Allison Transmission TS3977EN 1000 & 2000 Product Families Troubleshooting Manual – PDF DOWNLOAD
DESCRIPTION:
Allison Transmission TS3977EN 1000 & 2000 Product Families Troubleshooting Manual – PDF DOWNLOAD
This manual provides troubleshooting information for Allison Transmission 1000 and 2000 Product Families
transmissions. Service Manual SM4006EN, Mechanics Tips MT4007EN, and Parts Catalog PC3062EN may be
used in conjunction with this manual.
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 (SIL) 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
outlet for the currently 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.
TABLE OF CONTENTS:
Allison Transmission TS3977EN 1000 & 2000 Product Families Troubleshooting Manual – PDF DOWNLOAD
TS3977EN…………………………………………………………………………………………………………………………………………………………… 2
TITLE PAGE …………………………………………………………………………………………………………………………………………………….. 2
FOREWORD – HOW TO USE THIS MANUAL…………………………………………………………………………………………………………………………………. 3
IMPORTANT SAFETY NOTICE………………………………………………………………………………………………………………………………………….. 4
WARNINGS, CAUTIONS, AND NOTES…………………………………………………………………………………………………………………………………….. 4
TRADEMARKS USED IN THIS MANUAL……………………………………………………………………………………………………………………………………. 5
SERVICE LITERATURE………………………………………………………………………………………………………………………………………………. 5
TABLE OF CONTENTS……………………………………………………………………………………………………………………………………………….. 6
SECTION 1—GENERAL DESCRIPTION…………………………………………………………………………………………………………………………………….. 8
1-1. TRANSMISSION……………………………………………………………………………………………………………………………………………. 8
Figure 1-1. Transmission Control Module Block Diagram………………………………………………………………………………………………………… 8
Figure 1-2. Electronic Control Components…………………………………………………………………………………………………………………… 9
1-2. TRANSMISSION CONTROL MODULE (TCM)…………………………………………………………………………………………………………………………. 10
Figure 1-3. Transmission Control Module (TCM)……………………………………………………………………………………………………………….. 10
1-3. SHIFT SELECTOR………………………………………………………………………………………………………………………………………….. 10
Figure 1-4. Typical Lever-Type Shift Selector……………………………………………………………………………………………………………….. 11
Figure 1-5. Internal Mode Sensor (IMS)……………………………………………………………………………………………………………………… 12
1-4. THROTTLE POSITION SENSOR (TPS)……………………………………………………………………………………………………………………………. 12
Figure 1-6. Throttle Position Sensor (TPS)………………………………………………………………………………………………………………….. 12
1-5. SPEED SENSORS…………………………………………………………………………………………………………………………………………… 13
Figure 1-7. Typical Speed Sensor…………………………………………………………………………………………………………………………… 13
Figure 1-8. Speed Sensor Connector Orientation………………………………………………………………………………………………………………. 14
1-6. CONTROL VALVE ASSEMBLY…………………………………………………………………………………………………………………………………… 14
Figure 1-9. Control Valve Assembly…………………………………………………………………………………………………………………………. 15
1-7. WIRING HARNESS………………………………………………………………………………………………………………………………………….. 15
Figure 1-10. Typical External Wiring Harnesses………………………………………………………………………………………………………………. 16
Figure 1-11. Typical Internal Wiring Harness (24-Way Connector)……………………………………………………………………………………………….. 17
Figure 1-12. Typical Internal Wiring Harness (20-Way Connector for GM Applications Only)…………………………………………………………………………. 17
SECTION 2—DEFINITIONS AND ABBREVIATIONS……………………………………………………………………………………………………………………………. 18
2-1. CHECK TRANS LIGHT……………………………………………………………………………………………………………………………………….. 18
2-2. RANGE INHIBIT RESPONSES………………………………………………………………………………………………………………………………….. 18
2-3. Allison DOC™ FOR PC–SERVICE TOOL INHIBITS………………………………………………………………………………………………………………….. 18
2-4. Allison DOC™ FOR PC-SERVICE TOOL………………………………………………………………………………………………………………………….. 21
Figure 2-1. Allison DOC™ For PC-Service Tool………………………………………………………………………………………………………………… 21
2-5. ABBREVIATIONS…………………………………………………………………………………………………………………………………………… 22
SECTION 3—BASIC KNOWLEDGE………………………………………………………………………………………………………………………………………… 24
