Troubleshooting Manual Allison Transmission Allison 4° Generation Controls 1000 and 2000 Product Families 1000 EVS 2100 MH 1000 HS 2100 PTS 1000 MH 2100 RDS 1000 PTS 2100 SP. 1000 RDS. 2200 EVS 1000 SP 2200 HS 2000 MH 2200 MH 2100 EVS 2200 PTS 2100 HS 2200 RDS © Allison “, Transmission. Allison Transmission, Ine. PO. Box 894 Indianapols, Indiana 46206-0894 ‘wo alisonransmission.com 2200 SP 2300 HS 2300 RDS 2350 EVS 2350 HS. 2350 MH 2350 PTS 2350 RDS 2350 SP 2500 EVS 2500 HS 2500 MH 2500 PTS 2500 RDS 2500 SP 2550 EVS 2550 HS 2550 MH TS3977EN 2010 FEBRUARY 2550 PTS 2550 RDS 2550 SP B 210 B 220 Pinted m USA CopyGht © ZOTO Alison Tansmesion, TeALLISON 1000 and 2000 Product Families FOREWORD—how to Use This Manual This manual provides troubleshooting information for Allison Products. This manual includes: * Description of the electronic control system. + Description of the electronic control system components. + Description of diagnostic codes, system responses to faults, and troubleshooting, * Wire, terminal, and connector repair information. 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 (SILs) 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 rear cover. Check with your Allison Transmission service outtet for the currentiy 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 service of wiring harnesses and wiring hamess components as follows: + Repair parts for the intemal wiring harness will be available through the Allison Transmission Parts Distribution Center (PDC). Use the PIN 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 hamess components must be obtained {from the vehicle OFM or the OEM is responsible for warranty on these parts. ii Copyright © 2010 Allison Transmission, Inc.ALLISON 1000 and 2000 Product Families IMPORTANT SAFETY INFORMATION IT IS YOUR RESPONSIBILITY to be completely familiar with the warnings and cautions in this manual. ‘These warnings and cautions advise of specific methods or actions that can result in personal injury, equipment damage, or cause the equipment to become unsafe, These warnings and cautions are not exhaustive. Allison Transmission could not possibly know, evaluate, or advise the service trade of all conceivable procedures by which service might be performed or of the possible hazardous consequences of each procedure. Accordingly, ANYONE WHO USES A SERVICE PROCEDURE OR TOOL WHICH IS NOT RECOMMENDED BY ALLISON TRANSMISSION MUST first be thoroughly satisfied that neither personal safety nor equipment safety will be jeopardized by the service methods used. Vehicle manufacturers integrate Allison transmissions into vehicles used for a variety of vocations and services. The vehicle manufacturer is responsible for identifying the specific operating conditions to which the vehicle will be subjected and to communicate the appropriate means for preventing unintended vehicle movement within those conditions, in order to ensure vehicle and operator safety. The vehicle owner and operator should be aware of and follow the vehicle manufacturer's operating instructions and warnings related to parking and preventing unintended vehicle movement. Proper service and repair is important to the safe and reliable operation of the equipment. The service procedures recommended by Allison Transmission (or the vehicle manufacturer) and described in this manual are effective methods for performing service and diagnostic operations. Some procedures require using specially designed tools. Use special tools when and in the manner recommended. ‘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. WARNINGS, CAUTIONS, NOTES Three types of headings are used in this manual to attract your attention: T) WARNING: A warning is used when an operating procedure, practice, ete. which, if not correctly # J followed, could result in personal injury or loss of life. B)) CAUTION: A caution is used when an operating procedure, practice, etc. which, if not etcty observed, could result in damage to or destruction of equipment. (¥) NOTE: A note is used when an operating procedure, practice, etc., is essential to highlight. Copyright © 2010 Allison Transmission, Inc. iiALLISON 1000 and 2000 Product Families TRADEMARK USAGE The following trademarks are the property of the companies indicated: Adobe® Acrobat® Reader® are registered trademarks of Adobe Systems Incorporated Allison DOC® For PC-Service Tool is a registered trademark of Allison Transmission, Inc. LPS® Cleaner is a registered trademark of LPS Laboratories. Loctite® is a registered trademark of the Loctite Corporation. Teflon® is a registered trademark of DuPont Corporation. Windows® 95, Windows® 98, Windows® XP, and Windows NT® are registered trademarks of Microsoft Corporation LITERATURE This service literature provides fully illustrated instructions for operation, maintenance, service, overhaul, and parts support for your transmission. For maximum performance and service life from your unit, you may order additional publications via web, fax or phone. WEB: www.allisontransmissionpublications.com FAX: 317-471-4996 TOLL FREE: 888-666-5799 INTERNATIONAL: 317-471-4995 (surcharge will be applied for orders placed via phone or FAX) For more information about Allison products please visit www.allisontransmission.com. Copyright © 2010 Allison Transmission, Inc.ALLISON 1000 and 2000 Product Famili TABLE OF CONTENTS FOREWORD—How to Use This Manual IMPORTANT SAFETY INFORMATION TRADEMARK USAGE. LITERATURE. SECTION 1 GENERAL DESCRIPTION “4 12 13 4 16 16 w 18 19 +10 15 VARIABLE MODULATED MAIN PRESSURE 2010 UPRATE. LOAD BASED SHIFT SCHEDULE (LBSS), CONVERTER OVERTEMP TORQUE PROTECTION (COTP). CONVERTER TEMPERATURE MODELING (CTM) VEHICLE ACCELERATION CONTROL (VAC). ‘TRANSMISSION ‘TRANSMISSION CONTROL MODULE (TCM) 1000 AND 2000 PRODUCT FAMILIES SERVICE PROGNOSTICS ‘TRANSMISSION PROGNOSTICS SHIFT SELECTOR. [A Shift Selector Range Positions 8. Manual Solector Vaivo ©, Interna! Made Swit (MS) ‘THROTTLE POSITION SENSOR (TPS) SPEED SENSORS. |A. Input Engine) Speed Sensor 8, Turbine Speed Sensor ©. Output Speed Sensor ‘CONTROL VALVE ASSEMBLY A. Main Modulation WIRING HARNESS A. External Wiring Harness 8. Infma! Winng Hames ‘SPECIAL ELECTRONICIELECTRICAL TOOLS. SECTION 2 DEFINITIONS AND ABBREVIATIONS 2a 22 23 24 26 (CHECK TRANS LIGHT RANGE INHIBIT RESPONSES ALLISON DOC® FOR PC-SERVICE TOOL INHIBITS ALLISON D0C® FOR PC-SERVICE TOOL DEFINITIONS and ABBREVIATIONS SECTION 3 BASIC KNOWLEDGE a 32 33 34 36 26 ar 38 BASIC KNOWLEDGE REQUIRED USING THE TROUBLESHOOTING MANUA ‘SYSTEM OVERVIEW : : IMPORTANT INFORMATION IN THE TROUBLESHOOTING PROCESS. BASIC TROUBLESHOOTING INFORMATION ‘TCM DIAGNOSTIC PROCEDURE RESETTING OF TCM PARAMETERS TO SUPPORT ENGINE UPDATE. RESETTING TCM SEM AUTOSELECT Copyright © 2010 Allison Transmission, Inc. 1 4 14 14 12 12 15 15 16 7 7 18 18 18 19 110 +10 4-10 att at 419 113 +15 116 2a 2A 2a 23 24 aa 24 3A 32 30 210 210 attALLISON 1000 and 2000 Product Families TABLE OF CONTENTS SECTION 4 WIRE CHECK PROCEDURES 41 CHECKING OPENS, SHORTS BETWEEN WIRES, AND SHORTS-TO-GROUND (Use J 34520 A Digital VolVOhmmeter ‘ane 139197 Jumper Wice Set) a 42. CHECKING AT TRANSMISSION CONNECTOR AND THE INTERNAL HARNESS FOR OPENS, SHORTS BETWEEN WIRES, AND SHORTS-TO-GROUND es SECTION 5 DIAGNOSTIC TROUBLE CODES (DTC) 51 DTCMEWORY SA 5:2 FAILURE RECORDS. A 53 DTC READING AND DTC CLEARING 53 A. Clearing DTCs 53 B. Clearing Active Indicators 53 5-4 BEGINNING THE TROUBLESHOOTING PROCESS. 53 A Staring Procedure 53 8. Solenoid Lotations se . Wire/Terminal Numbering Scheme 55. . Avalabie Diagnostic Adaptors 55 55 DIAGNOSTIC TROUBLE CODE (DTC) REFERENCE TABLES 58 56 DTC LIST AND DESCRIPTION INDEX. ea7 SECTION 6 INPUT AND OUTPUT FUNCTIONS. 5-1 SPECIAL INPUT AND OUTPUT FUNCTIONS, : : : wee BA SECTION7 GENERAL TROUBLESHOOTING OF PERFORMANCE COMPLAINTS 7-1. GENERAL TROUBLESHOOTING OF PERFORMANCE COMPLAINTS: 74 APPENDICES A. DIAGNOSING INTERMITTENT DTCs B, MAIN PRESSURE CHECK PROCEDURE ©. SOLENOID AND CLUTCH TABLE D. WIREICONNECTOR TABLES E. CONNECTOR REPAIR INFORMATION THROTTLE POSITION SENSOR ADJUST! G, WELDING ON VEHICLEIVEHICLE IN H. HYDRAULIC SCHEMATICS. |. WIRING SCHEMATIC Ht J. RESISTANCE VS. TEMPERATURE. a k. L M. N 0. {FACE MODULE. ELECTRONIC INTERFERENCE ka ALLISON DOC FOR PC-SERVICE TOOL a INPUTIOUTPUT FUNCTIONS . . : : : cee MA 111999 AND 2284 HARDWARE AND TCM CONNECTIONS. Na FLUID CHECK PROCEDURE ot vi Copyright © 2010 Allison Transmission, Inc.ALLISON 1000 and 2000 Product Families Section 1—GENERAL DESCRIPTION 1-4. VARIABLE MODULATED MAIN PRESSURE 2010 UPRATE Variable modulated main pressure for 1000/2000 Product Families has been enhanced to schedule transmission main pressure, thereby improving transmission efficiency by reducing pump pressure when full pressure is not needed. Shift Energy Management (SEM)/Low Range Torque Protection (LRTP) is required for full functionality of this feature. Variable modulated main pressure adjusts hydraulic pressure based on current Allison transmission requirements. A new variable bleed solenoid is used to control main pressure. 1-2, LOAD BASED SHIFT SCHEDULE (LBSS) Load Based Shift Schedule (LBSS) was introduced in MY 2009 for non-Shift Energy Management (SEM)/Low Range Torque Protection (LRTP) engines. Super Economy Shift Schedule (SESS) is an additional shift schedule that allows three choices instead of the standard primary and secondary modes. SESS is for SEMILRTP engines. This enhancement automatically commands a fuel efficient shift schedule beyond those schedules specified for primary and secondary modes. When using SESS, the Transmission Control Module (TCM) automatically selects from one of the following three shift schedules: — Performance — Economy — Super Economy 1-3. CONVERTER OVERTEMP TORQUE PROTECTION (COTP) The Converter Overtemp Torque Protection (COTP): *+ Protects the torque converter from failure during sustained high slip conditions. + Determines torque converter temperature using mathematical analysis (refer to 1-4. CONVERTER TEMPERATURE MODELING (CTM) + Limits engine speed to 1400 rpm after 20 seconds of engine stall + Limits engine speed to 900 rpm after an additional 7 seconds of stall + Applies to Shift Energy Management (SEM)/Lower Range Torque Protection (LRTP) applications only. 1-4. CONVERTER TEMPERATURE MODELING (CTM) ‘The Converter Temperature Modeling (CTM) allows’ + The torque converter temperature to be determined in all modes of operation through a mathematical analysis. + Converter analysis to be incorporated into the Converter Overtemp Torque Protection (COTP) function. + Data to be stored and used as a troubleshooting tool for service and engineering. This is accessible through the Allison DOC® For PC-Service Tool, + This feature is only available on Shift Energy Management (SEM) vehicles. Copyright © 2010 Allison Transmission, Inc. 14ALLISON 1000 and 2000 Product Families GENERAL DESCRIPTION 1-5. VEHICLE ACCELERATION CONTROL (VAC) Vehicle Acceleration Control (VAC) limits engine torque so the vehicle will not exceed a predetermined acceleration profile. Beginning in January 2010, VAC will be available on all vehicles using Shift Energy Management (SEM)/Low Range Torque Protection (LRTP) approved engines. Overview: * Using control logic, VAC limits vehicle acceleration by monitoring and limiting turbine acceleration to prevent exceeding a predetermined acceleration curve. + The following are the different acceleration rates the customer can choose from, with Low being the default rate: — High uses a high level of acceleration control with a low acceleration rate, providing the highest potential fuel savings. — Medium uses a medium level of acceleration control with a medium acceleration rate, providing medium potential fuel savings. — Low uses a low level of acceleration control with a normal acceleration rate, providing the lowest potential fuel savings. + Allows a partially loaded bus to accelerate at or slightly below the rate of a loaded bus. + VAC requires the vehicle be equipped with the SAE J1939 Controller Area Network (CAN) vehicle bus standard used for communication and diagnostics among vehicle components. + VAC and Load Based Shift Schedule (LBSS) can be used simultaneously. + VAC availabilty is limited to certain transmission models and vocations. 1-6. TRANSMISSION The 1000 and 2000 Product Families Allison 4" Generation Controls system features closed-loop clutch contro! to provide superior shift quality over a wide range of operating conditions. The 1000 and 2000 Product Families configurations can be programmed to provide up to six forward speeds, neutral, and reverse. The fifth and sixth ranges are overdrive gear ratios. The 1000 and 2000 Product Families incorporates a variety of standard and optional design features. Figure 1-1 is a block diagram of the basic system inputs and outputs, 12 Copyright © 2010 Allison Transmission, Inc.ALLISON 1000 and 2000 Product Families GENERAL DESCRIPTION PRESSURE SWITCH MANIFOLD | INTERNAL MODE SWITCH it [ ‘SPEED SENSORS tf SOLENOIDS rom (vB8,ONOFA VEHICLE/ENGINE >| TEMPERATURE SENSOR COMMUNICATION LINKS (SUMP/ENGINE) WeUTS Sa Figure 1-1. Transmission Control Module (TCM) Diagram Figure 1-2 shows the electronic control components. Electronic controls consist of the following elements: Remote 12 volts or 24 volts Transmission Control Module (TCM) Throttle Position Sensor (TPS), electronic engine throttle data, or Pulse Width Modulation (PWM) signal ‘Speed Sensors—Input (Engine), Turbine, and Output Control Valve Assembly (Electro-Hydraulic Valve Body) Internal Mode Switch (IMS) Pressure Switch Manifold (PSM) Wiring Harnesses NOTE: All external hamesses are Original Equipment Manufacturer (OEM)-supplied. Copyright © 2010 Allison Transmission, Inc. 13ALLISON 1000 and 2000 Product Families ‘TRANSMISSION HARNESS aoway CONNECTOR To} ‘TRaususion BBitlecron ‘ono eu suppuco ‘von Irene RCE BARNES INPUT (ENGINE SPEED Sens "SonecTOR gureur, SED Senson GouectoR TyRgne ergo Sasa ‘CONNECTOR "inorgg rgegn Bases oa 2eway man zoway TRANSHISSION EonnecroR ‘CONNECTOR (ormonaty NOTE: Hasta it asa Atl fas ‘anigration may afr fan Bs station Figure 1-2. Electronic Control Components 14 Copyright © 2010 Allison Transmission, Inc.ALLISON 1000 and 2000 Product Families GENERAL DESCRIPTION 1-7. TRANSMISSION CONTROL MODULE (TCM) The electronic control of the transmission is performed by a microcomputer. The microcomputer is an independent controller and is referred to as a TCM. TCMs are available in both 12 volts and 24 volts configurations to match the configuration of the vehicle electrical system. The TCM (refer to Figure 1-3) receives and processes signals from various switches and sensors. The TCM determines shift sequences, shift timing, and clutch apply and release pressures. The TCM uses the information to control transmission solenoids and valves, supply system status, and provide diagnostic information. Figure 1-3. Transmission Control Module (TCM) 1-8. 