOLENOID S
BATTERY (–) A A
CHECK TRANS. LAMP B B
SAE J1587 B (–) A A
SAE J1587 A (+) B B
1 1
C C
2 2
D D
3 3
E E
FUNCTION F F
RANGE
SAE J1939 — CAN_H G G
COMPONENTS
SAE J1939 — CAN_L H H
SAE J1939 — CAN_SHLD J J
K K
A A
B B
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18
TRANSMISSION OUTPUT SPEED
WIRING HARNESS SENSOR ASSEMBLY
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18

Transmission Control Unit (TCU)

 SHIFT - N - CRUISE OEM HARNESS
Pedestal-Mount Wiring Diagram KEYPAD (SCHEMATIC OMITS OEM CONNECTORS)
J10
A

RESUME
B

PAUSE
SET
INPUT (PTO GEAR) SPEED
SENSOR ASSEMBLY

ENGAGE FORK POSITION

SOLENOID SENSOR
J11
1 2
2
3 S
Joystick (Shift Module) 4 1

J12
J6 J7
1
1 2 3 4 5 6 7 8 9 10 11 12 1 2 3 4 5 6 2
3
4
RAIL SELECT POSITION
SOLENOID SENSOR
J13
1 2
2
3 S
J8 4 1

A J14
B 1
C 2
D 3
E 4
F X–Y UNIT
G
H
J2
J19
1 HIGH POSITION
2 1 SOLENOID SENSOR
J15
3 2
A
4 3
B
5 4
6 5 LOW
SOLENOID S
7 6 J16
8 7 A
8 B
9
Transmission Control Unit (TCU)

J9
10 9
10 J17
11
A 1
12 11 B 2
13 12 C 3
D 4
14 13 E
15 14 F
G RANGE
15 H COMPONENTS
16 J
K
17
18
J1 19
20
J18
1 21
2 A
22
3 B
23
4 24
5 25 TRANSMISSION OUTPUT SPEED
6 26 WIRING HARNESS SENSOR ASSEMBLY
7 27
8 28
9 29
10 30
11 31
12 FUNCTION
13
BULKHEAD BATTERY (+)
14 CONNECTOR BATTERY (+)
15
IGNITION (+)
16
BATTERY (–)
17
CHECK TRANS. LAMP
18

OEM CONNECTIONS
SAE J1567 A (+)
SAE J1587 B (–)

FUNCTION
SAE J1939 – CAN H
SAE J1939 – CAN L
SAE J1939 – CAN Sh

PEDESTAL MOUNT
WIRE HARNESS
FUNCTION
BLACK – COMMON
WHITE – SET
GREEN – RESUME
YELLOW – PAUSE
YELLOW – PAUSE
 3

1
1 Main Countershaft
Speed Sensor
4
2 X-Y Position Sensors
3 Low Range Solenoid
4 High Range Solenoid 2 5
5 Range Position Sensor
6 Output Shaft Speed Sensor
6
7 Rail Select Solenoids
8 Engage Fork Solenoids 7

Component Resistance (Measured Across Pins)

WABCO
001 XXXX
884 010 098 0

Range Position Sensor 64.80 ohms — 79.20 ohms

Rail Select Solenoids 21.15 ohms — 25.85 ohms

Engage Fork Solenoids 9.63 ohms — 11.77 ohms

X-Y Position Sensors 64.80 ohms — 79.20 ohms

Main Countershaft
2.70 k ohms — 3.30 k ohms
Speed Sensor

High and Low Range

11.00 ohms — 21.00 ohms
Solenoids

Output Shaft Speed Sensor/

2.00 k ohms — 4.00 k ohms
Single Coil
SINGLE DUAL
COIL COIL
Output Shaft Speed Sensor/
1.50 k ohms — 3.50 k ohms
Dual Coil

ZF Meritor, LLC
22021 Skyway Church Road
Maxton, NC 28364 USA
800-535-5560
www.arvinmeritor.com
Information contained in this publication was in effect at the time the publication was approved for printing and is
subject to change without notice or liability. ArvinMeritor Commercial Vehicle Systems reserves the right to revise
the information presented or discontinue the production of parts described at any time.
Copyright 2000 TP-98114
ArvinMeritor, Inc. Revised 10-00
All Rights Reserved Printed in the USA 16579/24240