3-1. BASIC KNOWLEDGE REQUIRED…………………………………………………………………………………………………………………………………. 24
3-2. USING THE TROUBLESHOOTING MANUAL………………………………………………………………………………………………………………………….. 24
3-3. SYSTEM OVERVIEW…………………………………………………………………………………………………………………………………………. 24
3-4. IMPORTANT INFORMATION IN THE TROUBLESHOOTING PROCESS………………………………………………………………………………………………………… 25
3-5. BASIC TROUBLESHOOTING INFORMATION…………………………………………………………………………………………………………………………. 26
Figure 3-1. Proper Allison DOC™ For PC-Service Tool Connections……………………………………………………………………………………………….. 28
Figure 3-2. TCM/Load Box Setup…………………………………………………………………………………………………………………………….. 29
Figure 3-3. TCM/Vehicle Harness Setup………………………………………………………………………………………………………………………. 31
3-6. TCM DIAGNOSTIC PROCEDURE…………………………………………………………………………………………………………………………………. 32
3-7. RESETTING OF TCM PARAMETERS TO SUPPORT ENGINE UPDATE………………………………………………………………………………………………………… 32
3-8. RESETTING TCM AUTOSELECT…………………………………………………………………………………………………………………………………. 33
SECTION 4—WIRE CHECK PROCEDURES…………………………………………………………………………………………………………………………………… 34
4-1. CHECKING OPENS, SHORTS BETWEEN WIRES, AND SHORTS-TO-GROUND (Use Digital Volt/Ohmmeter J 34520-A and Jumper Wire Set J 39197-A)………………………………………. 34
Figure 4-1. Checking Continuity (External Harness)…………………………………………………………………………………………………………… 34
Figure 4-2. Short Between Wires and to Ground (External Harness)………………………………………………………………………………………………. 35
4-2. CHECKING AT TRANSMISSION CONNECTOR AND THE INTERNAL HARNESS FOR OPENS, SHORTS BETWEEN WIRES, AND SHORTS-TO-GROUND………………………………………………….. 35
Figure 4-3. Checking Continuity (Internal Harness)…………………………………………………………………………………………………………… 36
Figure 4-4. Short Between Wires and to Ground (Internal Harness)………………………………………………………………………………………………. 37
SECTION 5—DIAGNOSTIC TROUBLE CODES (DTC)…………………………………………………………………………………………………………………………… 38
5-1. DTC MEMORY……………………………………………………………………………………………………………………………………………… 38
Table 5-1. DTC List………………………………………………………………………………………………………………………………………. 38
5-2. FAILURE RECORDS…………………………………………………………………………………………………………………………………………. 38
Table 5-2. Failure Record Data…………………………………………………………………………………………………………………………….. 39
5-3. DTC READING AND DTC CLEARING……………………………………………………………………………………………………………………………… 40
5-4. BEGINNING THE TROUBLESHOOTING PROCESS……………………………………………………………………………………………………………………… 40
Figure 5-1. Solenoid Locations…………………………………………………………………………………………………………………………….. 41
Figure 5-2. J 39700 Breakout Box and J 47275 TCM Breakout Harness Adapter………………………………………………………………………………………. 42
Figure 5-3. J 39700 Breakout Box and J 47278 Transmission Breakout Harness……………………………………………………………………………………… 43
Figure 5-4. J 47276 “T” Breakout and TCM Reflashing Harness…………………………………………………………………………………………………… 44
5-5. DIAGNOSTIC TROUBLE CODES (DTC)……………………………………………………………………………………………………………………………. 47
Table 5-3. DTC LIST AND DESCRIPTION INDEX…………………………………………………………………………………………………………………… 47
Table 5-4. Gear Ratio…………………………………………………………………………………………………………………………………….. 50
Table 5-5. Main Pressure Schedule………………………………………………………………………………………………………………………….. 50
Table 5-6. Internal Mode Switch (IMS)………………………………………………………………………………………………………………………. 50
Table 5-7. Solenoid and Clutch Apply……………………………………………………………………………………………………………………….. 51
Table 5-8. Pressure Switch Status………………………………………………………………………………………………………………………….. 52
Table 5-9. Calculated Solenoid Resistance vs. Temperature…………………………………………………………………………………………………….. 53
Table 5-10. Speed Sensor vs. Temperature……………………………………………………………………………………………………………………. 54
Table 5-11. Transmission Fluid Temperature (TFT) Sensor Resistance vs. Temperature………………………………………………………………………………. 54
Table 5-12. TPS-Distance (mm) of Travel vs. Volts……………………………………………………………………………………………………………. 55
