Allison Transmission Ts3192En 2004 Service Manual-21516A320007.pdf -Bookmark created by https://wimanual.com TS3192EN TITLE PAGE FOREWORD � How to Use This Manual IMPORTANT SAFETY NOTICE WARNINGS, CAUTIONS, AND NOTES TRADEMARKS USED IN THIS MANUAL SERVICE LITERATURE TABLE OF CONTENTS SECTION 1� GENERAL DESCRIPTION 1�1. TRANSMISSION Figure 1�2. Electronic Control Components 1�2. TRANSMISSION CONTROL MODULE (TCM) Figure 1�3. Transmission Control Module (TCM) 1�3. SHIFT SELECTOR Figure 1�4. Typical Lever-Type Shift Selector Figure 1�5. NSBU Switch 1�4. THROTTLE POSITION SENSOR Figure 1�6. Throttle Position Sensor 1�5. SPEED SENSORS Figure 1�7. Typical Speed Sensor Figure 1�8. Speed Sensor Connector Orientation 1�6. CONTROL VALVE ASSEMBLY Figure 1�9. Control Valve Assembly 1�7. WIRING HARNESSES Figure 1�10. Typical External Wiring Harnesses Figure 1�11. Typical Internal Wiring Harness SECTION 2�DEFINITIONS AND ABBREVIATIONS 2�1. CHECK TRANS LIGHT 2�2. SCAN TOOL INHIBITS 2�3. SCAN TOOL (Allison DOC� For PC) Figure 2�1. Scan Tool 2�4. ABBREVIATIONS 2�5. RANGE INHIBIT RESPONSES SECTION 3�BASIC KNOWLEDGE 3�1. BASIC KNOWLEDGE REQUIRED 3�2. USING THE TROUBLESHOOTING MANUAL 3�3. SYSTEM OVERVIEW 3�4. IMPORTANT INFORMATION IN THE TROUBLESHOOTING PROCESS 3�5. BASIC TROUBLESHOOTING INFORMATION Figure 3�1. Proper Allison DOC� For PC Scan Tool Connections � J1939 Figure 3�2. Proper Allison DOC� For PC Scan Tool Connections � J1850 Figure 3�3. Proper Allison DOC� For PC Scan Tool Connections Using J1939 T-Adapter Harness (J 43890) 3�6. TCM REPLACEMENT PROCEDURE 3�7. RESETTING OF TCM PARAMETERS TO SUPPORT ENGINE UPDATE 3�8. RESETTING TCM AUTOSELECT SECTION 4�WIRE CHECK PROCEDURES 4�1. CHECKING OPENS, SHORTS BETWEEN WIRES, AND SHORTS-TO-GROUND Figure 4�1. Checking Continuity (External Harness) Figure 4�2. Short Between Wires and to Ground (External Harness) 4�2. CHECKING AT TRANSMISSION CONNECTOR AND THE INTERNAL HARNESSFOR OPENS, SHORTS BETWEEN WIRES, AND SHORTS-TO-GROUND Figure 4�3. Checking Continuity (Internal Harness) Figure 4�4. Short Between Wires and to Ground (Internal Harness) SECTION 5�DIAGNOSTIC TROUBLE CODES (DTC) 5�1. DTC MEMORY Table 5�1. DTC List 5�2. FAILURE RECORDS Table 5�2. Failure Record Data 5�3. DTC READING AND DTC CLEARING 5�4. BEGINNING THE TROUBLESHOOTING PROCESS Figure 5�2. J 39700 Breakout Box And J 43799 Adapter Figure 5�3. J 39700 Breakout Box And J 44722 Adapter 5�5. DIAGNOSTIC TROUBLE CODES (DTCs) DTC LIST AND DESCRIPTION INDEX DTC REFERENCE TABLES DTC P0122 Pedal Position Sensor Circuit Low Voltage DTC P0123 Pedal Position Sensor Circuit High Voltage DTC P0218 Transmission Fluid Over Temperature Condition DTC P0561 Unrealistic Variations in Vehicle System Voltage DTC P0562 System Voltage Low DTC P0563 System Voltage High DTC P0602 TCM Not Programmed DTC P0606 Controller Internal Performance DTC P0614 Torque Control Data Mismatch � ECM DTC P0701 Transmission Control System Performance DTC P0703 Brake Switch Circuit Malfunction DTC P0708 Transmission Range Sensor Circuit High Input DTC P0711 Transmission Fluid Temperature Sensor Circuit Performance DTC P0712 Transmission Fluid Temperature Sensor Circuit Low Input(High Temperature) DTC P0713 Transmission Fluid Temperature Sensor Circuit High Input(Low Temperature) DTC P0716 Turbine Speed Sensor Circuit Performance DTC P0717 Turbine Speed Sensor Circuit No Signal DTC P0719 Brake Switch ABS Input Low DTC P0721 Output Speed Sensor Circuit Performance DTC P0722 Output Speed Sensor Circuit No Signal DTC P0726 Engine Speed Input Circuit Performance DTC P0727 Engine Speed Input