TP-0199

Issued 06-01

Range Shift System

Diagnostic Flowcharts
Platform “G” Transmissions
Technical Bulletin

3. High Side Electrical Checks: Follow the high

WARNING side electrical checks flowchart to verify that
the high electrical system functions correctly.
To prevent serious eye injury, always wear safe
Perform high side electrical checks after
eye protection when you perform vehicle
mechanical checks and low side electrical
maintenance or service.
checks.
When you work on an electrical system, the When you find the fault, follow recommended
possibility of electrical shock exists, and sparks service procedures to repair it, and then test the
can ignite flammable substances. You must system. If a fault still exists, or if you find a new
always disconnect the battery ground cable one, repeat Steps 1–3 above, until you’ve repaired
before you work on an electrical system to all faults.
prevent serious personal injury and damage to
components.
IN LINE CONFIGURATION
NOTE: Call ArvinMeritor’s Customer Service LOW DIAGNOSTIC VEHICLE AIR
SUPPLY
Center at 800-535-5560 to order wiring diagram PORT, 55-70 PSI IN
~ 120 PSI
TP-9964, Electric Over Air (EOA) Range Shift LOW, 0 PSI IN HIGH
System, which is specified in this bulletin. You can
also access this item in the DriveTrain PlusTM by
ArvinMeritor Tech Library section of
arvinmeritor.com.
To order SPX Kent-Moore shift knob tester
J-44356, call the company’s customer service
center at 800-345-2233 or visit their web site at HIGH
DIAGNOSTIC REGULATED
spxkentmoore.com. DIAGNOSTIC
PORT
55-70 PSI IN HIGH PORTS, 55-70 PSI
These flowcharts provide diagnostic information 0 PSI IN LOW
AIR FILTER REGULATOR
for ZF Meritor’s Platform “G” transmission range
shift systems. When using diagnostics to
troubleshoot system faults, it’s important to follow
these flowcharts step-by-step and use the V CONFIGURATION LOW DIAGNOSTIC
following diagnostic procedures in the sequence PORT, 55-70 PSI IN
outlined below. LOW, 0 PSI IN HIGH

1. Mechanical Checks: Follow the mechanical

checks flowchart to verify that all mechanical VEHICLE AIR
SUPPLY
systems function correctly. Repair all ~ 120 PSI
mechanical issues before you perform
electrical checks.
2. Low Side Electrical Checks: Follow the low
side electrical checks flowchart to verify that
the low electrical system functions correctly. HIGH
Perform low side electrical checks after DIAGNOSTIC REGULATED
PORT DIAGNOSTIC
mechanical checks and before high side 55-70 PSI IN HIGH PORTS, 55-70 PSI
electrical checks. 0 PSI IN LOW AIR FILTER REGULATOR
Electric Over Air (EOA) Diagnostic Flowchart
Mechanical Checks
FAULT: Slow/No Range Shift (after following low electrical flowchart)

Check air Vehicle pressure Build up vehicle Vehicle air

pressure at at air filter air pressure. pressure at
diagnostic port regulator is Check truck air air filter
on air filter ~ 120 psi supply regulator is less
regulator than or greater
than ~ 120 psi

Replace air Air pressure Air pressure Air pressure Replace air filter Adjust air
filter regulator is less than is between is greater regulator pressure to
assembly and 55 psi 55-70 psi than 70 psi assembly. ~ 120 psi
check air (Contact OEM)
system Possible root
quality. cause:
damaged air
Possible root With the ignition on and the stick filter regulator
cause: in Neutral, move the selector assembly
contaminants switch to low. Check low
in air system diagnostic port air pressure

Air pressure Air pressure is less Check for air leakage

is between than or greater at transmission
55-70 psi than 55-70 psi lube vent
NO
YES

Is air exhausting YES Replace Replace aux

continuously out of range case range
high solenoid? piston shaft lip seal

NO

With the ignition on and the stick

in Neutral, move the selector
switch to high. Check high
diagnostic port pressure

Air pressure Air pressure is less Replace air filter

is between than or greater regulator and
55-70 psi than 55-70 psi range piston
housing