DTC P0122 Pedal Position Sensor Circuit-Low Voltage………………………………………………………………………………………………………….. 56
DTC P0123 Pedal Position Sensor Circuit-High Voltage…………………………………………………………………………………………………………. 60
DTC P0218 Transmission Fluid Over Temperature……………………………………………………………………………………………………………….. 64
DTC P0561 System Voltage-Performance……………………………………………………………………………………………………………………….. 67
DTC P0562 System Voltage-Low………………………………………………………………………………………………………………………………. 71
DTC P0563 System Voltage-High……………………………………………………………………………………………………………………………… 74
DTC P0602 TCM Not Programmed………………………………………………………………………………………………………………………………. 77
DTC P0606 TCM Internal-Performance…………………………………………………………………………………………………………………………. 78
DTC P0613 TCM Processor…………………………………………………………………………………………………………………………………… 79
DTC P0614 Torque Control Data Mismatch-ECM/TCM………………………………………………………………………………………………………………. 80
DTC P0634 TCM Internal Temperature Too High…………………………………………………………………………………………………………………. 83
DTC P0658 Actuator Supply Voltage 1 (HSD1)-Low………………………………………………………………………………………………………………. 85
DTC P0659 Actuator Supply Voltage 1 (HSD1)-High (batt)……………………………………………………………………………………………………….. 89
DTC P0701 Transmission Control System-Performance……………………………………………………………………………………………………………. 93
DTC P0703 Brake Switch Circuit…………………………………………………………………………………………………………………………….. 95
DTC P0706 Transmission Range Sensor Circuit-Performance………………………………………………………………………………………………………. 98
DTC P0708 Transmission Range Sensor Circuit-High Input………………………………………………………………………………………………………..102
DTC P0711 Transmission Fluid Temperature Sensor Circuit-Performance…………………………………………………………………………………………….107
DTC P0712 Transmission Fluid Temperature Sensor Circuit-Low Input………………………………………………………………………………………………112
DTC P0713 Transmission Fluid Temperature Sensor Circuit-High Input……………………………………………………………………………………………..117
DTC P0716 Turbine Speed Sensor Circuit-Performance……………………………………………………………………………………………………………121
DTC P0717 Turbine Speed Sensor Circuit-No Signal……………………………………………………………………………………………………………..125
DTC P0719 Brake Switch Circuit……………………………………………………………………………………………………………………………..129
DTC P0721 Output Speed Sensor Circuit-Performance…………………………………………………………………………………………………………….131
DTC P0722 Output Speed Sensor Circuit-No Signal………………………………………………………………………………………………………………135
DTC P0726 Engine Speed Sensor Circuit-Performance…………………………………………………………………………………………………………….139
DTC P0727 Engine Speed Sensor Circuit-No Signal………………………………………………………………………………………………………………142
DTC P0729 Incorrect 6th Gear Ratio………………………………………………………………………………………………………………………….145
DTC P0731 Incorrect 1st Gear Ratio………………………………………………………………………………………………………………………….148
DTC P0732 Incorrect 2nd Gear Ratio………………………………………………………………………………………………………………………….151
DTC P0733 Incorrect 3rd Gear Ratio………………………………………………………………………………………………………………………….154
DTC P0734 Incorrect 4th Gear Ratio………………………………………………………………………………………………………………………….157
DTC P0735 Incorrect 5th Gear Ratio………………………………………………………………………………………………………………………….160
DTC P0736 Incorrect Reverse Ratio…………………………………………………………………………………………………………………………..163
DTC P0741 Torque Converter Clutch (TCC) System-Stuck Off………………………………………………………………………………………………………166
DTC P0742 Torque Converter Clutch (TCC) System-Stuck On……………………………………………………………………………………………………….168
DTC P0751 Shift Solenoid 1 (SS1) Valve Performance-Stuck Off…………………………………………………………………………………………………..170
DTC P0752 Shift Solenoid 1 (SS1) Valve Performance-Stuck On……………………………………………………………………………………………………175
DTC P0756 Shift Solenoid 2 (SS2) Valve Performance-Stuck Off…………………………………………………………………………………………………..180
DTC P0757 Shift Solenoid 2 (SS2) Valve Performance-Stuck On……………………………………………………………………………………………………185
DTC P0761 Shift Solenoid 3 (SS3) Valve Performance-Stuck Off…………………………………………………………………………………………………..190
DTC P0762 Shift Solenoid 3 (SS3) Valve Performance-Stuck On……………………………………………………………………………………………………196