Circuit No Signal DTC P0731 Incorrect 1st Gear Ratio DTC P0732 Incorrect 2nd Gear Ratio DTC P0733 Incorrect 3rd Gear Ratio DTC P0734 Incorrect 4th Gear Ratio DTC P0735 Incorrect 5th Gear Ratio DTC P0736 Incorrect Reverse Ratio DTC P0741 Torque Converter Clutch System Stuck Off DTC P0742 Torque Converter Clutch System Stuck On DTC P0743 (Previously P1860) Torque Converter Clutch Pulse Width Modulation (PWM)Solenoid Circuit � Electrical DTC P0746 (Previously P1720) Solenoid A Controlled Clutch Stuck Off DTC P0747 (Previously P1723) Solenoid A Controlled Clutch Stuck On DTC P0748 Pressure Control Solenoid A Electrical DTC P0763 Shift Solenoid C Electrical DTC P0768 Shift Solenoid D Electrical DTC P0773 Shift Solenoid E Electrical DTC P0776 (Previously P1721) Solenoid B Controlled Clutch Stuck Off DTC P0777 (Previously P1724) Solenoid B Controlled Clutch Stuck On DTC P0778 Pressure Control Solenoid B Electrical DTC P0840 Transmission Pressure Switch Solenoid C Circuit DTC P0841 Transmission Pressure Switch Solenoid C Circuit Stuck Open DTC P0842 Transmission Pressure Switch Solenoid C Circuit Stuck Closed DTC P0843 Transmission Pressure Switch Solenoid C Circuit High DTC P0845 Transmission Pressure Switch Solenoid D Circuit DTC P0846 Transmission Pressure Switch Solenoid D Circuit Stuck Open DTC P0847 Transmission Pressure Switch Solenoid D Circuit Stuck Closed DTC P0848 Transmission Pressure Switch Solenoid D Circuit High DTC P0870 (Previously P1709) Transmission Pressure Switch Solenoid E Circuit DTC P0871 (Previously P1710) Transmission Pressure SwitchSolenoid E Circuit Stuck Open DTC P0872 (Previously P1711) Transmission Pressure Switch Solenoid E CircuitStuck Closed DTC P0873 (Previously P1712) Transmission Pressure Switch Solenoid E Circuit High DTC P0875 (Previously P1713) Transmission Reverse Pressure SwitchCircuit Malfunction DTC P0876 (Previously P1714) Transmission Reverse Pressure Switch Circuit Stuck Open DTC P0880 (Previously P1760) TCM Supply Voltage DTC P1688 Unmanaged Engine Torque Delivered To TCM Signal DTC P1779 Engine Torque Delivered To TCM Signal DTC P1891 Throttle Position Sensor (TPS) Pulse Width Modulation (PWM)Signal Low Input DTC P1892 Throttle Position Sensor (TPS) Pulse Width Modulation (PWM)Signal High Input DTC P2771 (Previously P0836, P1875) Four-Wheel Drive Switch Circuit DTC P2773 Torque Control Request Ignored � ECM DTC P2810 Solenoid G Electrical DTC U0031 (Previously U1300) J1850 (Class 2) Serial Data Communication Link Low DTC U0032 (Previously U1301) J1850 (Class 2) Serial Data Communication Link High DTC U0073 (Previously U2104) CAN Bus Reset Counter Overrun DTC U0100 (Previously U2105) CAN Bus ECM Error DTC U1000�U1096 Class 2 Controller State of Health Failure SECTION 6�INPUT AND OUTPUT FUNCTIONS 6�1. SPECIAL INPUT AND OUTPUT FUNCTIONS SECTION 7�GENERAL TROUBLESHOOTING OF PERFORMANCECOMPLAINTS Table 7�1. Troubleshooting Performance Complaints APPENDICES�INDEX APPENDIX A�DIAGNOSING INTERMITTENT DTCS APPENDIX B�MAIN PRESSURE CHECK PROCEDURE Figure B�1. Main Pressure Check Point Table B�1. Main Pressure Test Conditions APPENDIX C�SOLENOID AND CLUTCH TABLE Table C�1. Solenoid and Clutch Table � Software Levels Prior To N04 Table C�1. Solenoid and Clutch Table � Software Level N04 And Later APPENDIX D�WIRE Figure D�1. TCM Connector J2 Figure D�2. TCM Connector J1 Figure D�3. Delphi-Packard Main Transmission Connector Figure D�4. Speed Sensor Connector Figure D�5. TPS Connector Figure D�6. J1939 Interface Connector Figure D�7. NSBU Switch Connectors Figure D�8. Single Connector NSBU Figure D�9. Deutsch