1000 AND 2000 PRODUCT FAMILIES SERVICE PROGNOSTICS Prognostics are used to predict the need for transmission maintenance. Service prognostics were introduced with MY09 vehicles and require the use of Allison-approved TES 295 fluids and Control Main Filter PIN 29539579. MY09 Prognostics were offered as a package to Original Equipment Manufacturers (OEMs) as an option (refer to the following caution for vehicles not equipped for Prognostics). Starting in January 2010, the Service Prognostics package requires the use of Allison approved TES 295 or TES 389° fluids and Control Main Filter P/N 29539579. Transmission operating parameters monitored by the prognostics feature are: 1. Oil Life Monitor 2. Filter Life Monitor 3. Transmission Health Monitor NOTE: If you are unable to determine whether your vehicle has Prognostics enabled, consult with your OEM service department or an authorized Allison distributor or dealer When a specified service threshold is detected for one of these parameters, the TRANS SERVICE indicator is illuminated to alert the operator to the need for action. Failure to attend to the service condition and reset the TRANS SERVICE indicator within a defined operating period will resuit in the illumination of the CHECK TRANS indicator (in addition to the TRANS SERVICE light), indicating the increased probability that the service condition may/will develop into a more serious condition. ES 389 fds can ony be used with Prognostcs on Jaruary 2010 (or later) transmissions and calibrated TCMs, Copyright © 2010 Allison Transmission, Inc. 16ALLISON 1000 and 2000 Product Families GENERAL DESCRIPTION The process for resetting the TRANS SERVICE indicator varies for each feature and is described in each of the following sections. Use the Allison DOC® For PC-Service Tool to review the current status of any of these features and a history of indicator resets. CAUTION: Transmission Prognostics features may be turned ON or OFF by a special transmission 3) ration and REQUIRES the use of Allison approved TES 295 and TES 389 fluids. If any other ‘uids are used, prognostic features must be tuned OFF. Prognostic information wil not be accurate With the use of any other transmission fluids and could result in improper maintenance activities resulting in transmission damage. If Prognostics is not programmed or is tured OFF, the kilometers (milesy/hours/months method of determining fluid and fiter change intervals will apply. See charts in ‘the section of this book or visit www.allisontransmission.com for a list of Allison-approved TES fluids or read Service Tips 1099 (current revision) for details, 1-9, TRANSMISSION PROGNOSTICS This feature of the transmission system provides a constant monitor of various transmission operating parameters. These transmission parameters are: + oll life * fluid filter condition * clutch condition The transmission prognostics feature requires a TRANS SERVICE indicator to alert the operator when a service condition relating to any of these items exists. If the serviceable condition is ignored for a defined period, the CHECK TRANS light is illuminated, indicating the increased probability that the service condition will develop into a more serious condition. The prognostics feature is only available with transmissions using TranSynd? or an equivalent TES 295 transmission fluid. In addition, the prognostics feature is only functional itt is available in the Transmission Control Module (TCM) controls calibration (determined when the TCM is programmed) and is also enabled in the controls calibration (switched on or off as specified by the customer). Prognostics package requires the use of one of the following transmission fluids: + TES-296 licensed fluid - (MY2009 and January 2010 Uprate) * Schedule One TES-389 fluid - (Beginning January 2010 Uprate) Enabling Prognostics With the Allison DOC service tool. After setting the vehicle brakes to prevent movement of the vehicle, move the shift selector through the following sequence of range positions, pausing no more than three (3) seconds between consecutive shifts. N-D-N-R-N-D-N-R-N-D-N-R-N. If so desired, prognostics may be toggled off (disabled), using either of the same methods. Resetting Prognostic features To reset the OIL LIFE MONITOR use Allison DOC service tool or select N-D-N-D-N-R-N on the shift selector, pausing briefly (less than 3 seconds) between each selector movement, with the ignition on and the engine hot running 16 Copyright © 2010 Allison Transmission, Inc.ALLISON 1000 and 2000 Product Families GENERAL DESCRIPTION To reset the FILTER LIFE MONITOR use Allison DOC service tool or select N-R-N-R-N-D-N on the shift selector, pausing briefly (less than 3 seconds) between each selector movement, with the ignition on and the engine not running, TRANSMISSION HEALTH MONITOR will automatically reset upon elimination of the clutch clearance condition which initiated it. DOC service tool may be used to reset this feature. 1-10, SHIFT SELECTOR The vehicle is equipped with a lever-type shift selector (refer to Figure 1-4). In addition to the lever assembly provided for the operator, other components associated with the shift selector are the manual selector valve in the main control valve body and an Internal Mode Switch (IMS) mounted on the selector shaft inside the transmission oll pan. Shift selector components (with the exception of the transmission selector shaft) are customer-supplied. A. Shift Selector Range Po: ions. ‘The operator chooses the transmission range by moving the selector lever to the appropriate gate position (refer to Figure 1-4). When properly adjusted, the shifter gates prevent inadvertent shifting between ranges and correspond to the internal transmission detent positions. A positive detent is provided in the transmission to maintain the selector shaft in the selected position. SHIFT SELECTOR: TOP VIEW Figure 1-4. Typical Lever-Type Shift Selector The TCM shift calibration determines the available forward ranges for each selector position Although specific installations vary, typical selector positions for the 1000 and 2000 Product Families are: P-Park. Parking pawl or parking brake is engaged, if available. This position is not available cn all shift selectors R-Reverse Copyright © 2010 Allison Transmission, Inc. 17ALLISON 1000 and 2000 Product Families GENERAL DESCRIPTION N-Neutral. May be used when starting the engine and for stationary operations OD-Overdrive. The highest forward range used for normal driving. The transmission shifts to first range for starting, then automatically upshifts through the ranges (as operating conditions permit) until the highest range is attained D, 2, 1-Forward Range. The transmission shifts to first range for starting. The range selected on the shift selector is the highest range which will be attained during automatic shifting (on GM truck applications, a position M is used for Tap Up/Tap Down functionality) B. Manual Selector Valve. ‘The manual shift selector shaft is attached to the manual selector valve within the transmission main control valve body. The selector vaive has three positions: reverse, neutral, and forward. NOTE: For transmissions equipped with a P (Park) position, the selector valve remains in the neutral position when the selector is moved to P (Park). The neutral and reverse selector valve positions (refer to Appendix H. HYDRAULIC SCHEMATICS exhaust the C1 and C2 rotating clutches. By exhausting C1 and C2 clutches, forward range is inhibited. This provides the capability for the operator to override the electronically commanded ranges if neutral is required. C. Internal Mode Switch (IMS). An internally-mounted switch, commonly called an IMS (refer to Figure 1-5), mounts inside the transmission oil pan at the shift selector shaft. The IMS detects the angular position of the shift selector shaft. This position is communicated to the TCM so that certain vehicle control functions can be coordinated with the position of the shift controls. The neutral signal output of the IMS is typically used as confirmation that the transmission is in neutral before the engine starter is engaged, Figure 1-5. Internal Mode Switch (IMS) 1-11, THROTTLE POSITION SENSOR (TPS) The TPS can be mounted to the engine, chassis, or transmission. The TPS (refer to Figure 1-6) 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 18 Copyright © 2010 Allison Transmission, Inc.ALLISON 1000 and 2000 Product Families GENERAL DESCRIPTION Transmission Control Module (TCM) through the extemal hamess. The voltage signal indicates the throttle position and, in combination with other input data, determines shift timing. NS Figure 1-6. Throttle Position Sensor (TPS) 1-12, SPEED SENSORS There are three speed sensors available for use with 1000 and 2000 Product Families transmissions: the input (engine) speed sensor, the turbine speed sensor, and the output speed sensor (refer to Figure 1-7). The speed sensors provide rpm information to the TCM. The speed ratios between the various sensors allow the Transmission Control Module (TCM) to determine the transmission operating range. Speed sensor information is also used to control the timing of clutch apply pressures, resulting in the best possible shift quality. igure 1-7. Typical Speed Sensor ‘The speed sensors are variable reluctance devices which convert mechanical motion to an AC voltage. Each ‘sensor consists of a wire coll wrapped around a pole piece that is adjacent to a permanent magnet. These elements are contained in a housing which is mounted adjacent to a rotating ferrous member (such as a gear tooth). 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. Asa ferrous object (such as a gear tooth) approaches and passes through the gap at the end of the pole piece, an AC voltage pulse Is induced in the wire coll. The TCM calculates the frequency of these AC pulses Copyright © 2010 Allison Transmission, Inc. 19ALLISON 1000 and 2000 Product Families GENERAL DESCRIPTION and converts it to a speed value. The AC voltage generated varies from 150mV at low speed to 15 volts 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. Noise from other sources is eliminated by using two-wire differential inputs at the TCM. NOTE: Do not rotate the speed sensor in the retaining bracket. Orientation is fixed and, if changed, may cause improper operation A. Input (Engine) Speed Sensor. The input (engine) speed sensor is externally mounted in the torque converter housing directed at the ribs protruding from the torque converter. The input (engine) speed sensor connector should be positioned at approximately four o'clock, as viewed from the left side of the transmission (refer to Figure 1-8) B. Turbine Speed Sensor. The turbine speed sensor is externally mounted in the main housing directed at the tone wheel or PTO drive gear attached to the rotating clutch module. The turbine speed sensor connector should be positioned at approximately three o'clock, as viewed from the left side of the transmission (refer to Figure 1-8), C. Output Speed Sensor. The output speed sensor is externally mounted in the rear cover and directed at the teeth of a tone wheel splined to and rotating with the output shaft. The output speed sensor connector should be positioned at approximately five o'clock, as viewed from the left side of the transmission {refer to Figure 1-8), Copyright © 2010 Allison Transmission, Inc.ALLISON 1000 and 2000 Product Families GENERAL DESCRIPTION woes ee nape cee Sonar name oureur seco sensoR conEcTOR ORENTANON= 0k Figure 1-8, Speed Sensor Connector Orientation 1-13. CONTROL VALVE ASSEMBLY The hydraulic control valve assembly (refer to Figure 1-9 for pre-MY 2010, and Figure 1-10 for 2010 Uprate) governs fluid flow to the clutches (including the torque converter clutch). Solenoids, actuated by the Transmission Control Module (TCM), control valve movement. The control valve assembly consists of the main valve bady and the control valve body. The main valve body contains the pressure control valve, the Torque Converter Clutch (TCC) valve, the exhaust backfill valve, and the control main relief valve. The control valve body contains the shift valves, the control main pressure valve, and the manual selector valve. The control valve assembly attaches to the bottom of the gearbox module and is enclosed by the oil pan. An internal wiring hamess connects the