DTC P0776 Pressure Control Solenoid 2 (PCS2)-Stuck Off………………………………………………………………………………………………………..202
DTC P0777 Pressure Control Solenoid 2 (PCS2)-Stuck On…………………………………………………………………………………………………………206
DTC P0826 Up and Down Shift Switch Circuit…………………………………………………………………………………………………………………..210
DTC P0827 Up and Down Shift Switch Circuit-Low……………………………………………………………………………………………………………….213
DTC P0828 Up and Down Shift Switch Circuit-High………………………………………………………………………………………………………………216
DTC P0842 Transmission Pressure Switch 1 (PS1) Circuit-Low…………………………………………………………………………………………………….219
DTC P0843 Transmission Pressure Switch 1 (PS1) Circuit-High……………………………………………………………………………………………………224
DTC P0847 Transmission Pressure Switch 2 (PS2) Circuit-Low…………………………………………………………………………………………………….229
DTC P0848 Transmission Pressure Switch 2 (PS2) Circuit-High……………………………………………………………………………………………………234
DTC P0872 Transmission Pressure Switch 3 (PS3) Circuit-Low…………………………………………………………………………………………………….239
DTC P0873 Transmission Pressure Switch 3 (PS3) Circuit-High……………………………………………………………………………………………………244
DTC P0877 Transmission Fluid Pressure Switch 4 (PS4) Circuit-Low……………………………………………………………………………………………….249
DTC P0878 Transmission Fluid Pressure Switch 4 (PS4) Circuit-High………………………………………………………………………………………………255
DTC P0880 TCM Power Input Signal……………………………………………………………………………………………………………………………261
DTC P0881 TCM Power Input Signal-Performance…………………………………………………………………………………………………………………264
DTC P0882 TCM Power Input Signal-Low………………………………………………………………………………………………………………………..268
DTC P0883 TCM Power Input Signal-High……………………………………………………………………………………………………………………….271
DTC P0960 Pressure Control Solenoid Main Mod (MAIN MOD) Control Circuit-Open…………………………………………………………………………………….274
DTC P0962 Pressure Control Solenoid Main Mod (MAIN MOD) Control Circuit-Low……………………………………………………………………………………..279
DTC P0963 Pressure Control Solenoid Main Mod (MAIN MOD) Control Circuit-High…………………………………………………………………………………….284
DTC P0964 Pressure Control Solenoid 2 (PCS2) Control Circuit-Open………………………………………………………………………………………………288
DTC P0966 Pressure Control Solenoid 2 (PCS2) Control Circuit-Low……………………………………………………………………………………………….293
DTC P0967 Pressure Control Solenoid 2 (PCS2) Control Circuit-High………………………………………………………………………………………………298
DTC P0972 Shift Solenoid 1 (SS1) Control Circuit-Open…………………………………………………………………………………………………………303
DTC P0973 Shift Solenoid 1 (SS1) Control Circuit-Low………………………………………………………………………………………………………….308
DTC P0974 Shift Solenoid 1 (SS1) Control Circuit-High…………………………………………………………………………………………………………312
DTC P0975 Shift Solenoid 2 (SS2) Control Circuit-Open…………………………………………………………………………………………………………317
DTC P0976 Shift Solenoid 2 (SS2) Control Circuit-Low………………………………………………………………………………………………………….322
DTC P0977 Shift Solenoid 2 (SS2) Control Circuit-High…………………………………………………………………………………………………………327
DTC P0978 Shift Solenoid 3 (SS3) Control Circuit-Open…………………………………………………………………………………………………………332
DTC P0979 Shift Solenoid 3 (SS3) Control Circuit-Low………………………………………………………………………………………………………….337
DTC P0980 Shift Solenoid 3 (SS3) Control Circuit-High…………………………………………………………………………………………………………342
DTC P1688 Unmanaged Engine Torque Delivered to TCM Signal……………………………………………………………………………………………………..346
DTC P1779 Engine Torque Delivered to TCM Signal………………………………………………………………………………………………………………348
DTC P1891 Throttle Position Sensor (TPS) PWM Signal-Low Input………………………………………………………………………………………………….351
DTC P1892 Throttle Position Sensor (TPS) PWM Signal-High Input…………………………………………………………………………………………………354
DTC P2637 Torque Management Feedback Signal-SEM………………………………………………………………………………………………………………357
DTC P2641 Torque Management Feedback Signal-LRTP……………………………………………………………………………………………………………..359