Is air exhausting YES Replace

continuously out range
of low solenoid? piston
NO

Go to low
electric check
for the range
system

TP-0199
Issued 06-01 16579/24240
Page 2 Copyright ArvinMeritor, Inc., 2001 Printed in the USA
Electric Over Air (EOA) Diagnostic Flowchart
Electrical Checks, Low Side — Low Electrical Check
NOTE: Follow the mechanical flowchart BEFORE the low side electrical flowchart.
FAULT: Slow/No Range Shift (after following mechanical flowchart)

Resistance between Remove connector on low Resistance outside Replace low

11-21 ohms solenoid. Measure resistance the limits of solenoid
across pins A and B of solenoid 11-21 ohms

Voltage between Turn ignition on, and put the lever Voltage outside the
11.8-13.8 in Neutral. Select low range while limits of 11.8-13.8
in Neutral. Measure voltage at A
and B pins of low transmission
harness connector
Go to high Disconnect Neutral switch
electrical flowchart and measure resistance while
transmission is in Neutral

With ignition ON, put the stick

into gear. Disconnect neutral
switch and measure resistance Resistance Resistance is
0.0-0.5 ohms infinite

Resistance is Resistance Shift transmission Remove Neutral

infinite 0.0-0.5 ohms into gear. Measure switch and recheck
resistance at Neutral resistance with pin
switch extended

Go to high Replace Neutral

electrical checks switch

Resistance is Resistance is Resistance Resistance is

infinite measurable 0.0-0.5 ohms infinite

Check voltage at shift knob harness Replace Neutral Press pin and Replace Neutral
(pins A and D of four pin connector) switch check resistance switch

Voltage between Voltage is greater than Resistance is Resistance is

11.8-13.8 or less than 11.8-13.8 infinite measurable

Use SPX Kent-Moore shift Check wiring harness Check wiring harness Check top Replace Neutral
knob tester J-44366 to test for damage. Perform for damage. Perform cover for switch
the shift knob continuity checks continuity checks damage (Refer
(Refer to publication (Refer to publication to publication
TP-9964) TP-9964) TP-9964)

Shift knob passes Shift knob does not

test pass test

Go to high Replace shift

electrical flowchart knob

TP-0199
16579/24240 Issued 06-01
Printed in the USA Copyright ArvinMeritor, Inc., 2001 Page 3
Electric Over Air (EOA) Diagnostic Flowchart
Electrical Checks, High Side — High Electrical Check
NOTE: Follow the low electrical flowchart BEFORE this flowchart.
FAULT: Slow/No Range Shift (after following low electrical flowchart)

Resistance Remove connector on high Resistance Replace high

between solenoid. Measure resistance outside the solenoid
11-21 ohms across pins A and B of solenoid limits of
11-21 ohms

Voltage Turn ignition on, and put the Voltage

between lever in Neutral. Select high outside the
11.8-13.8 range while in Neutral. limits of
Measure voltage at pins A and B 11.8-13.8
of high transmission harness
connector

Contact Check voltage of

ZF Meritor lever harness at
800-535-5560 shift knob across
pins B and D of four
pin connector

Voltage Voltage outside

between the limits of
11.8-13.8 11.8-13.8

Use SPX Check voltage

Kent-Moore shift at OEM two pin
knob tester J-44366 harness
to test the shift knob

Shift knob passes Shift knob Voltage between Voltage outside the
test does not 11.8-13.8 limits of 11.8-13.8
pass test

Contact ZF Meritor Replace Check wiring harness for Contact OEM to fix
800-535-5560 shift knob damage. Perform continuity vehicle switched
checks (Refer to publication power
TP-9964)

ZF Meritor, LLC Information contained in this publication was in effect at the time the publication was approved for printing and is
22021 Skyway Church Road subject to change without notice or liability. ArvinMeritor Commercial Vehicle Systems reserves the right to revise
Maxton, NC 28364 USA the information presented or discontinue the production of parts described at any time.
800-535-5560
arvinmeritor.com Copyright 2001 TP-0199
ArvinMeritor, Inc. Issued 06-01
All Rights Reserved Printed in the USA 16579/24240