solenoids and Pressure Switch Manifold (PSM) to the main transmission connector and external wiring harness. ‘A. Main Modulation. Pre-MY 2010: Main pressure is reduced by using an on/off Main Mod solenoid that is located in the control valve body assembly. The Main Mod solenoid body is bolted to the main valve body. Main pressure will be reduced under various conditions such as low throttle, low torque, low engine speeds, and low output speeds. The primary benefit of modulating main pressure is to increase coolant fiow at low engine speeds. Copyright © 2010 Allison Transmission, Inc. cer)ALLISON 1000 and 2000 Product Families GENERAL DESCRIPTION MAIN won —7 ss aah Figure 1-9. Control Valve Assembly (Pre-MY 2010) Variable Main Modulated Pressure 2010 Uprate: Variable main modulated pressure for 1000/2000 Product Families requires Shift Energy Management/Low Range Torque Protection (SEM/LRTP) for full functionality of this feature. Variabie main modulated pressure adjusts hydraulic pressure based on current Allison Transmission requirements. This feature allows the main pressure to be fully variable depending Cn transmission input torque response and the selected range of the transmission. A new variable bleed solenoid is used to control main pressure. sa Figure 1-10. Control Valve Assembly (2010 Uprate) Copyright © 2010 Allison Transmission, Inc.ALLISON 1000 and 2000 Product Families GENERAL DESCRIPTION 1-14, WIRING HARNESS A. External Wiring Harness. The external wiring harness (refer to Figure 1-11) requirements are typically met through the use of a single harness with one branch conneciing the Transmission Control Module (TCM) to the transmission, Throttle Position Switch (TPS), Internal Mode Switch (IMS), and speed sensors; another branch connecting the TCM to Allison DOC® For PC-Service Tool and other vehicle interfaces. All wiring harnesses and mating connectors are Original Equipment Manufacturer (QEM)-supplied, NOTE: Obtain repair parts for the extemal hamess and extemal harness components through the vehicle OEM. The OEM is responsible for warranty on these parts, Copyright © 2010 Allison Transmission, Inc. 1.13ALLISON 1000 and 2000 Product Families TRANSMISSION HARNESS anway ‘CoNNECTOA aise Gottecron oeu supruien ITERFACE HARNESS INPUT (een) Peep Genaoe ‘CONNECTOR oureur SPEED SENSOR Connecron THROTTLE POsmION ‘SENSOR (TP3) ‘ConNECTOn (OPTIONAL) TuROTHE POSITION ‘SENSOR (TPS) 2b WAY MAIN ‘TRANSAISSION ‘CONNECTOR NOTE: mustaon snot eal Actual arses ‘Sintraton ayaa fem hs uataton, Figure 1-11. Typical External Wiring Harnesses. 114 Copyright © 2010 Allison Transmission, Inc.ALLISON 1000 and 2000 Product Families GENERAL DESCRIPTION B. Internal Wiring Harness. An internal wiring hamess (refer to Figure 1~12 for pre-2010 Uprate and Figure 1~13 for 2010 Uprate) connects the Shift Solenoids (SS1, SS2, SS3), Pressure Control Solenoids (PCS1, PCS2), Torque Converter Clutch (TCC) solenoid, IMS, Pressure Switch Manifold (PSM), and temperature sensor to the external harness leading to the TCM. wan TRANSINSSION COMMECTOR ma MoD a tocxa rea pl Z Be — a s hd ba ray Figure 1-12. Typical Internal Wiring Harness (Pre-2010 Uprate 24-Way Connector) TRANSIMSSION ‘CONNECTOR locker ws INTERNAL Pose MODE \ E swe Figure 1-13. Typical Internal Wiring Harness (2010 Uprate 24-Way Connector) Copyright © 2010 Allison Transmission, Inc. 1.18ALLISON 1000 and 2000 Product Families GENERAL DESCRIPTION 1-15. SPECIAL ELECTRONIC/ELECTRICAL TOOLS All special tools listed below are available for overhaul, maintenance, and/or recalibration of the 1000 and 2000 transmission product families. The special tools listed below are only available for purchase from SPX Service Solutions unless otherwise noted, Table 1-1. Essential Tools ‘¥-34520-AlJ-46708 High 147275 TOM Breakout Impedance Digital Multimeter Harness Adapter Kits NOTE: Used with J-39700 Universal Breakout Box ‘539700 Universal Breakout Box 447276 “Breakout and . TOM Reflashing Hames . ‘B BS ‘J-42455-A Load Box 4-47278 1000 and 2000 a Product Families Breakout rn Harness: ice | NOTE: Used with J-39700 D Universal Breakout Box 1J-44950 Allison DOC® For < 447943 DPAA USB Transiator P6-Serice Too —— Devic KitorJ-47948-A DPA =f Plus USB Translator Device NOTE: J-44950 is superseded q \ kit for each new CD release of _. Allison DOC? For PC-Service NOTE: Support for J1850 Tool. 28 | communication protocol is only available on the J-47943-A when used spacificially with J-47949-A, ‘J-47944 1000 and 2000 Product Families Main Transmission Connector Removal Too! 4-44722-B Breakout Cable Adapter Kit NOTE: The J-44722-B Kit includes the J-44722-2 Breakout Cable, the J-46971 Single Connector NSBU Breakout Adapter Cable, the 4-44722-1B Overlay, and the J-44722-3 Overiay (for plok-up trucks) 116 Copyright © 2010 Allison Transmission, Inc.ALLISON 1000 and 2000 Product Families GENERAL DESCRIPTION Table 1-1. Essential Tools (cont'd) J-47949 GMLAN Cable or J-47949-4 NOTE: The J-47949 supports only GMLAN. J-47949-A supports GMLAN ‘and J1850 communications protocols, Table 1-2. Available Tools ‘Al special tools listed in this table are available for overhaul, maintenance, andlor recalibration of the 1000 and 2000) transmission product families. The special tools listed below are only available for purchase from SPX Service Solutions unless otherwise noted. J-38125-12A Terminal Remover 4472-3 Overlay L/P | (@oonay connector) GM PIN py ‘2094429, NOTE: J-44722-3 overlay is y for pick-up truck use only. The J-44722-3 is included in the 144722-8 Kit 1-39197-A Jumper Wire Kit E8727 Terminal Probe NOTE: J-47277 is now included within the 4-39197-A Kit ‘J-48624 Nexig USB-Link™ NOTE: Also available from Nexiq (Nexiq PIN: 125032) ‘The J-47949-A can be used with the Nexiq USB-Link™ for GMLAN communications protocol, Table 1-3. J-47139 (Molex P/N 63811-2700) NOTE: Refer to SIL 19-TR-07 Rev A for purchase information, ‘The J-47189 (Molex P/N 63811-2700) is available from SPX Service Solutions. 4.47139 (Molex PIN 63811-2700) Copyright © 2010 Allison Transmission, Inc. 17ALLISON 1000 and 2000 Product Families GENERAL DESCRIPTION Table 1-4. Terminal and Crimper Part Numbers Terminal PINS ‘Tool PINS St Clair | Molex Premium Grade™ ‘Service Grade™ Left payoff | Right Payoff | Molex PIN’ | SPXPIN? | Molex PIN | SPX PIN from Spool _| from Spoo! “Curent” | 300247 33001-3004 | 33001-2004 | 63811-6000 | N/A 64076-0133 | NIA Terminal “Former | 300247 33001-1004 | 33001-0004 | 63811-2700 | Ja7139 NIA NA terminal ‘Available from both Helind/Force Electronies and Newark InOne. 2 available only from Newark InOne (Melee me C40160999) olen BN C981 000) Figure 1-14. Molex Crimpers 118 Copyright © 2010 Allison Transmission, Inc.ALLISON 1000 and 2000 Product Families Section 2—DEFINITIONS AND ABBREVIATIONS 241. CHECK TRANS LIGHT The electronic control system is programmed to inform the operator of a problem with the transmission system and automatically take action to protect the operator, vehicle, and transmission. To do this, the Transmission Control Module (TCM) tums on the CHECK TRANS light or the MIL (Malfunction Indicator Light — used in OBD-II applications) on the instrument panel, which notifies the operator that a Diagnostic Trouble Code (DTC) has been stored. Each time the engine is started, the TCM illuminates the CHECK TRANS light or the MIL, then turns it off after a few seconds. This is a circuit check to verify that the lamp and wiring are in proper working order. Illumination of the CHECK TRANS light or the MIL at any time after start-up indicates that the TCM has set a DTC. Use Allison DOC® For PC— Service Tool to verify that the TCM has set a DTC (refer to 2-4, ALLISON DOC® FOR PC-SERVICE TOOL. While the CHECK TRANS light is on, upshifts and downshifts may be restricted and direction changes (D-R, R-D) may not occur. The torque converter clutch may be inhibited when transmission shifting is restricted or during any critical transmission malfunction The 1000 and 2000 Product Families transmissions DTCs are latching DTCs. When a failure condition is detected, the DTC set by the TCM remains active for the entire time the ignition is on. When the ignition is tumed off and then on again, the transmission DTCs reset and the TCM rechecks for the failure condition. If the failure condition is not present, the previously set DTC remains in history; the CHECK TRANS light or the MIL tums off after the circuit check, and the transmission will function normally unless another failure occurs. This feature allows the vehicle to be driven to a service center. 2-2. RANGE INHIBIT RESPONSES The range inhibit feature is a function of the TCM logic. The TCM senses when certain input variables are exceeded and takes action to prevent transmission damage. The TCM inhibits neutral-to-range shifts and illuminates a light on the dash when the inhibit is active, ‘See Section 2-3 for a complete list of inhibits. There are two levels of special logic inhibits. + Self-clearing inhibit - This inhibit clears itself if one of the above conditions is not present after a calibrated time. This calibrated time is three seconds in the case of medium-duty vehicles. If the shift inhibit is active, but not latched, the light stays lit until self-cleared, + Latching inhibit - This inhibit latches when one of the conditions listed above is still present after a calibrated time. This calibrated time is greater than three seconds for medium duty vehicles. To clear a latching inhibit, move the selector into any position other than the selector position originally chosen. 2-3. ALLISON DOC® FOR PC-SERVICE TOOL INHIBITS If an inhibit has occurred since the last DTC was cleared, the inhibit state indicates on and stays on until the next manual DTC clears with Allison DOC® For PC-Service Tool. These latched inhibits do not turn off after a specified number of ignition cycles. The RANGE INHIBIT light illuminates and/or an inhibited state is shown on Allison DOC® For PC-Service Tool when the transmission is inhibited to neutral for the following reasons + Converter Overheat Torque Protection (COTP) limits the time the converter can be stalled at high power and alerts the operator of abusive conditions. COTP prevents converter damage Copyright © 2010 Allison Transmission, Inc. 24ALLISON 1000 and 2000 Product Families 22 DEFINITIONS AND ABBREVIATIONS resulting from abuse without interfering with operator control during normal operation. Shift Energy Management/Lower Range Torque Protection (SEM/LRTP) equipped transmissions will imit the engine to 1400 rpm when the following conditions are met = 1400 rpm of converter slip — 25 percent throttle or greater — Less than 200 rpm output speed — More than 16 seconds of previous conditions — After an additional 7 seconds of stall, engine speed is limited to 900 rpm The RANGE INHIBIT light flashes for one second before, and for the duration of, a torque out if the vehicie is SEM/LRTP or LRTP equipped. Only SEM/LRTP or LRTP equipped vehicles are able to offer torque limits. If a vehicle is not SEM/LRTP or LRTP equipped, the RANGE INHIBIT light flashes but there is no torque limiting Low Main Pressure, If the transmission pressure switches do not indicate the transmission to be pressurized at start-up, shifts-to-range may be inhibited and the RANGE INHIBIT light illuminates. Allison DOC® For PC-Service Tool indicates an active inhibit. Common causes are transmission low on fluid, transmission filter has just been changed, or pan has been removed and fluid recently drained, This may produce DTC P0701 Transfer Case Neutral. If the transfer case is shifted into neutral while the transmission is in drive or reverse at a speed above idle, the transmission continues to command range unti the output speed is reduced to a point where neutral range is commanded. The RANGE INHIBIT light illuminates and Allison DOC® For PC-Service Tool indicates an active inhibit. DTC Active. This indicates that an active DTC was set and the driver attempted a range selection that was inhibited. In some failure modes, reverse cannot and will not be commanded. If R (Reverse) is selected during these failure modes a RANGE INHIBIT light illuminates while in reverse. During diagnostic responses, neutraleto-range inhibits and direction change inhibits continue to operate, but they may latch under certain conditions. In these cases, shutting down the ignition and waiting for at least 5 seconds before restarting clears the inhibit condition. Allison DOC® For PC-Service Tool indicates an active inhibit Auto Neutral for Power Takeoff (PTO). Neutral-to-drive and neutralto-reverse shifts are inhibited to neutral and Alison DOC® For PC-Service Tool shows an inhibited state when the Transmission Control Module (TCM) detects auto neutral function input is active. Reverse Enable. Neutral-to-reverse shifts are inhibited to neutral and Allison DOC® For PC-Service Tool shows an inhibited state when no input is detected from the dash or floor mounted reverse enable switch when selecting R (Reverse) range. Allison DOC® For PC-Service Tool indicates an active inhibit. This function is only used in European transit and tour bus applications. Refuse Packer Step. Switch transmission operation is limited to only 1* range. Neutra-to-reverse shifts are inhibited to neutral and Allison DOC® For PC-Service Tool shows an inhibited state when input is detected from a step switch indicating that personnel are present on rear step platform. Auxiliary Function Range. Inhibit neutral-to-drive and neutral-to-reverse shifts are inhibited to neutral and Allison DOC® For PC-Service Tool shows an inhibited state when input is detected from an