DTC P2670 Actuator Supply Voltage 2 (HSD2)-Low……………………………………………………………………………………………………………….361
DTC P2671 Actuator Supply Voltage 2 (HSD2)-High (batt)………………………………………………………………………………………………………..365
DTC P2723 Pressure Control Solenoid 1 (PCS1)-Stuck Off………………………………………………………………………………………………………..370
DTC P2724 Pressure Control Solenoid 1 (PCS1)-Stuck On…………………………………………………………………………………………………………373
DTC P2727 Pressure Control Solenoid 1 (PCS1) Control Circuit-Open………………………………………………………………………………………………376
DTC P2729 Pressure Control Solenoid 1 (PCS1) Control Circuit-Low……………………………………………………………………………………………….381
DTC P2730 Pressure Control Solenoid 1 (PCS1) Control Circuit-High………………………………………………………………………………………………386
DTC P2761 TCC PCS Control Circuit Open………………………………………………………………………………………………………………………391
DTC P2763 TCC PCS Control Circuit High………………………………………………………………………………………………………………………396
DTC P2764 TCC PCS Control Circuit Low……………………………………………………………………………………………………………………….401
DTC P2771 4-Wheel Drive Lo Switch Circuit……………………………………………………………………………………………………………………406
DTC U0010 CAN 1 Bus Reset Counter Overrun……………………………………………………………………………………………………………………410
DTC U0073 CAN 2 GMLAN Bus Reset Counter Overrun………………………………………………………………………………………………………………414
DTC U0100 Lost Communication With ECM/PCM (CAN 2)…………………………………………………………………………………………………………….418
DTC U0115 Lost Communication With ECM/PCM (CAN 1)…………………………………………………………………………………………………………….423
DTC U1016 Class 2 Powertrain Controller State of Health Failure………………………………………………………………………………………………..428
DTC U1041 Class 2 Anti-lock Brake Controller (ABS) State of Health……………………………………………………………………………………………..431
DTC U1064 Class 2 Truck Body Controller (TBC) State of Health………………………………………………………………………………………………….434
DTC U1096 Class 2 Instrument Panel Controller (IPC) State of Health…………………………………………………………………………………………….437
DTC U1300 Serial Data Communication Link Low (Class 2)………………………………………………………………………………………………………..440
DTC U1301 Serial Data Communication Link High (Class 2)……………………………………………………………………………………………………….443
SECTION 6—INPUT AND OUTPUT FUNCTIONS……………………………………………………………………………………………………………………………….447
6-1. SPECIAL INPUT AND OUTPUT FUNCTIONS…………………………………………………………………………………………………………………………447
Table 6-1. I/O Packages and Wire Numbers………………………………………………………………………………………………………………………..448
SECTION 7—GENERAL TROUBLESHOOTING OF PERFORMANCE COMPLAINTS…………………………………………………………………………………………………………..449
7-1. General Troubleshooting of Performance Complaints……………………………………………………………………………………………………………449
APPENDICES—INDEX…………………………………………………………………………………………………………………………………………………463
APPENDIX A—DIAGNOSING INTERMITTENT DTC S……………………………………………………………………………………………………………………………465
APPENDIX B—MAIN PRESSURE CHECK PROCEDURE……………………………………………………………………………………………………………………………467
B-1. MAIN PRESSURE CHECK PROCEDURE……………………………………………………………………………………………………………………………..467
Figure B-1. Main Pressure Check Point……………………………………………………………………………………………………………………….467
Table B-1. Main Pressure Test Conditions…………………………………………………………………………………………………………………….468
Table B-2. Modulated Main Pressure Schedule………………………………………………………………………………………………………………….468
APPENDIX C—SOLENOID AND CLUTCH TABLE……………………………………………………………………………………………………………………………….469
C-1. SOLENOID AND CLUTCH TABLE…………………………………………………………………………………………………………………………………469
Table C-1. Solenoid and Clutch Table………………………………………………………………………………………………………………………..469
APPENDIX D—WIRE/CONNECTOR TABLES…………………………………………………………………………………………………………………………………..471
Figure D-1. AFL Automotive 80-Way TCM Connector………………………………………………………………………………………………………………….472
Figure D-2. AFL Automotive Main Transmission Connector (24-Way)……………………………………………………………………………………………………475
Figure D-3. Delphi-Packard Main Transmission Connector (20-way)……………………………………………………………………………………………………476
Figure D-4. Speed Sensor Connector……………………………………………………………………………………………………………………………..477
