SIL 10-TR-19

June, 2019
Page 1 of 4

SUBJECT: Diagnosing 5th Generation Transmission Control Module (TCM)

MODELS AFFECTED: All Transmissions with 5th Generation Controls

LOCATIONS AFFECTED: All US and Canadian Distributors and Distributor Branches (Dealers excluded)

Introduction:
Testing at Allison Transmission of the 5th Generation TCMs has revealed that many returned TCMs tested
No Trouble Found (NTF). In an effort to reduce the NTF returns, Allison Transmission is adding a step in the
troubleshooting tree of a suspect TCM, effective June 1, 2019. The added step is to reflash the suspect TCM with
the most current calibration before removing the TCM, then attempt to duplicate the complaint (see Service
Procedure below). If troubleshooting determines that the TCM must be replaced, Allison TAC must be
contacted to start a TAC Case. This TAC case number from a completed case authorizing TCM replacement
will be required as part of the claims submission process in AWAARE. Failure to submit a claim with a
completed TAC case number will result in the claim being reviewed for denial.

NOTE: A TCM reflash will load the most current version of the calibration and software that is available
for that vehicle into the TCM.

NOTE: Test TCMs must be registered in CDS or a non-FuelSense® 2.0 calibration must be loaded
into the test TCM within 10 days of the FuelSense® 2.0 calibration load date to avoid FuelSense® 2.0
entitlement charges (refer to SIL 7-TR-17).

Service Procedures:
1. Complete all steps in the troubleshooting tree for the active Diagnostic Trouble Code (DTC).
a. Print pages that pertain to the DTC from the troubleshooting manual (see Figure 1 for an example).
b. Perform the troubleshooting steps and document the measured values in the Value(s) column.
c. Attach the completed troubleshooting steps with the measured (actual) values to the TCM AWAARE
claim.

GK / SL8501EN 4560505
Copyright © 2019 Allison Transmission, Inc. All Rights Reserved.
 SIL 10-TR-19
June, 2019
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Figure 1. DTC Page Example

2. Using Allison TCM ReflashTM software, download the latest calibration and software for the original TCM
using the TCM serial number.
3. Reflash the original TCM with the downloaded calibration and software.
4. Connect to the TCM using Allison DOC® software once the reflash event is complete.
5. Acquire and save an Allison DOC® snapshot while driving the vehicle under the same conditions, if possible,
noted in the failure records.
6. Did the DTC return?
7. If the answer to Step 6 is No with the original TCM, the repair is complete.
8. If the answer to Step 6 is Yes, install a test TCM with the same updated calibration and software and
repeat Step 5 then contact TAC.

NOTE: For FuelSense® 2.0 TCM troubleshooting, the Test TCM must be registered. If not, a
non-FuelSense® 2.0 calibration must be loaded within 10 days of the troubleshooting to avoid a charge.

9. Contact Allison TAC for troubleshooting assistance.

Copyright © 2019 Allison Transmission, Inc. All Rights Reserved.

 SIL 10-TR-19
June, 2019
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Authorization is to be obtained from Allison once the troubleshooting performed by your repairing facility has
determined that the TCM must be replaced. Prior to replacing the TCM, Allison Technical Assistance Center (TAC)
must be contacted. Please call the appropriate number during the times listed below:
• 8:00AM - 6:00PM EST (Eastern Standard Time) Monday thru Friday call: 800-252-5283
• For emergency situations between 6:00PM (EST) and 8:00AM (EST) or on weekends that require TCM
replacements, please perform repairs as needed but still contact TAC the next business day.

TAC will log a case number and review the troubleshooting procedure that has been performed by your facility and
then guide you through additional troubleshooting steps if necessary before authorizing TCM replacement.

Once the TAC case has been completed, TAC will furnish the repairing outlet with a TAC Case Number that will
be used as the authorization number for 5th Gen TCM replacement. This TAC Case Number will be required
on all claims in which a 5th Gen TCM has been replaced. On the final page of this SIL, you will find a TCM
Replacement Evaluation form which must be attached to each returned TCM.

Copyright © 2019 Allison Transmission, Inc. All Rights Reserved.

 

TCM Replacement Evaluation

(Return this form with the TCM)
 

Completed TAC Case Number (REQUIRED*):

 
Transmission Serial Number: Transmission Model:

Distributor/Branch Code:

TCM Serial Number:

Calibration ID:

Diagnostic Codes (Check Before Troubleshooting) Shift Complaint

Code: Active: Y N
Harsh Shift
Shift Flare
Shift Cycle
Other
Define:
 
 
 
 
 

Shift Inhibit   Y N
Indicator: Active:

FuelSense® 2.0 Calibration: If YES, transfer entitlement to new TCM

Shifts Affected
Can Complaint Be Reproduced? Throttle Conditions (Check All That Apply)
Y N Shift Full Part Closed Step-Thru Back-Off
N-R
    N-1    
    R-1    
    1-R    
    1-2    
    2-3    
    3-4    
    4-5    
    5-6    
    6-5    
    5-4    
    4-3    
    3-2    
    2-1    
 
Other Components Swaps Performed:

* If TAC case is missing, the return will be rejected