auxiliary switch or device. This inhibit remains active until the auxiliary switch input is shut off and range is reselected, Copyright © 2010 Allison Transmission, Inc.ALLISON 1000 and 2000 Product Families DEFINITIONS AND ABBREVIATIONS PTO Neutral Lockup. Allison DOC® For PC-Service Tool shows an inhibited state when neutral lockup is active and range shifts are being inhibited to neutral. When the selector is moved, lockup is, released and the inhibit clears. + Engine Speed, Neutral-to-drive and neutralto-reverse shifts are inhibited to neutral and the RANGE INHIBIT light illuminates if the engine speed is greater than a calibrated value (1400 rpm for medium duty non-emergency vehicles). Allison DOC® For PC-Service Tool indicates an active inhibit. + Output Speed. Reverse-to-drive, drive-to-reverse, and neutral-to-reverse shifts initiated above 300 rpm of output speed are inhibited to neutral and the RANGE INHIBIT light illuminates. Allison DOC® For PC-Service Tool indicates an active inhibit. Throttle. Reverse-to-drive, drive-to-reverse, neutral-to-drive, and neutral-to-reverse shifts where throttle position is greater then 25 percent are inhibited to neutral and the RANGE INHIBIT light illuminates. Allison DOC® For PC-Service Too! indicates an active inhibit. + IMS Function or Alignment. Reverse-to-drive, drive-to-reverse, neutral-to-drive, and neutral-to-reverse. shifts are inhibited to neutral and the RANGE INHIBIT light illuminates when an Internal Mode Switch (IMS) failure or misalignment is detected. A common cause would be an error in the four-bit IMS input signal that is sent to the TCM. Allison DOC® For PC-Service Tool indicates an active inhibit + IMS PS4 Disagree. Reverse-to-drive, drive-to-reverse, neutral-to-drive, and neutral-to-reverse shifts are inhibited to neutral and the RANGE INHIBIT light illuminates when PS4 status is in the incorrect state when compared to the IMS state. Allison DOC® For PC-Service Too! indicates an active inhibit. This inhibit may be caused by a defective IMS, Pressure Switch Manifold (PSM), or valve body concerns. + Manual Selector Valve (MSV) Misalignment/Unable to detect ratio after shift to range. If the range verification test fails to detect turbine speed pull down or valid gear ratio when the MSV shifts to either forward or reverse range from neutral, the transmission shifts back to a neutral condition and the RANGE INHIBIT light illuminates. Conditions that may cause this include: = Attempts to shift the transmission from neutral-to-drive or neutral-to-reverse with the transfer case in neutral — transmission low on fluid = misadjustment in the IMS or selector linkage — turbine or output speed sensor failure that may prevent the pull down test/ratio test from passing; solenoid A or B hydraulic failures — possibly failed range clutch (C1 or C5 for 1*, C3 or CS for Reverse). Allison DOC® For PC-Service Tool indicates an active inhibit response. + Wheel Spin or Lock. When the TCM detects that wheel lock or spin is occurring, the Torque Converter Clutch (TCC) is disengaged and a lock-to-range response is commanded for 6 seconds. Allison DOC® For PC-Service Tool indicates an active inhibit response. 2-4. ALLISON DOC® FOR PC-SERVICE TOOL, Allison DOC® For PC-Service Too! v8.0 (or later) is available through Kent-Moore Heavy-Duty Division. When installed on a Windows® PC, the Allison DOC® For PC-Service Tool (refer to Figure 2-1) transmits and receives data to and from the Transmission Control Module (TCM) via the vehicle data communications Copyright © 2010 Allison Transmission, Inc. 23ALLISON 1000 and 2000 Product Families DEFINITIONS AND ABBREVIATIONS link, processes the data, and displays appropriate information. Use Allison DOC® For PC-Service Tool during installation, checkout, and troubleshooting, For more details on Allison DOC® For PC-Service Tool features, refer to the Allison DOC® For PC-Service Tool User Guide, GN3433EN. Figure 2-1. Allison DOC® For PC-Service Tool 2-5. DEFINITIONS and ABBREVIATIONS AN Assembly Number ABS Anti-lock Brake System — OEM provided means to detect and prevent wheel stoppage to enhance vehicle hanaling. Retarder and engine brakes should not apply when ABS is active. Ac Alternating Current Amp Ampere — Unit of electrical current, CAN Controller Area Network — A network for all SAE J1939 communications in a vehicle (engine, transmission, diagnostics, ABS, etc.) ce Calibration Compatibility — First two digits of the Calibration Identification Number (cin. cIN Catration lentcaton Number — Used to identity transmission conto sofware corp Converter Over-Temp Protection cme Customer Modifiable Constants cr Closed Throtlle c™ Converter Temperature Modeling oc Direct Current 24 Copyright © 2010 Allison Transmission, Inc.ALLISON 1000 and 2000 Product Families DEFINITIONS AND ABBREVIATIONS DNA Does Not Adapt — Adaptive shift control is disabled DNS DO NOT SHIFT — Refers to the DO NOT SHIFT diagnostic response during which the CHECK TRANS lights illuminated and the transmission will not shift and will not respond to the Shift Seles pic Diagnostic Trouble Code Dvom Digital Volt / Ohmmeter ECM Engine Control Module — Available on electronically-contralied engines—provides relevant data to the TCM. EMI Electromagnetic Interference FM Filter Life Monitor Pl General Purpose Input — Input signal to the TCM to request a special operating mode or condition. Po General Purpose Output — Output signal from the TCM to control vehicle components (such as PTOs, backup lights, etc.) or allow a special operating mode or condition, ims Internal Mode Switch Ipc. Instrument Panel Controller 1939 High-speed vehicle serial data communications standard Less. Load Based Shift Schedule LeD Light-Emitting Diode—Electronic device used for illumination LRTP, Low Range Torque Protection—A feature limiting engine torque in lower ranges and reverse to protect the transmission from damage. NL Neutral Very Low — The TCM has sensed turbine speed below 150 rpm. This is usually caused by a dragging C1 or C3 clutch or a failed turbine speed sensor, When attained, the C4 and C5 clutches are applied to lock the transmission output, 080 I On Board Diagnostics Second generation. EPA mandated specification for vehicle diagnostics. OEM Original Equipment Manufacturer of vehicle or equipment. ‘Ohm Unit of electrical resistance. ‘om Oil Life Monitor c Personal Computer PCcs Production Calibration Configuration System PSM Pressure Switch Manifold — Part of transmission control system located inside the oll pan. PCM Powertrain Control Module — Electronic device used on some vehicles Pos Pressure Control Solenoid Pov Pressure Control Valve POM Parallel Data Module PPC Pressure Proportional to Current solenoid. Solenoid control of clutch pressure is, proportional to the current being supplied to the solenoid PROM Programmable Read Only Memory Ps. Pressure Switch Copyright © 2010 Allison Transmission, Inc. 25ALLISON 1000 and 2000 Product Families PSM PTO PWM. RFI RPR SESS sem SOL OFF ss sv TBC Tec Tom Ter ™ vac vas voc vw vom vw wor DEFINITIONS AND ABBREVIATIONS Pressure Switch Manifold — Part of transmission control system located inside the cil an. Power Takeoff Pulse Width Modulation Radio Frequency Interference Retum to Previous Range — Diagnostic response in which the transmission is ‘commanded to return to previously commanded range. ‘Super Economy Shift Schedule Shift Energy Management — Allows the TCM to request torque reduction from the ECM during upshits for increased clutch If. All Solenoids OFF Shift Solenoid Shift Valve Truck Body Controller Torque Converter Clutch Transmission Control Module (also commonly referred to as the “computer") Transmission Fluid Temperature — Data provided by thermistor that is par of the PSM. Transmission Health Monitor Vehicle Acceleration Control Variable Bleed Solenoid — Another name for Pressure Proportional to Current (PPC) solenoid. Solenoid control of clutch pressure is proportional to the current being supplied to the solenoid, Volts Direct Current Vehicle interface Wiring — Interfaces TCM programmed input and output functions with the vehicle wiring, Volt — Unit of electrical force Volt / Ohmmeter Variable Main Modulation Wide Open Throttle Infinity — Condition of a circuit with higher resistance than can be measured: effectively an open circuit, Copyright © 2010 Allison Transmission, Inc.ALLISON 1000 and 2000 Product Families Section 3—BASIC KNOWLEDGE 3-1. BASIC KNOWLEDGE REQUIRED To service 1000 and 2000 Product Families Allison 4" Generation Controls, the technician must understand basic electrical concepts. Technicians need to know how to use a digital volvohmmeter (DVOM) to make resistance and continuity checks. Most troubleshooting checks consist of checking resistance and continuity, and checking for snorts between wires and to ground. The technician should be able to use jumper wires and breakout hamesses and connectors, Technicians unsure of making the required checks 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 B. MAIN PRESSURE CHECK PROCEDURE. Input power, ground, and neutral start circuitry, can cause problems with electronic controls or vehicle functioning and may not generate a Diagnostic Troubleshooting Code (DTC). A working knowledge of 1000 and 2000 Product Families Allison 4!" Generation Controls vehicle installation is necessary in troubleshooting installation-related problems. Refer to 7-1, GENERAL TROUBLESHOOTING OF PERFORMANCE COMPLAINTS for information concerning performance complaints (non- DTC) troubleshooting. A complete wiring schematic is shown in Appendix |, WIRING SCHEMATIC, Refer to the 1000 and 2000 Product Family Tech Data for information conceming electronic controls installation and the Installation Checklist. Reliable transmission operation and performance depend upon a correctly installed transmission. For proper installation, review the Installation Checklist in the 1000 and 2000 Product Family Tech Data, available on the Extranet under Engineering at www allisontransmission.com. 3-2. USING THE TROUBLESHOOTING MANUAL Use this manual as an aid to troubleshooting the 1000 and 2000 Product Families Alison 4" Generation Controls and 2010 Uprate transmissions. Every possible problem and its solution cannot be addressed by any manual. However, this manual does provide a starting point from which most problems can be resolved ‘Once a problem's solution is discovered in the manual do not |ook 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 ensure 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. 3-3. SYSTEM OVERVIEW 1000 and 2000 Product Families Allison 4" Generation Control functions are controlled by the Transmission Control Module (TCM). The TCM reads shift selector range selection, output speed, and throttle position to determine when to command a shift. When a shift occurs, the TCM monitors turbine speed, output speed, and throttle position to control the oncoming and off-going clutches during the shift When the TCM detects an electrical fault, it logs a Diagnostic Trouble Code (DTC) indicating the faulty circuit and may alter the transmission operation to prevent or reduce damage. Copyright © 2010 Allison Transmission, Inc. 34ALLISON 1000 and 2000 Product Families BASIC KNOWLEDGE ‘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. The 1000 and 2000 Product Families transmission uses clutch shift control to achieve range changes. In every case (except shifts to or from neutral), one clutch is exhausted and another applied to make a range shift. The hand off between exhausting and applying clutches is very precisely controlled by use of two Variable Bleed Solenoids (VBS), commonly known as Pressure Proportional to Current (PPC) solenoids. These solenoids are labeled PCS1 and PCS2 in the transmission, and are referred to as pressure control solenoids. For example, to make a 1-2 shift, PCS1 is used to trim pressure off of the C5 clutch, and PCS2 is Used to trim pressure on the C4 clutch. The TCM modulates the current to both PCS1 and PCS2, which transiates to a proportional level of pressure to the clutch. In order to make a shift, the TCM uses sofware and calibration settings of several program Parameters to determine the level of current sent to the respective pressure control solenoids. These parameters are referred to as adaptive values. With a new transmission and TCM calibration, the adaptive values are set to base calibration level. The transmission uses the base calibration to perform the first of each type of shifl. However, once it has performed a shift, the TCM evaluates the actual shift and compares it to an ideal shift in the TCM's memory. Based on that comparison, the TCM changes the settings of the adaptive values to a level that it believes will result in a shift closer to the “ideal” shift the next time it makes that type of shift. This is referred to as adaptive shifting ‘When the TCM calibration is new, the TCM is in fast adaptive mode. In other words, the TCM is allowed to make relatively large changes in the adaptive values after each shift. Once the TCM determines that a given shif is close to its ideal level it switches to slow adaptive mode. In slow adaptive mode the TCM evaluating shifts and changing adaptive values, but is only allowed to do so in smaller increments, still The TCM is programmed to try to switch from fast to slow adaptive mode within approximately five shifts. Its important to understand that there are many different distinct shifts recognized by the TCM, and each of these shifis has its own adaptive values. For example, there are upshift and downshifts to and from each range, as well as unique adaptive values for several different throttle regions for each upshift and downshift. It may take a significant amount of time before most of the shifts converge from fast to slow adaptive, and it is not unusual to experience somewhat harsh or unpleasant shift quality until these shifts are adapted Torque Converter Clutch (TCC) engagement is accomplished by a separate Pressure Proportional to Current (PPC) TCC solenoid. There are adaptive values for this as well, and will require some driving for the TCC engagement to adapt. 