Figure D-5. TPS Connector……………………………………………………………………………………………………………………………………..478
Figure D-6. J1939 Interface Connector…………………………………………………………………………………………………………………………..479
Figure D-7. GMC Connector for OBD-II Diagnostic Adapter…………………………………………………………………………………………………………..480
Figure D-8. Deutsch Diagnostic Tool Connector……………………………………………………………………………………………………………………481
Figure D-9. Transmission Internal Harness (20-Way)……………………………………………………………………………………………………………….482
Figure D-10. Transmission Internal Harness (24-way)………………………………………………………………………………………………………………483
APPENDIX E—CONNECTOR REPAIR INFORMATION…………………………………………………………………………………………………………………………….485
List of Special Tools Required To Service 1000 and 2000 Product Families Wiring Harnesses…………………………………………………………………………….486
Figure E-1A. AFL 80F Bolt-Assist TCM Connector…………………………………………………………………………………………………………………..488
Figure E-1B. AFL 80F Bolt-Assist, Dir ‘A’ 90 Degree TCM Connector………………………………………………………………………………………………….489
Figure E-1C. AFL 80F Bolt Assist, Dir ‘B’ 90 Degree TCM Connector………………………………………………………………………………………………….490
E-1. AFL AUTOMOTIVE 80F BOLT ASSIST CONNECTORS (TCM CONNECTOR)…………………………………………………………………………………………………….491
Figure E-2A. AFL 80F Cam-Assist, Dir ‘A’ Connector (TCM Connector)…………………………………………………………………………………………………495
Figure E-2B. AFL 80F Cam-Assist, Dir ‘B’ Connector (TCM Connector)…………………………………………………………………………………………………496
E-2. AFL AUTOMOTIVE 80F CAM-ASSIST CONNECTORS (TCM CONNECTOR)……………………………………………………………………………………………………..497
Figure E-3. AFL 24F Transmission Connector………………………………………………………………………………………………………………………500
E-3. AFL AUTOMOTIVE 24F TRANSMISSION CONNECTOR…………………………………………………………………………………………………………………..501
Figure E-4. Delphi-Packard Micro Pack 100W Connector (Main Transmission Connector)…………………………………………………………………………………..504
E-4. DELPHI-PACKARD MICRO PACK 100W CONNECTOR (MAIN TRANSMISSION CONNECTOR)…………………………………………………………………………………………505
Figure E-5A. Delphi-Packard GT 150 Series Connectors-Push-to-Seat (Speed Sensors)……………………………………………………………………………………507
Figure E-5B. Delphi-Packard GT 150 Series Connectors-Push-to-Seat (Speed Sensors)……………………………………………………………………………………508
E-5. DELPHI-PACKARD GT 150 SERIES CONNECTORS—PUSH-TO-SEAT (SPEED SENSORS)…………………………………………………………………………………………..509
E-6. INTERNAL WIRING HARNESS…………………………………………………………………………………………………………………………………..511
Figure E-6A. Internal Wiring Harness; 24-Way (Medium Duty)………………………………………………………………………………………………………..511
Figure E-6B. Internal Wiring Harness; 20-Way (GM Pickup Only)……………………………………………………………………………………………………..511
Figure E-7A. Delphi-Packard WeatherPack Connectors (TPS)………………………………………………………………………………………………………….512
E-7. DELPHI-PACKARD WEATHERPACK CONNECTORS (TPS)…………………………………………………………………………………………………………………513
Figure E-7B. Terminal Crimping With Tool J 35606…………………………………………………………………………………………………………………514
Figure E-8. Deutsch IPD/ECD Connectors (9-Way DDR)……………………………………………………………………………………………………………….516
E-8. DEUTSCH IPD/ECD CONNECTORS (J1939 DIAGNOSTIC LINK 9-WAY DDR)………………………………………………………………………………………………….517
Figure E-9. Deutsch DT Series Connector (3-Way J1939 Interface)……………………………………………………………………………………………………520
E-9. DEUTSCH DT SERIES CONNECTORS (3-WAY J1939 INTERFACE)…………………………………………………………………………………………………………521
E-10. REPAIR OF A BROKEN WIRE WITH IN-LINE BUTT SPLICE……………………………………………………………………………………………………………522
Figure E-10. Crimper J 38125-8…………………………………………………………………………………………………………………………………523
List of 1000 and 2000 Product Families Connector Parts……………………………………………………………………………………………………………524
APPENDIX F—THROTTLE POSITION SENSOR ADJUSTMENT………………………………………………………………………………………………………………………527
F-1. TPS ADJUSTMENT…………………………………………………………………………………………………………………………………………..527
Figure F-1. Throttle Position-to-Voltage Conversion…………………………………………………………………………………………………………..527