DDR Connector Figure D�10. Transmission Internal Harness APPENDIX E�CONNECTOR REPAIR INFORMATION List Of Special Tools Required To Service 1000 and 2000 Product Families Wiring Harnesses Figure E�1A. Delphi-Packard Micro Pack Connector (TCM J1 and J2) Figure E�1B. Delphi-Packard Micro Pack Connector (Main Transmission Connector) 1�1. DELPHI-PACKARD MICRO PACK 100W CONNECTORS(TCM J1 AND J2, MAIN TRANSMISSION CONNECTOR) Figure E�2. Delphi-Packard Metri-Pack 150 Series Connectors 1�2. DELPHI-PACKARD METRI-PACK 150 SERIES CONNECTORS � PULL-TO-SEAT(SPEED SENSORS) Figure E�3. Delphi-Packard Metri-Pack 150 Series Connectors � Push-to-Seat (NSBU Switch) 1�3. DELPHI-PACKARD METRI-PACK 150 SERIES CONNECTORS � PUSH-TO-SEAT(NSBU SWITCH) Figure E�4. Internal Wiring Harness 1�4. INTERNAL WIRING HARNESS Figure E�5A. Delphi-Packard WeatherPack Connectors (TPS) 1�5. DELPHI-PACKARD WEATHERPACK CONNECTORS (TPS) Figure E�5B. Terminal Crimping With Tool J 35606 Figure E�6. Deutsch IPD 1�6. DEUTSCH IPD Figure E�7. Deutsch DT Series Connector (3-Way J1939 Interface) 1�7. DEUTSCH DT SERIES CONNECTORS (3-WAY J1939 INTERFACE) 1�8. REPAIR OF A BROKEN WIRE WITH IN-LINE BUTT SPLICE Figure E�8. Crimper J 38125-8 1-9. List of 1000 and 2000 Product Families Connector Parts APPENDIX F�TPS ADJUSTMENT Figure F�1. Throttle Position-to-Voltage Conversion Figure F�2. Throttle Position Determination Diagram Table F�1. Distance (mm) of Travel Versus Volts Figure F�3. Throttle Position Sensor Adjustment APPENDIX G�WELDING ON VEHICLE 1�1. WELDING ON VEHICLE APPENDIX H�HYDRAULIC SCHEMATICS Figure H�1. Hydraulic Schematic � Neutral Figure H�2. Hydraulic Schematic � Reverse (Prior To Software Level N04) Figure H�3. Hydraulic Schematic � Reverse (Software Level N04 And Later) Figure H�4. Hydraulic Schematic � 1st Range Figure H�5. Hydraulic Schematic � 2nd Range Figure H�6. Hydraulic Schematic � 3rd Range Figure H�7. Hydraulic Schematic � 4th Range Figure H�8. Hydraulic Schematic � 5th Range Figure H�9. Hydraulic Schematic � Hydraulic Default Forward Figure H�10. Hydraulic Schematic � Hydraulic Default Reverse Figure J�1. 1000 and 2000 Product Families Wiring Schematic APPENDIX J�WIRING SCHEMATICS Figure J�2. J1939 Backbone (CAN Bus) APPENDIX K�RESISTANCE VS. TEMPERATURE Figure K�1. Solenoid Resistance vs. Temperature Graph Table K�1. Solenoid Resistance vs. Temperature Figure K�2. Transmission Fluid Temperature Sensor Resistance vs. Sump Temperature Graph Table K�2. Transmission Fluid Temperature Sensor Resistance vs. Temperature Figure K�3. Speed Sensor Resistance vs. Temperature Graph Table K�3. Speed Sensor Resistance vs. Temperature APPENDIX L�ELECTRONIC INTERFERENCE 1�1. ELECTROMAGNETIC INTERFERENCE (EMI) 1�2. GENERAL GUIDELINES FOR RADIO EQUIPMENT INSTALLATION 1�3. EXTERNALLY-GENERATED SPEED SENSOR SIGNALS APPENDIX M � ALLISON DOC� DIAGNOSTIC TOOL APPENDIX N�INPUT Figure N�1. Secondary Shift Schedule Figure N�2. PTO Enable Figure N�3. Auxiliary Function Range Inhibit Figure N�4. Exhaust Brake Figure N�5. Exhaust Brake Figure N�6. Exhaust Brake Figure N�7. Automatic Neutral for PTO Figure N�8. Reverse Enable Figure N�9. Kickdown Figure N�10. Refuse Packer Step Switch Figure N�11. Overdrive Disable Figure N�12. Sump Temperature Indicator Figure N�13. Range Indicator Figure N�14. Output Speed Indicator APPENDIX P � FLUID CHECK PROCEDURE Figure P�1. Fill Tube And Dipstick Requirements (Standard Oil Pan) Figure P�2. Fill Tube And Dipstick Requirements (Shallow Oil Pan) . Notice: This is a preview not fully updated, please download the full version at https://wimanual.com