3-4. IMPORTANT INFORMATION IN THE TROUBLESHOOTING PROCESS Before beginning the troubleshooting process, read and understand the following: + Allison-recommended wire numbers (i.e. 212) are a combination of the first digit indicating the TCM 80-way connector number and the last two digits indicating the pin-out information (i.e. 12). + Shut off the engine and ignition before any harness connectors are disconnected or connected + Remember to do the following when checking 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. 32 Copyright © 2010 Allison Transmission, Inc.ALLISON 1000 and 2000 Product Families BASIC KNOWLEDGE — Wiggle connectors, harnesses, and splices when looking for opens. This simulates vehicle movements which occur during actual operation. + When disconnecting a hamess connector, be sure that pulling force is applied to the connector itself and not the wires extending from the connector. + Resistance checks involving the wiring between the component and other components adds about one ‘Ohm of resistance to the component resistance shown. * Inspect all connector terminals for damage. Terminals may have bent or lost the necessary tension to maintain frm contact. + Clean dirty terminals or connectors with isopropyl alcohol and a cotton swab, or a good quality, non-residue, non-lubricating, cleaning solvent such as LPS Electro Contact Cleaner® or LPS NoFlash Electro Contact Cleaner®. CAUTION: The cleaning solvent must not be chlorine based, contain petroleum distillates, or ‘conduct electricity. The cleaning solvent should evaporate quickly fo prevent the possibility of condensation within the connectors. Always blow or shake any excess cleaner from the connector before assembling it to its mating connector or hardware. Cleaner trapped in the connector can affect the connector seal. (Refer to SIL 17-TR-94 for detailed information on the recommended cleaners.) i) CAUTION: Core should be taken wien welding on a vehide exuped with elecronie contol. Refer to Appendix G. WELDING ON VEHICLE/VEHICLE INTERFACE MODULE. + DTC displayed if system power is tured on while a harness connector is disconnected can be ignored and cleared from memory. Refer to Section 5. DIAGNOSTIC TROUBLE CODES (DTC) for the DTC clearing procedure. 3-5. BASIC TROUBLESHOOTING INFORMATION 1. Begin troubleshooting by checking the transmission fluid level and ignition voltage. Remember that some problems may be temperature related. Perform troubleshooting, including the fluid level and ignition voltage checks, at the temperature level where the problem occurs, NOTE: Fluid level and ignition voltage must be checked before any troubleshooting is performed. NOTE: If you are experiencing harsh shifts, itis important to use Alison DOC® For PC-Service Too! to verify whether that particular shift is adapted. Ifitis not, the Transmission Control Module (TCM) is stil learning how to adapt that shift and simply needs to be driven further while performing more of that particular type of shift If a particular shiftis in slow adapt but still objectionable, it is {900d troubleshooting practice to reset the adaptive values for that shift back to base calibration level. This automatically resets the TCM to fast adaptive mode. The vehicle should then be driven to allow the TCM to re-learn the shift. Many times this corrects the problem. Itis possible to reset individual shifts without affecting the other shifts Copyright © 2010 Allison Transmission, Inc. 33ALLISON 1000 and 2000 Product Families BASIC KNOWLEDGE CAUTION: Whenever a transmission is overhauled, exchanged, or has undergone repairs, the TCM must be “RESET TO UNADAPTED SHIFTS.” This will cause the TCM to erase previous adaptive information and begin to adapt in Fast Adaptive Mode from the base calibration. Failure to follow this procedure may cause premature failure of the overhauled, repaired, or replaced transmission. 2. Ifa transmission has been overhauled, exchanged, or repaired, use Allison DOC® For PC-Service Too! to RESET ADAPTIVE SHIFT PARAMETERS. To reset adaptive shift parameters: + Select the Action Request dropdown menu. + Click the Reset Adaptive Shift Parameters menu item. The Reset Adaptive Parameters window is displayed. + The Reset Adaptive Shift Parameters window contains 10 tabs — one for each upshift and downshift region, garage shifts and a reset tab for all regions. — To reset all adaptive shift parameters, select the ALL tab. — The adaptive shift parameters are reset when you click the RESET ADAPTIVE SHIFT PARAMETERS button—the Reset Adaptive Shift Parameters Successful window displays. Click the OK button 3. For proper operation of Allison DOC® For PC-Service Tool v8.0 (or later), check the following — Microsoft Windows® XP Professional, Microsoft Windows® 2000 (SP4 or later) Professional, and Windows® Vista® Home Basic (or better). NOTE: In order to install and run Allison DOC® For PC-Service Tool v8.0 (or later) on Windows® Vista® , the user must have full administrative privileges and the User Account 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 space 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 port-USB 1.1 (USB 2.0 recommended) — A serial port is required if connecting legacy CECI controllers, or if using the J-44652-A-SPX 4J1850-VPW (Class 2) translator device — 16x CD-ROM, (48x or greater recommended) — Full administrative privi For PC-Service Tool jes are required to install, use, and update the Allison DOC® — Internet connection capability (Intemet Explorer 5.0 or greater) NOTE: A broadband internet connection is recommended for receiving updates and file downloads. 34 Copyright © 2010 Allison Transmission, Inc.ALLISON 1000 and 2000 Product Families BASIC KNOWLEDGE — Adobe® Acrobat® Reader® is installed by default Error messages, sudden disconnection, and poor performance are some of the results users will experience if Allison DOC® For PC-Service Too! v8.0 (or later) is installed on PCs that do not meet one or more of the above specifications. NOTE: Refer to the CD Readme.txt file for more information. + The proper driver (electronic file) is installed for the computer interface module, + Power at the Deutsch 9-pin diagnostic connector (pin A is negative, pin B is positive). + The proper connections exist for communicating with Allison DOC® For PC-Service Tool (refer to Figure 3-1). Presently there are three communication standards supported by the 1000 and 2000 Product Families: J1850, J1939, and GMLAN J2284. All three standards are supported by Allison DOC® For PC-Service Tool v8.0 (or later). eaesuse Aeon cena comous fan oF Sarsoanm won on te am : sean) ey mete (PRES aT GENERATION CONTROLS) —, Be a Connector one Oeescsmp SbthecroR susounoe™ enw utr FoR Ste Toot _o- 2 on ate = “i AND < ronict panes Rt Eat) L~ 1) Bitecroe ‘Taanst arom on epwte rin rn € Sathekion (an or sara S28 ausouerHcevenaroncomrnois mime Deouunp, cami on Sate DNoTrARTOrsBAKT) EDU DUTY Figure 3-1. Proper Allison DOG® For PC-Service Tool Connections 4. Check DTCs by using Allison DOC® For PC-Service Too! TCMILoad Box Setup Copyright © 2010 Allison Transmission, Inc. 35ALLISON 1000 and 2000 Product Families BASIC KNOWLEDGE For TCM/Load Box setup (no connection to vehicle) use the J-47276 “T” Breakout and TCM Reflashing Harness. This hamess is required for bench-type refiashing of Allison 4" Generation Controls TCMs. Use one of the following methods for TCM reflashing (refer to Figure 3-2). + J1939-13 connector (for J1939 communication) in combination with J-42455-A Load Box + J1962 connector (for GMLAN high speed CAN communications) in combination with J-42455-A Load Box /TCM J-47943-A | J-47943 DPA4 USB Translator Device Kit is required to establish connection between the PC and the TCM. NOTE: To use the J1962 connector, J-47949-A / J-47949 GMLAN Cable is required. 4J-47949-A | J-47949 GMLAN Cable is available for purchase from SPX Service Solutions. 36 Copyright © 2010 Allison Transmission, Inc.ALLISON 1000 and 2000 Product Families BASIC KNOWLEDGE sora use CABLE. co Px azo Soa ena WVALABLE FRO i PRNENTHHOORE) conmesron ‘uso 990m ‘pansuarod oBvcE Fon Pe-seRMCe TOOL (PART OF 4796.8) tats (29m) CounceroR (250 Kops cam arrorsaratianny NY eneakour AND To MeFLAGHING HARNESS sm counnceron "WoT UsED ‘connector sez teeny ‘Gitan comceron (0 ps ca Scag cary Shou nore. SN ‘detain Ise whoa hanes une Tove xsi vent HARNESS ane coneeroR (wor useD} ‘Ta GENERATION TOM Figure 3-2. TCM/Load Box Setup TCMIVehicle Hames Setup On the vehicle, use the J-47276 “T” Breakout and TCM Reflashing Harness to connect the Allison DOC® For PC-Service Too! directly to the TCM to bypass the diagnostic tool connector. Use J-47943-A / J-47943 DPA4 USB Translator Device Kit to establish connection between the PC and the TCM. Copyright © 2010 Allison Transmission, Inc. 37ALLISON 1000 and 2000 Product Families BASIC KNOWLEDGE NOTE: When communications are not available at the diagnostic tool connector on the vehicle, DTCs can be read directly from the TCM using the diagnostic tool connectors on the J-47276 " Breakout and TCM Reflashing Hames. Use one of the following diagnostic tool connectors on the hamess to establish a diagnostic, connection between the TCM and the service tool (refer to Figure 3-3) + 1939-13 connector (for J1939 communication) + J1962 connector (for GMLAN high speed CAN communications) NOTE: To use the J1962 connector, J-47949-A / J-47949 GMLAN Cable is required. 4J-47849-A | J-47949 GMLAN Cable is available for purchase from SPX Service Solutions. 5. When a problem exists but a DTC is not indicated, refer to 7-1. GENERAL TROUBLESHOOTING OF PERFORMANCE COMPLAINTS. 6. Ifa DTC is found in the TCM memory, save all available DTCs and failure record information before clearing the active indicator (refer to 5-3. DTC READING AND DTC CLEARING) 7. When certain DTCs are active, a range selection into reverse or forward may not be possible. To determine if a failure is electrical or hydraulic, perform the following limp home test. WARNING: Never remove electronic control connectors while the engine is running. Always turn off ‘he ignition, set parking brake and chock the wheels. Failure to follow this procedure may result in unexpected vehicle movement. Limp Home Test With the ignition in the OFF position (engine not running), the selector in N (Neutral), and the parking brake set, remove the 80-way connector at the TCM, It is necessary to provide battery power at pin 41 of the 80-way connector in order to energize the neutral start relay, This can be accomplished by using a jumper wire between pin 10 and 41 at the 80-way connector. When the engine is restarted, the transmission defaults to a limp home capability. In this state, PCS1 (de-energized) allows C3 clutch to be applied. If the selector valve is moved to the reverse range position, main pressure is routed to C5 clutch, allowing reverse operation. if the selector valve is moved to the drive range position, main pressure is routed to C1 clutch, allowing third range operation. This allows a technician to use limp home capability to determine if a hydraulic or an electrical problem exists. If reverse and third ranges are available in limp home, an electrical failure may be indicated. If only one of the two ranges or neither was obtainable, this may indicate an intemal hydraulic failure (failed clutch, stuck valve, or solenoid failure). The clutches that could possibly have an indicated failure in limp home are C1, C3, and C5. 38 Copyright © 2010 Allison Transmission, Inc.ALLISON 1000 and 2000 Product Families BASIC KNOWLEDGE Jamasusa cane parr oF ase.) ‘onan GAD (@vALABLE Fou Shimer ore) INOTPARTOFJATS-AKT— — cpoans.pm “isa A a saansarod Dace panror HaSeAnT gaa sem ‘ComesToR 2s naps ca T sarvena i panrorsarbaanm NY HARNESS tal comcron ‘Sms {00s can Fr Saree car) SS consti = ror exsmcvewcur_” aes sana) “COMNETOR F vant “TH ceNERATION Te Figure 3-3. TCMiVehicle Harness Setup NOTE: Removing the 80-way connector may set several DTCs. Make sure all codes are cleared before proceeding with further troubleshooting, 8. Test drive the vehicle to confirm a DTC or performance complaint. Copyright © 2010 Allison Transmission, Inc. 39ALLISON 1000 and 2000 Product Families BASIC KNOWLEDGE + Ifthe DTC reappears, refer to 55. DIAGNOSTIC TROUBLE CODE (DTC) REFERENCE TABLES. The DTC section lists diagnostic codes and their description. Locate the appropriate troubleshooting table and follow the instructions. + Ifthe DTC does not reappear and the test has passed, it may be an intermittent problem. Use Alison DOC® For PC-Service Tool and the DTC (refer to 5-5. DIAGNOSTIC TROUBLE CODE (DTC} REFERENCE TABLES, The DTC display procedure identifies possible causes of the problem. + Appendix A. DIAGNOSING INTERMITTENT DTCs deals with the identification of potential circuit problems. Refer to Appendix A. DIAGNOSING INTERMITTENT DTCs if a circuit problem is suspected NOTE: Information concerning specific items is contained in the appendices located in the back of this manual. The appendices are referred to throughout the manual. 