Figure F-2. Throttle Position Determination Diagram…………………………………………………………………………………………………………..527
Table F-1. Throttle Position Travel vs. Voltage………………………………………………………………………………………………………………529
Figure F-3. Throttle Position Sensor Adjustment………………………………………………………………………………………………………………530
APPENDIX G—WELDING ON VEHICLE/VEHICLE INTERFACE……………………………………………………………………………………………………………………..531
G-1. WELDING ON VEHICLE……………………………………………………………………………………………………………………………………….531
APPENDIX H—HYDRAULIC SCHEMATICS……………………………………………………………………………………………………………………………………533
Figure H-1. 1000 and 2000 Product Families Hydraulic Schematic-Neutral/Park…………………………………………………………………………………………535
Figure H-2. 1000 and 2000 Product Families Hydraulic Schematic-Reverse……………………………………………………………………………………………..536
Figure H-3. 1000 and 2000 Product Families Hydraulic Schematic-Hydraulic Default Reverse (“Limp Home”)…………………………………………………………………537
Figure H-4. 1000 and 2000 Product Families Hydraulic Schematic-Hydraulic Default Forward (Thid Range “Limp Home”)……………………………………………………….538
Figure H-5. 1000 and 2000 Product Families Hydraulic Schematic-First Range………………………………………………………………………………………….539
Figure H-6. 1000 and 2000 Product Families Hydraulic Schematic-Second Range…………………………………………………………………………………………540
Figure H-7. 1000 and 2000 Product Families Hydraulic Schematic-Third Range………………………………………………………………………………………….541
Figure H-8. 1000 and 2000 Product Families Hydraulic Schematic-Fourth Range…………………………………………………………………………………………542
Figure H-9. 1000 and 2000 Product Families Hydraulic Schematic-Fifth Range………………………………………………………………………………………….543
Figure H-10. 1000 and 2000 Product Families Hydraulic Schematic-Sixth Range…………………………………………………………………………………………544
APPENDIX J—WIRING SCHEMATICS………………………………………………………………………………………………………………………………………545
Figure J–1. 1000 and 2000 Product Families Wiring Schematic……………………………………………………………………………………………………….545
APPENDIX K—RESISTANCE VS. TEMPERATURE………………………………………………………………………………………………………………………………546
Figure K-1. Solenoid Resistance vs. Temperature Graph…………………………………………………………………………………………………………….546
Table K–1. Solenoid Resistance vs. Temperature…………………………………………………………………………………………………………………..546
Figure K-2. Transmission Fluid Temperature Sensor Resistance vs. Sump Temperature Graph………………………………………………………………………………548
Table K-2. Transmission Fluid Temperature Sensor Resistance vs. Temperature…………………………………………………………………………………………548
Figure K-3. Speed Sensor Resistance vs. Temperature Graph…………………………………………………………………………………………………………550
Table K-3. Speed Sensor Resistance vs. Temperature……………………………………………………………………………………………………………….550
APPENDIX L—ELECTRONIC INTERFERENCE…………………………………………………………………………………………………………………………………552
L-1. ELECTROMAGNETIC INTERFERENCE (EMI)/RADIO FREQUENCY INTERFERENCE (RFI)………………………………………………………………………………………….552
L-2. GENERAL GUIDELPINES FOR RADIO EQUIPMENT INSTALLATION…………………………………………………………………………………………………………552
L-3. EXTERNALLY-GENERATED SPEED SENSOR SIGNALS…………………………………………………………………………………………………………………..553
APPENDIX M—Allison DOC™ FOR PC–SERVICE TOOL…………………………………………………………………………………………………………………………554
APPENDIX N—INPUT AND OUTPUT FUNCTIONS………………………………………………………………………………………………………………………………556
Input Function A. Secondary Shift Schedule (enabled by wire 142)…………………………………………………………………………………………………..556
Input Function C. PTO Enable (enabled by wire 143)……………………………………………………………………………………………………………….558
Input Function E. Auxiliary Function Range Inhibit, Standard (enabled by wire 101)…………………………………………………………………………………..560
Guidelines for Selecting Input Function H, Engine Brake Enable and Preselect Request…………………………………………………………………………………562
Input Function H1. Engine Brake Enable and Preselect Request Input, Plus Engine Brake Enable Output-Exhaust Brake (enabled by input wire 102, output wire 104)……………….563