3-6. TCM DIAGNOSTIC PROCEDURE + Using Allison DOC® For PC-Service Tool, verify the current Calibration Identification Number (CIN) 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 80-way connector for damaged or bent pins. + Replace TCM with a new or known good TCM from a similar vehicle. + Ifthe replacement TCM corrects the original complaint, reinstall the original TCM to verify the complaint returns, If original complaint is confirmed, install a new TCM. + Ifthe complaint does not return, leave the original TCM installed + Clear any DTCs that may be present and test drive the vehicle to confirm the repair. NOTE: All 1000 and 2000 Product Families Transmission Control Modules (TCMs) are designed to be isolated from the vehicle chassis ground. Be sure the TCM case is not contacting the vehicle frame or any other point that might provide a ground connection. 3-7. RESETTING OF TCM PARAMETERS TO SUPPORT ENGINE UPDATE Shift Energy Management (SEM) Autoselect feature may be used on certain transmissions. Autoselect is deactivated following the first five engine starts where engine and transmission communication are present. If during the first five engine starts, the TCM recognizes an engine to be on its list of certified engines, it locks to the SEM active state. If the engine is not supported, the TCM locks 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 engine models within the same engine family or when a recalibration of engine software 3-10 Copyright © 2010 Allison Transmission, Inc.ALLISON 1000 and 2000 Product Families BASIC KNOWLEDGE has taken piace. If a vehicle receives upgraded engine hardware or software it may become necessary to reactivate the Autoselect feature to redetect the engines current SEM status. NOTE: Once TCM Autoselect locks, the only way to reactivate is to perform a reset procedure (refer to 3-8, RESETTING TCM SEM AUTOSELECT). 3-8. RESETTING TCM SEM AUTOSELECT Verify a new engine rating by checking the engine data tag. The engine must be compatible with the transmission rating. if the engine rating is not compatible, return the vehicle to the OEM for engine recalibration. If the rating is correct for the transmission, perform the following steps. Allison DOC® For PC-Service Too! is used to reset Autoselect function + Click the action requested button + On the dropdown, select Reset SEM Autoselect ‘The TCM is now reset to Autoselect and will start looking for supporting engine software. Drive the vehicle; confirm DTCs have not retumed Copyright © 2010 Allison Transmission, Inc. attALLISON 1000 and 2000 Product Families NOTES Copyright © 2010 Allison Transmission, Inc.ALLISON 1000 and 2000 Product Families Section 4—WIRE CHECK PROCEDURES 41. CHECKING OPENS, SHORTS BETWEEN WIRES, AND SHORTS-TO-GROUND (Use J 34520-A Digital Volt/Ohmmeter and J 39197 Jumper Wire Set) NOTE: Refer to 3-5. BASIC TROUBLESHOOTING INFORMATION to begin the troubleshooting process. Make sure all connectors are tightly connected and re-check the circuit. 2. Disconnect and inspect all connectors 3. 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 I the problem recurs, proceed with Step 4. ‘CAUTION: The cleaning solvent must not be chlorine based, contain petroleum distilates, or conduct electricity. The cleaning solvent should evaporate quickly to prevent the possibilty of condensation within the connectors, Always blow or shake any excess cleaner from the connector before assembling it to its mating connector or hardware. Cleaner trapped in the connector can affect the connector seal. (Refer to SIL 17-TR-94 for detailed information on the recommended cleaners.) 4. Review the wire numbering system described in 3-4. IMPORTANT INFORMATION IN THE: TROUBLESHOOTING PROCESS. 5. Ifall connectors are clean and properly seated, determine which wires in the chassis harness are indicated by the DTC. For example, DTC P2727-P2729, indicates an open or a short-to-ground in the PCS1 circuit-wires 111 and 155 a. Check continuity of wires 111 and 155 by performing the following (refer to Figure 4~1) i. Disconnect the 80-way connector from the TCM and disconnect the harness from the transmission main connector. At one end of the harness, using J-39197 Jumper Wire Set or 4J-39197A Jumper Kit and the body connector probes in J-39775-CP Connector Probe Set, connect pins 14 and 15 to each other, being careful not to distort the terminals. Jumping the wires together creates a circuit between wires 111 and 155. NOTE: J-39197A Jumper Kit adds a female probe J-47277. Copyright © 2010 Allison Transmission, Inc. 44ALLISON 1000 and 2000 Product Families WIRE CHECK PROCEDURES “TRANSISION CONNECTOR ins HARNESS ro S soa S< i cconnceron co OHMS Crest one nt have connaly de to braten we open crea DVO reading very nigh ‘ovom esting es 266 (istinta Dme ar —Onri, Figure 4~1. Checking Continuity (External Harness) CAUTION: Do not insert test probes larger than 0.81 mm into the TCM 80-way and transmission 24-way connectors. Use the gray-colored 150 Series Metripack Flexible Male Connector probe contained in J-39197 or J-39197-A Jumper Kit 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. ii. On the opposite end of the harness, check the continuity of the jumpered pair. No continuity in a jumpered pair circuit (infinite resistance reading) indicates an open in the wire being tested. Refer to OEM wiring harness repair procedure. b. If the continuity check is good (0-2 Ohms resistance), remove the jumpers. Check the harness for shorts between wires and shorts-to-ground by performing the following (refer to Figure 4~2): i. Atthe TCM end of the hamess, touch one VOM probe to one wire of the circuit being tested and touch the other probe to each terminal in the same connector, then touch the probe to chassis ground and to the transmission main housing. Do this for both wires in the circuit being tested. ii. Ifatany time the VOM shows zero to low resistance, or the meter’s continuity beeper sounds, there is a short between the two points being probed—wire-to-wire or wire+to-ground. Isolate and repair the short. 42 Copyright © 2010 Allison Transmission, Inc.ALLISON 1000 and 2000 Product Families WIRE CHECK PROCEDURES "TRANGISSION CONNECTOR anc HARNESS su ania ‘CONNECTOR piciraL frome ot 0 OHMS “wo wires have Fayed ad re shorted loge Continly boar of VOM 0 OHMS Hereas hes been caled end one or more eshrladl-ground. DVOM conity al sume ecg wl 9010, Teepe ul ind aren go '6| toro hme han thee wo wae 2ere Oe when metre probing ‘are probed wth the DYOM. between tis re and chess ground, ere Figure 4-2, Short Between Wires and to Ground (External Harness) 4-2. CHECKING AT TRANSMISSION CONNECTOR AND THE INTERNAL HARNESS FOR OPENS, SHORTS BETWEEN WIRES, AND SHORTS-TO-GROUND 1. Disconnect the external wiring harness from the transmission, 2. Inspect the connectors. Thoroughly clean any terminals which are corroded or dirty ‘CAUTION: The cleaning solvent must not be chlorine based, contain petroleum distillates, or ‘conduct electricity. The cleaning solvent should evaporate quickly to prevent the possibility of ‘condensation within the connectors. Always blow or shake any excess cleaner from the connector before assembling it to its mating connector or hardware. Cleaner trapped in the connector can affect the connector seal. (Refer to SIL 17-TR-94 for detailed information on the recommended cleaners.) 3. Ifthe connectors are clean and properly seated, determine which wires in the harness to test. Use the diagnostic code system schematic to locate the wire terminals. For this example, OTCs P2727 and 2729 indicate an open or a short-to-ground in the Pressure Control Solenoid 1 (PCS1) circuit—wires 411 and 155 (refer to Figure 4-3 and Figure 4~4). a. At the transmission connector, check the resistance of the PCS1 circuit. Resistance of a solenoid circuit should be 5.5-8 Ohms—covering a temperature range of -18°C to 149°C (-0°F to 300°F). Refer to Appendix J. RESISTANCE VS. TEMPERATURE. No continuity in the circuit (infinite resistance) indicates an open in the internal harness, the feedthrough connector, or the solenoid coil. Replace the internal harness, replace the feedthrough connector, or replace the solenoid. Copyright © 2010 Allison Transmission, Inc. 43ALLISON 1000 and 2000 Product Families WIRE CHECK PROCEDURES ain BEX eee VOLTIOHM. MEIER wou). 5.5—8 OHMS: uit doesnot have contin due oa AT NORMAL OPERATING brlenwe(opn erat, VOW renng TEMPERATURE ‘Wey high (tie chins or OL-ovein). Thi ould alo Beato an open solenoid ol or bad conection, on ‘iculthas continu, Figure 4-3. Checking Continuity (Internal Harness) b. Ifthe resistance check is good, check the harness for shorts between wires and to ground by performing the following (refer to Figure 4~4) i. At the transmission connector, touch one probe of the VOM to one wire of the circuit being tested and touch the other probe to each terminal in the connector and to chassis ground and the transmission main housing. Do this for both wires in the circuit being tested If the VOM shows zero to low resistance, or the continuity beeper sounds, there is a short i, between the two points being probed, wire-to-wire or wire-to-ground, An indication of a short may be caused by a splice to the wire being checked. Check the wiring diagram in Appendix H. HYDRAULIC SCHEMATICS for splice locations. If the short is not a splice, then isolate and repair the short 44 Copyright © 2010 Allison Transmission, Inc.ALLISON 1000 and 2000 Product Fami WIRE CHECK PROCEDURES wan. TRANSMISSION CONNECTOR SOLENOIDS 0 OHMS 0 OHMS ‘Two wires hae frayed and are shorted Harness has bon cated and one or more {ogethur. Continuity hooper of DVOM will wits ar sort to ground. DVO continuity ‘sound, oF reading wl goto 2r0 Ohms beeper wil sound ot mete reading wl go hen these wo wes ae probed with to zr0 Ohms when meters probing between ‘the VOU this wee and enasss grou vereaaae Figure 4-4, Short Between Wires and to Ground (Internal Harness) Copyright © 2010 Allison Transmission, Inc. 45ALLISON 1000 and 2000 Product Families 46 NOTES Copyright © 2010 Allison Transmission, Inc.ALLISON 1000 and 2000 Product Families Section 5—DIAGNOSTIC TROUBLE CODES (DTC) 51. DTC MEMORY Diagnostic Trouble Codes (DTCs) are logged in a list in Transmission Control Module (TCM) memory. The DTCs contained in the list have information recorded as shown in Table 5-1 (example), The TCM is capable of displaying all historic and active DTCs, Table 5-1. DTC List prc. ‘Active | Historie Check Fallure Description Indicator Trans Record Ports Y Y N Y Transmission Fluid Temperature Sensor Circuit High Input The following paragraphs define the different parts of the DTC list. A. DTC. The number assigned to a given fault condition in accordance with SAE J2012. B. Active Indicator. Indicates when a DTC is active. If a DTC is active, Allison DOC® For PC-Service Tool displays Y. If a DTC is not active, N is displayed. C. Historic. Indicates when an active DTC has had sufficient activity to be stored to the TCM. If a DTC has been stored to the TCM, Allison DOC® For PC-Service Tool displays Y. If the DTC has not been stored to the TCM, N is displayed. Check Trans. Indicates if CHECK TRANS light is illuminated, E. Failure Record. Indicates when a snapshot of transmission data has been stored in the TCM. The last five DTC failures can be viewed. If the DTC can be viewed as part of the failure record, Allison DOC® For PC-Service Too! displays Y. If the DTC cannot be displayed, N is displayed. F. Description. Name assigned to a given fault condition in accordance with SAE J2012. 5-2. FAILURE RECORDS Failure records contain a snapshot of transmission data that is stored in the Transmission Control Module (TCM) when Diagnostic Trouble Codes (DTCs) are logged. A limit of five failure records can be stored When an additional DTC is logged, the new failure record pushes the oldest record from the TCM memory, Table 5-2 illustrates the failure record data stored in the TCM when a DTC is set. Table 5-2. Failure Record Data Data Description Freeze Frame Diagnostic Trouble Code Distance at First Failure Distance at Last Failure Failure Record Fail ignition Cycle Counter Failure Record Pass Ignition Cycle Counter Failure Record Not Run Ignition Cycle Counter Goar Selected Copyright © 2010 Allison Transmission, Inc. 54ALLISON 1000 and 2000 Product Families DIAGNOSTIC TROUBLE CODES (DTC) Table 5-2. Failure Record Data (cont'd) Gear Commanded Current Gear Previous Gear TCM Battery Voltage ‘Trans Fluid Temperature (TFT) Trans Input Shaft Speed ‘Trans Output Shaft Speed Turbine Speed Diagnostic Transmission Gear Ratio Accelerator Effective Position Main Mod Solenoid Commanded Pressure PCS2 Commanded Pressure PCS1 Commanded Pressure TCC Pressure Control Solenoid Command Pressure ‘Transmission Fluid Pressure Switch Status Shift Solenoid Status TCM Substrate Temperature Drive Demanded Engine Torque Engine Torque Requested Torque Normal Shift Pattern Cold Shift Pattem Hot Mode (Transmission) ‘Trallering/Hauling Shift Pattern Engine in Default Mode Shift Pattern Main Modulation Solenoid Fail Shift Pattern Main Modulation Available Engine Run Time Driver Select Tap Up/Down Input AC Enabled Cruise Enabled IMs A, IMs 8 IMs ¢ IMs P Number of Current Malfunctions Copyright © 2010 Allison Transmission, Inc.ALLISON 1000 and 2000 Product Families DIAGNOSTIC TROUBLE CODES (DTC) Table 5-2. F: ire Record Data (cont'd) Transmission Input State #1 Transmission Input State #2 TCM Non-Volatile Inhibit Record 5-3, DTC READING AND DTC CLEARING Diagnostic Trouble Codes (DTCs) can be read and cleared by using Allison DOC® For PC-Service Tool. The use of Allison DOC® For PC-Service Tool is described in the instruction manual furnished with each tool. A. Clearing DTCs. + DTCs automatically clear after 40 code-free warm-up cycles. + DTCs can be manually cleared by the Allison DOC® For PC-Service Tool. B. Clearing Active Indicators. + A DTC's active indicator can be cleared, which removes the DTC shift inhibitions while the DTC remains in the queue as inactive. + The active indicator clearing method is to power down (all active indicators are cleared at Transmission Control Module [TCM] power down). ‘CAUTION: If an active indicator is cleared while the transmission is locked in a forward range or reverse (fail-to-range), the transmission will remain in the forward range or reverse after the clearing procedure is completed. N (Neutral) must be manually selected. 5-4. BEGINNING THE TROUBLESHOOTING PROCESS A. Starting Procedure. NOTE: Review 3-5. BASIC TROUBLESHOOTING INFORMATION and check fluid level and ignition voltage before performing any troubleshooting, 1. Begin troubleshooting by reading 3-5. BASIC TROUBLESHOOTING INFORMATION, checking the transmission fluid level, and checking the Transmission Control Module (TCM) input voltage. Check for DTCs by using the Allison DOC® For PC-Service Tool 2. When a problem exists, but a Diagnostic Trouble Code (DTC) is not indicated, refer to Section 7. GENERAL TROUBLESHOOTING OF PERFORMANCE COMPLAINTS for a isling of various electrical and hydraulic problems, their causes, and remedies. 3. fa DTCs found in the TCM memory, record all available DTC information and failure record data before clearing the DTC (refer to 3-8. BASIC TROUBLESHOOTING INFORMATION). Copyright © 2010 Allison Transmission, Inc. 53ALLISON 1000 and 2000 Product Families DIAGNOSTIC TROUBLE CODES (DTC) 4, Test drive the vehicle to confirm a DTC or performance complaint. + If the DTC reappears, refer to the appropriate DTC table. The DTC section lists DTCs and their description. Locate the appropriate troubleshooting table and follow the instructions. + If the DTC does not reappear, it may be an intermittent problem. Use the Allison DOC® For PC-Service Tool and the DTC display procedure described in Section 5. DIAGNOSTIC TROUBLE CODES (DTC). Refer to the troubleshooting tabie for possible causes of the problem. + Appendix A. DIAGNOSING INTERMITTENT DTCs deals with the identification of Potential circuit problems. Refer to Appendix A. DIAGNOSING INTERMITTENT DTCs if a circuit problem is suspected. NOTE: 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 5~1 and Figure 5-2. Refer to Figure 5~1 and Figure 5-2 as necessary when using the DTC schematics. Toc vererecen Figure 5-1. Solenoid Locations (Pre MY 2010) 54 Copyright © 2010 Allison Transmission, Inc.ALLISON 1000 and 2000 Product Families DIAGNOSTIC TROUBLE CODES (DTC) a Figure 5-2. Solenoid Locations (2010 Uprate) C. Wire/Terminal Numbering Scheme. Allison Transmission recommended wire numbers (such as 112) consist of three digits, where the first digit indicates the TCM 80-way connector number, and the last two digits indicate the pin-out information (such as 12). D. Available Diagnostic Adapters. Figure 5-3 and Figure 5~4 show the J-47275 TCM Breakout Hamess Adapter and 47278 Breakout Hamess that are available for use with the J-39700 Universal Breakout Box. Figure 5-5 shows the J- 47276 ‘T" Breakout and TCM Reflashing Hamess Copyright © 2010 Allison Transmission, Inc. 55ALLISON 1000 and 2000 Product Families DIAGNOSTIC TROUBLE CODES (DTC) Tit Breaout Hares aapter Figure 5-3. J-39700 Universal Breakout Box and J-47275 TCM Breakout Harness Adapter 56 Copyright © 2010 Allison Transmission, Inc.ALLISON 1000 and 2000 Product Families DIAGNOSTIC TROUBLE CODES (DTC) sur aRENKOUT HO 7 Hames e eexatng clamor oe i) encom, ce ~~ To Output testy comec Sone tr == ven Figure 5-4. J-39700 Universal Breakout Box and J-47278 Breakout Harness, Copyright © 2010 Allison Transmission, Inc.ALLISON 1000 and 2000 Product Families DIAGNOSTIC TROUBLE CODES (DTC) G ie. ita, Figure 5-5. J-47276 “ reakout and TCM Reflashing Harness 5-5. DIAGNOSTIC TROUBLE CODE (DTC) REFERENCE TABLES Table 5-3, Gear Ratio Range Close Ratio Wide Ratio 1 3.101 3514 2 1814 1.90:1 3 144 141 4 1.00:1 1.00:1 5 orn oat 6 o6tt 0.641 R 4.4951 =5.08:1 58 Copyright © 2010 Allison Transmission, Inc.ALLISON 1000 and 2000 Product Families DIAGNOSTIC TROUBLE CODES (DTC) Table 5-4. 4! Gen Main Pressure Schedule Range Main Pressure @ 600 rpm Main Pressure @ 2100 rpm. ForwardiReverse 1590-720 kPa (86-104 psi) (634-758 kPa (92-110 psi) Converter with Main Mod Active (viewable in Allison DOC® For PC-Service Too!) Forward Converter with 700-1380 kPa (101-200 psi) 1515-1796 kPa (220-260 psi Main Mod Inactive Forward Lockup with Main Mod Active * Forward Lockup with Main Mod Inactive * 510-627 kPa (74-91 psi) 1000-1170 kPa (145-170 psi) NeutraliPark with Main 590-720 kPa (86-104 psi) Mod Active NeutraliPark with Main {800-1655 kPa (116-240 psi) 1515-1795 kPa (220-260 psi) Mod Inactive Medium duty gasoline engines only, NOTE: For 2010 Uprate, Variable Modulated Main Pressure was introduced. This feature allows the main pressure to be constantly variable depending on the transmission turbine torque input and vehicle throttle setting. Table 5-5 indicates the pressure readings for transmissions with Shift Energy Management (SEM) and Table 5-6 indicates the pressure readings for transmissions without SEM. Certain diagnostic codes cause the Variable Modulated Main Pressure to disable, other diagnostic codes allow only step mod operation. In order to determine the proper response see “Actions Taken When the DTC Sets’ for each individual DTC. Electrical system failure will cause the transmission to operate at full main pressure, see column A in Table 5-5 and Table 5-6. Table 5-5. 2010 Uprate Variable Modulated Main Pressure Schedule Shift Energy Management (SEM) (use Allison DOC® For PC-Service Tool to verify). All pressures should be taken at 80° C (176° F) Gotunn A Column 8 Gatun © Range @ 700-775 Main Pressure @ 700-775 is i rom (Verale | rpm (ariblo Msuloted Wain | Mai ressure @ 1400 pm (arabe Modulated Main Pressure Active) lodulated Main Pressure Active) Pressure Of 1580-1910 a 7 Reverse (226-277 psiy (600-850 kPa (87-123 psi) 1445-1765 kPa (210-256 psi) T6t6 1925 wo wouter | 1515-1925 38 | are coo wPaea-72 ps) 460-560 sa (67-81 ps Copyright © 2010 Allison Transmission, Inc. 59ALLISON 1000 and 2000 Product Families DIAGNOSTIC TROUBLE CODES (DTC) Table 5-5. 2010 Uprate Variable Modulated Main Pressure Schedule (cont'd) Shift Energy Management (SEM) (use Allison DOC® For PC-Service Tool to verify). All pressures should be taken at 80° C (176° F) ConA Column 5 Game Fal Main Pressure . cam enable | rpm Varco Mult Man | Mala reese @ 140 rpm Vale Modulated Main Pressure Active) toda lated Main Pressure Active) ve ange | "25,5262 Tas sasira 62-7095) | 758-008 sh 109-1047) ae rango | S1-TEOK 2 | san s20 a (70-00 pe | 645-1090 4Pa (122-149 ped - 290-1220 Pa enone | 292,1220 2 | os cas ura ez 70s) | 10-8064Pa (107-191 ps rn ee range | 388-7050 Pe | aps ura @a-70 po) | _600-10001Pa 110-145 pe ; 7300-1508 KPa a> range | 1808-15952 | ing as ura G2-70 psy | 760-990} (110-198 po * Pressures recorded with Allison DOG? For PG-Service Tool in clutch test mode, at 1400 engine ram, no output speed Table 5-6. 2010 Uprate Variable Modulated Main Pressure Schedule No Shift Energy Management (SEM) (use Allison DOC* For PC-Service Tool to verify). All prossures should be taken at 80° C (176° F) Column A Column & Column ¢ Full Main Pressure @ Range ut ® | Main Pressure @ 700-775 | Main Prossure @ 1400 rpm * oo 77S rem (Variable | ‘rpm (Variable Modulated | (Variable Modulated Main Modulated Main Pressure { red Main Pressure Active) Pressure Active) off Reverse 1580-1910 W'9 228-277 | 709-265 kPa (101-125 psi) | 1995-1705 kPa (202-247 psi Neutral TET 1628 Wee 225-279 | 395-512 kPa (56-14 ps 460-560 kPa (67-81 psi) 1 Range | 1245-1520 kPa (180-220 psi) | 500-635 KPa (72-02 psi) | 850-1040 kPa (123-751 psi) 28 Range _ | 945-1150 kPa (137-167 psi) | 500-620 kPa (72-90 psi) | 875-1072 kPa (127-155 psi) 3" Range | 990-1220 kPa (144-177 psi) | 500-620 kPa (72-00 psi) | _ 760-930 KPa (110-135 psi) a Range | 170-1480 (170-207 | 500-620 kPa (72-90 psi) {655-800 kPa (95-116 psi) sm Range | 1990-1850 Ka (195-299 | 590-620 kPa (72-90 psi) | 830-1017 KPa (120-147 psi 5-10 Copyright © 2010 Allison Transmission, Inc.ALLISON 1000 and 2000 Product Families DIAGNOSTIC TROUBLE CODES (DTC) Table 5-6. 2010 Uprate Variable Modulated Main Pressure Schedule (cont'd) No Shift Energy Management (SEM) (use Alison DOC® For PG-Service Tool to verily) All pressures should be taken at 80° C (176° F) Galumn A Column 6 Caumne Fal Main Pressure range | Fultan Pressure @ | wan pressure @ 700-77 | Wan Pressure @ 1490 rpm yi20-775 0m arable | "om arabe Modulated | arable Mdultee Main off) Main Pressure Active) Pressure Active) * 6 Range 1800 oe (188-231 | 500-620 kPa (72-90 psi) 778-950 kPa (113-138 psi) * Pressures recorded with Allison DOC® Far PC-Service Tool in clutch test mode, at 1400 engine rpm, no output speed. Table 5-7. Allison DOC® For PC-Service Tool Internal Mode Switch (IMS) Status ‘Selector Position A B c P Neutral Start P OFF oN oN ‘OFF ON R OFF OFF ON ‘ON OFF N ON OFF ON ‘OFF ON D 5) [5@ | 56 ON OFF OFF ‘ON ON Mw 3 faa OFF OFF OFF OFF OFF 4 2[23 OFF ON. OFF ‘ON OFF Blocked +14 4 ON. ON, OFF OFF OFF When using a DVOM to check the IMS stalus of A, B, C, and P switches, note the physical switch states are the ‘opposite of Alison DOC® For PC-Service Too! status shown above. When using a DVOM to check the switch state of Neutral Start (NS), the switch state will be the same as the Allison DOC® For PC-Service Tool status shown above. ‘The IMS has four positions available in forward, Therefore, one range position is omitted at the selector. The omitted positon can be 2°, 3%, or 4, depending upon chosen calibration M mode allows tap-up tap-down feature functionally between 1* through 6 ranges. Table 5-8. Solenoid and Clutch Apply Siady] ups [MEH] posi | csz | ssi | ss2_| ssa | roc | mana OFFION Soonld Stats R Calbraton steady oFF: ca | on;es Deperdert State — | Seoica | Aontoa | ON J on | ON | OFF | Oren Tbe, rote Tain and aber facets Copyright © 2010 Allison Transmission, Inc. 5-11ALLISON 1000 and 2000 Product Families DIAGNOSTIC TROUBLE CODES (DTC) Table 5-8. Solenoid and Clutch Apply (cont'd) steady] upsnins [MEN | posi | pcs2 | ssi | sez | ssa | roe | main wos = steady State ore. cs | on: 68 we] og | — [orcs] once | or | on | on | orr | on ciovos Tete an | = [Snating ice | of | on | ow [or | — OFF, £98 Ton: os we | = [tmnmrs] rc | ov on] ow J ore] — ova N orrics | oF = | on | on | on | oF | coset pot throttle ow 67 vs | = | 9868] sthmino | on | on fon fore} — orcs | OFF. — 7 iN 7 Applied | Exhausted ON ON ON | OFF on a 1 C1 OFF: C5 | OFF; 4 OFF ON OFF | OFF closed ve | ocr fomes | ore | on | ort | ore | — hast “ning orcs | oF ce on | ig ow ererder 2 cr | oN or | or | or |e Sinus] Spied rg Dependent Speed ores | OFF ce 23 | cr | ttmmng| Smaust- | or | ore | ore | on | — on | On 68 a2 | cr [omc] stom | ore | ore | ofr | on | — on orm ca | OFF ca ‘ecaton 3 ot Applied | Exhausted ON OFF OFF oN Dependent ON, ce a4] cr [oxic | simming | on | ore | orr | on) — onALLISON 1000 and 2000 Product Families DIAGNOSTIC TROUBLE CODES (DTC) Table 5-8. Solenoid and Clutch Apply (cont'd) Sie86y] paris [MEM] posi ] pcs2 | ser | sez | sse | rec | mainmoa OFF c3 as | co | Tamme | OFF: S2 | on | ore | ore | on) — on. 9 on | On G1 Vocation 4 ce Exhausted| Applied ON OFF ON ON | Dependent OFF. c3 45 2 | Trimming | OFF: C1 ‘ON OFF on | on ning | Satna OFF Gt sa | ce |,o-c3 | Smee | on | ore | on f on) — OFF | OFF Ot | on Vovatn 5 cz Applied | Exhausted OFF OFF ON ON | Dependent On. 56 c2 ON: C3 | trimming OFF OFF on | on om |g ow. | Ow S| ops Vecaion 6 id EX Applied oF OFF oN ON | dependent clutch, PCS2 controls C3 clutch. Above 20 percent throttle, SS1 is ON, PCS1 controls C3, PCS2 controls C5. Under 10 percent throttle, TOM reverts back to the close throttle (Idle) schedule, Table 5-9. Pressure Switch Status (wioy" (io) (NiO) (Nic PSt PS2 PS3 PS4 ‘Switch] Allison | Switch | Allison | Switch | Allison | Switch | Allison DOC® Status] Doc? | status | poc® | status | pOc®For | Status | For PC-Service For PC- For PC- PC-Service Tool Status Service Service Tool Status Too! Too! Range Status Status R_ | Open | Exhaustea/ | Closea | Pressurized] Closed | Pressurizedi| Closed | Exhausted/ON OFF" ON ‘ON N_ | Closed) Pressurized] Closea | Pressurized) Closed | Pressurizedi| Closed | ExhaustediON ON ON ‘ON 1 [Open | Exhausted’ | Closed | Pressurized] Closed | Pressurized/| Open Pressurized OFF ON ON OFF 2 | Open | Exhausted | Closed [Pressurized] Open | Exhausted’ [ Open Pressurized OFF ON OFF OFF Copyright © 2010 Allison Transmission, Inc. 5-13ALLISON 1000 and 2000 Product Families Table 5-9. Pressure Switch Status (cont'd) DIAGNOSTIC TROUBLE CODES (DTC) (Noy (Nioy" (woe (Nice Pst PS2 PSs ps4 Switch] Allison | Switch | Allison | Switch | Allison | Switch | Allison DOC® Status] Doc® | status | Doc® | Status | Doc®For | Status | For Pc-Service For PC- For PC- Pc-Service Tool Status Service Service Too! Status Tool Tool Range Status Status ‘3 | Closed] Pressurized/| Open | Exhausted’| Open | Exhausted’ | Open Pressurized! ‘ON OFF oF OFF 4 | Closed] Pressurized/| Open | Exhausted’] Open | Pressurized’ — Open’ Pressurized! ‘ON OFF ‘ON OFF 5 | Open | Exhausted’ | Open | Exhausted’ | Closed | Pressurzedi| Open Pressurized! OFF OFF ‘ON OFF Open | Exhausted’ | Open | Exhausted | Closed | Pressurized] Open Pressurized! OFF OFF ‘ON OFF ® NiO = Normally Open NIC = Normally