Input Function H2. Engine Brake Enable and Preselect Request Input, Plus Engine Brake Enable Output-ECM-Controlled Exhaust Brake (enabled by input wire 102, output wire 104)….565
Input Function I1. European Engine Brake Enable and Preselect Request Input, Plus Engine Brake Enable Output- Exhaust Brake (input wire 102, output wire 104)………………..567
Input Function L. Automatic Neutral-Single Input (enabled by input wire 123)………………………………………………………………………………………..569
Input Function V. Reverse Enable (enabled by input wire 143)………………………………………………………………………………………………………571
Guidelines for Implementing Input Function Y, ABS Response………………………………………………………………………………………………………..573
Input Function Y1. Anti-lock Brake Response, No Direct Input From Brake System (enabled by input wire 121)……………………………………………………………..574
Input Function Y2. Anti-lock Brake Response, With Input From Brake Pressure Switch (enabled by input wire 121)………………………………………………………….576
Input Function Y3. Anti-lock Brake Response Via J1939 Communication Link (enabled by wire 121)………………………………………………………………………..578
Input Function AA. Service Brake Status (enabled by input wire 162)………………………………………………………………………………………………..580
Input Function AH. Kickdown (enabled by input wire 122)…………………………………………………………………………………………………………..581
Input Function AM. Refuse Packer Step Switch (enabled by input wire 123)……………………………………………………………………………………………583
Input Function AR. Overdrive Disable (enabled by input wire 161)…………………………………………………………………………………………………..585
Input Function BQ1. 3rd Lockup Pump Mode, Operator and Pump Acti vated (enabled by input wires 122 and 123, output wire 145)……………………………………………..586
Input Function BQ2. 3rd Lockup Pump Mode, Operator Only Activated (enabled by input wires 122 and 123, output wire 145)………………………………………………….588
Output Function B. Sump Temperature Indicator (activation wire 164)………………………………………………………………………………………………..590
Output Function D. Output Speed Indicator A (activation wire 105)………………………………………………………………………………………………….592
APPENDIX P—J1939 HARDWARE AND TCM CONNECTIONS……………………………………………………………………………………………………………………….594
P-1. TCM J1939 INTERFACE………………………………………………………………………………………………………………………………………594
P-2. TRADITIONAL STUB…………………………………………………………………………………………………………………………………………594
Figure P-1. Stub Interface…………………………………………………………………………………………………………………………………594
P-3. PASS–THROUGH…………………………………………………………………………………………………………………………………………….594
Figure P-2. Pass-Through Interface………………………………………………………………………………………………………………………….594
P-4. BACKBONE TERMINATION……………………………………………………………………………………………………………………………………..595
Figure P-3. Backbone Termination……………………………………………………………………………………………………………………………595
P-5. J1939 NETWORK OVERVIEW……………………………………………………………………………………………………………………………………596
Figure P-4. TCM and Selector Stub Interfaces…………………………………………………………………………………………………………………596
Figure P-5. Pass Through Interface………………………………………………………………………………………………………………………….603
Figure P-6. Backbone Termination Interfaces………………………………………………………………………………………………………………….603
APPENDIX R—FLUID CHECK PROCEDURE…………………………………………………………………………………………………………………………………..597
Figure R-1. Short and Medium Fill Tube And Dipstick Requirements…………………………………………………………………………………………………..598
Figure R-2. Long Fill Tube And Dipstick Requirements……………………………………………………………………………………………………………..599
IMAGES PREVIEW OF THE MANUAL:
VIDEO PREVIEW OF THE MANUAL:
PLEASE NOTE:
- This is the SAME MANUAL used by the dealerships to diagnose your vehicle
- No waiting for couriers / posts as this is a PDF manual and you can download it within 2 minutes time once you make the payment.
- Your payment is all safe and the delivery of the manual is INSTANT – You will be taken to the DOWNLOAD PAGE.
- So have no hesitations whatsoever and write to us about any queries you may have : heydownloadss @gmail.com
S.V