Closed "PSI reverts to the CLOSEDION state with tattle applied in reverse, Table 5-10. Calculated Solenoid Resista nce vs. Temperature ‘Sump Temperature ‘TCC, PCS1, PCS2 (a) MAIN MOD ‘$81, $82, $83, Main Mod Solenoid (2010 Uprate) (4th Gen) (2) cy (CF) [Minimum] Nominal | Maximum | Minimum | Nominal | Maximum 65 85 323 3.36 3.50 13.98 14.65 15.32 -40 40 amt 3.86 4.01 16.05 16.81 17.58 -30 22 3.90) 4.08 422 16.87 17.88 18.48 -20 4 4.09) 426 4a2 17.70 18.54 19.38 =10 14 4.28 445 4.63 18.52 19.41 20.29 0 32 447 465 4.84 19.35 20.27 21.19 10 50 4.66 485 5.04 20.17 21.14 22.10 20 66 485 5.05 6.25 21.00 22.00 23.00 30 86 5.04 825 5.46 21.83 22.86 23.90 40 104 623 5.45 5.66 22.65 23.73 24.81 60 122 a2, 5.65 5.87 23.48 28.59 60 140 661 5.84 6.08: 24.30 25.46 70 188 5.80) 6.04) 6.28 25.13 26.32 80 176 5.99) 6.24 6.49) 25.95 27.19 90 194 6.18 6.44 6.69 26.18 28.05 100 212 6.37 6.90 27.80 28.92 614 Copyright © 2010 Allison Transmission, Inc.ALLISON 1000 and 2000 Product Families DIAGNOSTIC TROUBLE CODES (DTC) Table 5-10. Calculated Solenoid Resistance vs. Temperature (cont'd) ‘Sump Temperature TCG, PCS1, PCS2 (Q) MAIN MOD 881, $82, $83, Main Mod Solenoid (2010 Uprate) (4th Gen) (2) (c) CF) | Minimum | Nominal | Maximum | Minimum | Nominal 110 230 657 6.84 7M 28.43, 29.78 120 248 676 7.03) 731 29.25 30.65 130 266 6.95 7.23 782 30.08) 31.81 140 284 7.14 7.43, 773 30.90) 32.38 160 302 7.33 7.63) 7.93 3173) 33.24 160 320 7.52 7.83 8.14 32.55 34.10 165 329) 7.61 7.93) B24 32.97, 34.54 Table 5-11. Speed Sensor vs. Temperature Temperature Resistance cy Minimum (2) Nominal (0) Maximum (2) 25 1929) 2143 2358 0 32 2157 2397 2637 25 77 2340 72600 2860 50 122 2614 2904 3195 75 167 2842 3158 3474 100 212 3071 3412 3753, 125 287 3299 3666 4032 150 302 3483, 3870 4257 Table 5-12. Transmission Fluid Temperature (TFT) Sensor Resistance vs. Temperature Temperature Resistance ec) Cry Minimum (2) Nominal (0) Maximum (2) 45 -49 128 665 141 961 155 388 -40 -40 95 826, 100 735 105 644 “35 “31 88 952 72 318 75 879 “25 13 36 845 38 478 40 103 15 5 20 746 21 286 22 097 10 14 15 467 21 286 22 097 6 23 +1 781 12197 22 097 0 32 9045 9345) 9646 5 41 6998 7219) 74a 10 50 5458 5623) 5787 Copyright © 2010 Allison Transmission, Inc. 5-15ALLISON 1000 and 2000 Product Families DIAGNOSTIC TROUBLE CODES (DTC) Table 5-12. Transmi jon Fluid Temperature (TFT) Sensor Resistance vs. Temperature (cont'd) ‘Temperature Resistance e) CFP Minimum (9) Nominal (2) ‘Maximum (2) 15 58 4291 4413 4536 20 68 3398 3490 3582 25 77 2710 2778 2849 30 86 2173 2228 2282 35 5 1754 1797 1640 40 104 1424 1459 1493 45 113 1163 1191 1218 50 122 955.0 e774 999.2 55 131 7886 8055 824.5 60 140 6547 669.3 683.9 65 148 545.3 558.3 570.2 70 188 458.1 4679 4778 75 167 3858 394.1 4022 80 176 3266 333.3 340.1 85 185 275 2832 288.8 20 194 2365 2416 246.7 98 203 202.4 208.8 28 100 212 1738 178 182.0 105 224 1498 1836 187.3 110 230 128.7 133.0 136.4 115 239 1126 1158 1187 120 248 98.17 100.88 103.6 125 257 85.87 88.29 90.71 130 266 75.35 77.52 79.69 135 215 66.34 68.27 70.21 140 264 58.58 60.31 62.04 145 203 51.88 53.42 54.97 150 302 46.08 4746 48.84 155 311 41.04 42.27 43.50 160 320 36.65 3774 38.84 Table 5-13, TPS—Distance (mm) of Travel vs. Volts mm) Volts mm Volts mm) Volts mm Volts 0 0 12 1.317 24 2.634 36 3.981 5-16 Copyright © 2010 Allison Transmission, Inc.ALLISON 1000 and 2000 Product Families DIAGNOSTIC TROUBLE CODES (DTC) Table 5-13. TPS—Distance (mm) of Travel vs. Volts (cont'd) mam Vets mam Volts mm Votts ram Vorts 1 00 13 1427 25 2.744 37 4.061 2 0.220 14 1587 26 2.854 38 aim 3 0.328 15 1646 27 2.964 39 4281 4 0.439 16 1.756 28 3.073 40 4.390 3 0549 7 71866 29 3.183 a 4500 é 0.659 18 1976 30 3.293 a2 4510 7 0.768 19 2.085 at 3.403 3 4720 é 0.878 20 2.195 2 3512 aa 4829 2 0.988 2 2.305 33 3.622 5 4.939 10 71098 22 2415 34 3.732 6 5.049 11 1207 2 2524 35 3.842 DTC LIST AND DESCRIPTION INDEX Table 5-14. Diagnostic Trouble Codes and Descriptions CHECK TRANS iagnosti pre Description wotetegn) | Liaht(Non-oep | — agnostic Page SY) | Strategy) ‘a o122 Pedal Position Sensor yes Circult—Low Voltage Po123 Pedal Position Sensor yes B32 Circuit—High Voltage o2te “Transmission Fluid Over no no 537 Temperature POs6I System no no Sat Voltage—Performance P0862 Systom Voltage Low no no 526 PO56S Systom Voltage—High no no 0802 “TCMiTransmission Control Module Not Programmed 0610 ToMTransmission Control no yes Module Vehicle Options (Transib) Error Posts TOM Processor na no 5.59 Posi4 Torque Control Data Mis- na yes 5.60 match - ECMITOM 0884 TCM Internal Temperature | yes no Too High Copyright © 2010 Allison Transmission, Inc. 817ALLISON 1000 and 2000 Product Families DIAGNOSTIC TROUBLE CODES (DTC) Table 5-14. Diagnostic Trouble Codes and Descriptions (cont'd) CHECK TRANS ore bescrotion | MELOBD | meqionoud | — DBBNES | pagg ay) Il Strategy) Pe PecsT | Actor Supriy Vago 1 yes Open -oass —Tacaior ppv WoageT | ye re (HSD1}—Low PORES Actor Sup Volage 7 | 98 ves sory gh Silom Povormance Po702 | Tension Conta 7 Yes (TransiD) Ba70S [Brake Swich Grout 7 a706 | Transmission Yes re Range Sensor Soro Greut Hah Bart | Tension Fuld re 7 PaT2 | Tannission Fula ve % FT Ere high pat BaTS | Turbine Speed Sena | yee ve a Crait_Porrmanee Crete Sir Paria [Bake Sun Creu % Porat | Oui Speed Sons | yee yes Crate Sire BGT | Engine Speed Sensor | vee * sas Crat-Pocorares aTaT | Erane Spoed Sensor | yee 7% a Crate ira 5-18 Copyright © 2010 Allison Transmission, Inc.ALLISON 1000 and 2000 Product Families DIAGNOSTIC TROUBLE CODES (DTC) Table 5-14. Diagnostic Trouble Codes and Descriptions (cont'd) CHECKTRANS | Giaroen ore peserptin | MLIO8D || nrimoncon | Diagrene | page ay) Il Strategy) Pt Ba7S5 | ieoroct re Gear Rao | yes Yes OTSA [covet th Gear Rao | yes yes OTS5 | hncorect th Gear Rao | yes Yes OTS6 | ncorect Reverse Ratio | yes = avs | Torque Conver Cuion | yes Yes (10) Syston Stuck OF (TCO) System—Stuck On avs [sit Scloni es es 501 ssi) owe or parse [sit Scions re re s8 1 (SS1) Valve on a es es ozs 2 (682) Ve on a re re 2 (SS2) Valve on a ves yes 3 (609) Yowe Pevomance Stuck or a re = 3 (689) Yao Pevoanco Stuck on arte [Pressure Oona Saenoa | Yes re i 2 B82) Stuck on 2'pes2}— Suck on a656 [Up ana Dom Shit Swich | oo va Circuit Copyright © 2010 Allison Transmission, Inc. 5-19ALLISON 1000 and 2000 Product Families DIAGNOSTIC TROUBLE CODES (DTC) Table 5-14. Diagnostic Trouble Codes and Descriptions (cont'd) CHECK TRANS, Light (Non-OBD 1 Strategy) MIL (OBD I! Strategy) Diagnostic pre Description Response P0827 Up and Down Shift Switch no na Circult—Low P0828 Up and Down Shift Switch no na Cireuit—High 0842 ‘Transmission Pressure yes yes. Switch 1 (PS1) Circuit—Low P0843 Transmission Pressure yes yes: 5.277 Switen 1 (PS1) Gircuit—High oB47 ‘Transmission Pressure yes yes ‘Switen 2 (PS2) Circuit—Low P0848 Transmission Pressure yes yes: 5-291 Switen 2 (PS2) Circuit—High P0872 Transmission Pressure yes yes: Switch 3 (PS3) Gircuit—Low P0873 Transmission Pressure yes yes: ‘Switen 3 (PS3) Circuit—High 0877 Transmission Fluid yes yes: Pressure Switch 4 (PS4) Gircuit—Low PO87S Transmission Fluid yes yes Pressure Switch 4 (PS4) Cireult—High P0880 TCMTransmission Control no no 5-328 Module Power Input Signal P0881 TOMTransmission Control no yes: 5-332 Module Power Input Signal—Performance Poss2 TCMTransmission Control no yes: Module Power Input Signal—Low 088s TCMTransmission Control no yes: 5341 Module Power Input Signal—High POBBB, Transmission Filter Very na yes Deteriorated 6-20 Copyright © 2010 Allison Transmission, Inc.ALLISON 1000 and 2000 Product Families DIAGNOSTIC TROUBLE CODES (DTC) Table 5-14. Diagnostic Trouble Codes and Descri ions (cont'd) CHECK TRANS: ore pescrption | MLIOBD" | eecomonD | BME | pagg ay) Il Strategy) Pt Dati BOGGS [Pressure Gonal Sono | yes es Er Main Mod (MAIN MOD) Syotom Prtrance BOSSE | Pressure Contol Sosa] yes es ia Mary ea (IAIN MOD) Cone Gat Low Main Mod (MAIN MOD) PaaG4 | Pressure Const Soto | yes ie 536 2059) conto Gree Open ase [Pressure ConsarSaeroa | Yes = sae 2059) Conte Grete BuGeT | Pressure Contr Saenoa | yes es ia 2 (PCS2) Control Gen Coie Great Open P0873 Shift Solenoid 1 (SS1) yes yes 5-395 one Ort Low Corie ret igh a ea es ea7 Gel Great” Open puaTe [sit Scio 2 652) | yee yes saa Conve reat tow oar [sit soimoa 2 652) | Yes yes a oie Great tigh ave [sit Saino 3 883) | Yes re aa pave [sit Soinca 3 653) | Yeo yes oa Gane! Groot tow Basee [sit tno 3 683) | yes es sa Goria Great ghALLISON 1000 and 2000 Product Families DIAGNOSTIC TROUBLE CODES (DTC) Table 5-14. Diagnostic Trouble Codes and Descriptions (cont'd) CHECK TRANS, Light (Non-OBD 1 Strategy) MIL (OBD I! Strategy) Diagnostic pre Description Response Press Unmanaged Engine yes yes. 5445, Torque Delivered to TCMTransmission Control Module Signal P1779 Engine Torque Delivered yes yes: Earn] to TCMTransmission Control Module Signal P1891 Throttle Position Sensor na no 5-451 (TPS) PWMPulse-Width Modulated Signal—Low Input Pig92 Throltle Position Sensor na no 5-455, (TPS) PWMPulse-Wiath Modulated Signal—High Input P2637 Torque Management na yes: 5-459) Feedback Signal—SEMShift Energy Management P2641 Torque Management na yes: 5-462 Feedback Signal—LRTPLower Range Torque Protection 2669 ‘Actuator Supply Voltage 2 na yes 5-465 Open 2670 ‘Actuator Supply Voltage yes yes. 5.472 2 (HSD2High Side Driver 2)-Low P2671 ‘Actuator Supply Voltage yes yes: 5-477 2 (HSD2High Side Driver 2)-High (Batt) P2723 Pressure Control Solenoid | yes yes: 1 (PCS1Pressure Control Solenoid 1}—Stuck Off pares Pressure Control Solenoid | yes yes: 1 (PCS1Pressure Control Solenoid 1)}—Stuck On P2727 Pressure Control Solenoid | yes yes: 5-492, 1 (PCS1Pressure Control Solenoid 1) Control Circuit—Open 6-22 Copyright © 2010 Allison Transmission, Inc.ALLISON 1000 and 2000 Product Families DIAGNOSTIC TROUBLE CODES (DTC) Table 5-14. Diagnostic Trouble Codes and Descriptions (cont'd) pre Description MIL (OBD It Strategy) CHECK TRANS: Light (Non-OBD Ml Strategy) Diagnostic Response Page P2728 Pressure Control Solenoid 4 (PCS1Pressure Control Solenoid +) Control Circuit—Low yes yes 5-499 P2730 Pressure Control Solenoid 4 (PCS1) Control Circuit—High yes P2761 TCC Torque Converter Clutch PCS Control Circuit Open yes: yes P2763 TCCTorque Converter Clutch PCS Control Circuit High yes: yes P2764 TCCTorque Converter Clutch PCS Control Circuit Low yes: yes P2771 “4-Wheel Drive Le Switch Circuit no na P2772 4-Wheel Drive Lo Switch—Performance yes P2789 Clutch Adaptive Leaming at Limit yes u0010 CANController Area Network 1 Bus Reset Counter Overrun yes: no u0073 CANController Area Network 2 GM LAN Bus Reset Counter Overrun yes: u0100 Lost Communication With ECM/PCM (CAN 2) uotts Lost Communication With ECM/PCM (CAN 1) no yes u0146 Lost Communication With Gateway A no no u0400 Invalid J1939 Communications u0442 Invalid Data Received from ECMIPCM B (CAN1/1939) no 1016 Class 2 Powertrain Controller State of Health Failure Copyright © 2010 Allison Transmission, Inc. 6-23ALLISON 1000 and 2000 Product Families DIAGNOSTIC TROUBLE CODES (DTC) Table $14, Diagnostic Trouble Codes and Descriptions (cont) CHECK TRANS ore bescrotion | MELOBD | meqionoud | — DBBNES | pagg ay) Il Strategy) Pe Controller (ABS) State of feat Tose] cass 2 Tack Boy 7 7% ia feath Toes | Gass 2tatapantPanet | vo 09 FT via00 Sera Daa 7 7 ial Communication Lk tow (lee 2 Tao | Seat Dat 7 7 a Conmumeaton irk High (Class 2) 6-24 Copyright © 2010 Allison Transmission, Inc.ALLISON 1000 and 2000 Product Families DIAGNOSTIC TROUBLE CODES (DTC) DTC P088B Transmission Filter Very Deteriorated Circuit Description Filter Life Monitor (FM) is a part of Allison 4!" Generation MY09 Prognostics functionality. When enabled in the Transmission Control Module (TCM), prognostic logic determines control main filter life based on hours accumulated and vehicle mileage. This information is used to determine the remaining control main fitter useable life. When the TCM determines the filter life has degraded, a J1939 message is sent to a dash mounted SERVICE TRANS indicator lamp. A flashing SERVICE TRANS indicator lamp informs the driver that the transmission control main filter should be serviced. If the SERVICE TRANS indicator lamp is ignored for 100 hours, a CHECK TRANS light illuminates and DTC POR8B sets, Condit ions for Running the DTC + Components are powered and the ignition voltage is greater than 9 volts and less than “8 volts (12 volts TCM), or greater than 18 volts and less than 32 volts (24 volts TCM). + Engine speed is greater than 200 rpm and less than 7500 rpm for 5 seconds. + Prognostic function is enabled. + No active DTCs, ons for Setting the DTC + DTC P088B sets during a current ignition cycle where SERVICE TRANS indicator lamp has been displayed (flashing) for more 6000 minutes after the shift to drive + This DTC indicates that oil fiter life has been determined to be under 3 percent useful life Action Taken When the DTC Sets + The TCM illuminates the CHECK TRANS light + For 2010 Up’ + DTC P0888 is stored in the TCM history. Conditions for Clearing the DTC the TCM forces variable main mod off Use the Allison DOC® For PC-Service Too! 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. Diagnostic Aids + For MY 2009 this feature requires that TES 296 fluid be used. For 2010 Uprate, either TES 295 or TES 389 may be used. * This function can also be reset by turing on the ignition and selecting N (Neutral) —R (Reverse)—N (Neutral)—R (Reverse)—N (Neutral)—D (Drive}-N (Neutral). Step Action’ Value(s) Yes No 1 [Was 5-4. BEGINNING THE TROU- Goto Step2 | Go to 54. BLESHOOTING PROCESS performed? BEGINNING THE TROU- BLESHOOTING PROCESS Copyright © 2010 Allison Transmission, Inc. 5-25