Allison Transmission Ts3977En 1000 2000 Troubleshooting Manual-21516A380008.pdf -Bookmark created by https://wimanual.com FOREWORD - How to Use This Manual WARNINGS, CAUTIONS, AND NOTES SERVICE LITERATURE IMPORTANT SAFETY NOTICE TRADEMARKS USED IN THIS MANUAL TABLE OF CONTENTS Section 1- GENERAL DESCRIPTION 1-1. TRANSMISSION 1-2. TRANSMISSION CONTROL MODULE (TCM) 1-3. SHIFT SELECTOR A. Shift Selector Range Positions B. Manual Selector Valve C. Internal Mode Switch (IMS) 1-4. THROTTLE POSITION SENSOR (TPS) 1-5. SPEED SENSORS A. Input (Engine) Speed Sensor B. Turbine Speed Sensor C. Output Speed Sensor 1-6. CONTROL VALVE ASSEMBLY A. Main Modulation 1-7. WIRING HARNESS A. External Wiring Harness B. Internal Wiring Harness 1-8. SPECIAL ELECTRONIC Section 2- DEFINITIONS AND ABBREVIATIONS 2-1. CHECK TRANS LIGHT 2-2. RANGE INHIBIT RESPONSES 2-3. ALLISON DOC� FOR PC-SERVICE TOOL INHIBITS 2-4. ALLISON DOC� FOR PC-SERVICE TOOL 2-5. ABBREVIATIONS 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 3-6. TCM DIAGNOSTIC PROCEDURE 3-7. RESETTING OF TCM PARAMETERS TO SUPPORT ENGINE UPDATE 3-8. RESETTING TCM SEM AUTOSELECT Section 4- WIRE CHECK PROCEDURES 4-1. CHECKING OPENS, SHORTS BETWEEN WIRES, AND SHORTS-TO-GROUND (Use J-34520-A Digital Volt 4-2. CHECKING AT TRANSMISSION CONNECTOR AND THE INTERNAL HARNESS FOR OPENS, SHORTS BETWEEN WIRES, AND SHORTS-TO-GROUND Section 5- DIAGNOSTIC TROUBLE CODES (DTCs) 5-1. DTC MEMORY 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 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. D. 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 failure can be v... F. Description. Name assigned to a given fault condition in accordance with SAE J2012. 5-2. FAILURE RECORDS 5-3. DTC READING AND DTC CLEARING A. Clearing DTCs B. Clearing Active Indicators 5-4. BEGINNING THE TROUBLESHOOTING PROCESS A. Starting Procedure B. Solenoid Locations C. Wire D. Available Diagnostic Adapters 5-5. DIAGNOSTIC TROUBLE CODES (DTCs) 5-6. DTC REFERENCE TABLES DTC P088B Transmission Filter Very Deteriorated DTC P0122 Pedal Position Sensor Circuit-Low Voltage DTC P0123 Pedal Position Sensor Circuit-High Voltage DTC P0218 Transmission Fluid Over Temperature DTC P0561 System Voltage-Performance DTC P0562 System Voltage-Low DTC P0563 System Voltage-High DTC P0602 TCM Not Programmed DTC P0606 TCM Internal-Performance DTC P0610 TCM Vehicle Options (TransID) Error DTC P0613 TCM Processor DTC P0614 Torque Control Data Mismatch-ECM DTC P0614 Torque Control Data Mismatch-ECM DTC P0634 TCM Internal Temperature Too High DTC P0657 Actuator Supply Voltage 1 Open DTC P0658 Actuator Supply Voltage 1 (HSD1)-Low DTC P0659 Actuator Supply Voltage 1 (HSD1)-High (batt) DTC P0701 Transmission Control System-Performance DTC P0702 Transmission Control System Electrical (TransID) DTC P0703 Brake Switch Circuit DTC P0706 Transmission Range Sensor Circuit-Performance 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 DTC P0713 Transmission Fluid Temperature Sensor Circuit-High Input DTC P0716 Turbine Speed Sensor Circuit-Performance DTC P0717 Turbine Speed Sensor Circuit-No Signal DTC P0719 Brake Switch Circuit DTC P0721 Output Speed Sensor Circuit-Performance DTC P0722 Output Speed Sensor Circuit-No Signal DTC P0726 Engine Speed Sensor Circuit-Performance DTC P0727 Engine Speed Sensor Circuit-No Signal DTC P0729 Incorrect 6th Gear Ratio 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 (TCC) System-Stuck Off DTC P0742 Torque Converter Clutch (TCC) System-Stuck On DTC P0751 Shift Solenoid 1 (SS1) Valve Performance-Stuck Off DTC P0752 Shift Solenoid 1 (SS1) Valve Performance-Stuck On DTC P0756 Shift Solenoid 2 (SS2) Valve Performance-Stuck Off DTC P0757 Shift Solenoid 2 (SS2) Valve Performance-Stuck On DTC P0761 Shift Solenoid 3 (SS3) Valve Performance-Stuck Off DTC P0762 Shift Solenoid 3 (SS3) Valve Performance-Stuck On DTC P0776 Pressure Control Solenoid 2 (PCS2)-Stuck Off DTC P0777 Pressure Control Solenoid 2 (PCS2)-Stuck On DTC P0826 Up and Down Shift Switch Circuit DTC P0827 Up and Down Shift Switch Circuit-Low DTC P0828 Up and Down Shift Switch Circuit-High DTC P0842 Transmission Pressure Switch 1 (PS1) Circuit-Low DTC P0843 Transmission Pressure Switch 1 (PS1) Circuit-High DTC P0847 Transmission Pressure Switch 2 (PS2) Circuit-Low DTC P0848 Transmission Pressure Switch 2 (PS2) Circuit-High DTC P0872 Transmission Pressure Switch 3 (PS3) Circuit-Low DTC P0873 Transmission Pressure Switch 3 (PS3) Circuit-High DTC P0877 Transmission Fluid Pressure Switch 4 (PS4) Circuit-Low DTC P0878 Transmission Fluid Pressure Switch 4 (PS4) Circuit-High DTC P0880 TCM Power Input Signal DTC P0881 TCM Power Input Signal-Performance DTC P0882 TCM Power Input Signal-Low DTC P0883 TCM Power Input Signal-High DTC P0897 Transmission Fluid Deteriorated DTC P0960 Pressure Control Solenoid Main Mod (MAIN MOD) Control Circuit-Open DTC P0962 Pressure Control Solenoid Main Mod (MAIN MOD) Control Circuit-Low DTC P0963 Pressure Control Solenoid Main Mod (MAIN MOD) Control Circuit-High DTC P0964 Pressure Control Solenoid 2 (PCS2) Control Circuit-Open DTC P0966 Pressure Control Solenoid 2 (PCS2) Control Circuit-Low DTC P0967 Pressure Control Solenoid 2 (PCS2) Control Circuit-High DTC P0972 Shift Solenoid 1 (SS1) Control Circuit-Open DTC P0973 Shift Solenoid 1 (SS1) Control Circuit-Low DTC P0974 Shift Solenoid 1 (SS1) Control Circuit-High DTC P0975 Shift Solenoid 2 (SS2) Control Circuit-Open DTC P0976 Shift Solenoid 2 (SS2) Control Circuit-Low DTC P0977 Shift Solenoid 2 (SS2) Control Circuit-High DTC P0978 Shift Solenoid 3 (SS3) Control Circuit-Open DTC P0979 Shift Solenoid 3 (SS3) Control Circuit-Low DTC P0980 Shift Solenoid 3 (SS3) Control Circuit-High DTC P1688 Unmanaged Engine Torque Delivered to TCM Signal DTC P1779 Engine Torque Delivered to TCM Signal DTC P1891 Throttle Position Sensor (TPS) PWM Signal-Low Input DTC P1892 Throttle Position Sensor (TPS) PWM Signal-High Input DTC P2637 Torque Management Feedback Signal-SEM DTC P2641 Torque Management Feedback Signal-LRTP DTC P2669 Actuator Supply Voltage 2 Open DTC P2670 Actuator Supply Voltage 2 (HSD2)-Low DTC P2671 Actuator Supply Voltage 2 (HSD2)-High (batt) DTC P2723 Pressure Control Solenoid 1 (PCS1)-Stuck Off DTC P2724 Pressure Control Solenoid 1 (PCS1)-Stuck On DTC P2727 Pressure Control Solenoid 1 (PCS1) Control Circuit-Open DTC P2729 Pressure Control Solenoid 1 (PCS1) Control Circuit-Low DTC P2730 Pressure Control Solenoid 1 (PCS1) Control Circuit-High DTC P2761 TCC PCS Control Circuit Open DTC P2763 TCC PCS Control Circuit High DTC P2764 TCC PCS Control Circuit Low DTC P2771 4-Wheel Drive Lo Switch Circuit DTC P2772 4-Wheel Drive Lo Switch-Performance DTC P2789 Clutch Adaptive Learning at Limit DTC U0010 CAN 1 Bus Reset Counter Overrun DTC U0073 CAN 2 GMLAN Bus Reset Counter Overrun DTC U0100 Lost Communication With ECM DTC U0115 Lost Communication With ECM DTC U0400 Invalid J1939 Communications DTC U0442 Invalid Data Received from ECM DTC U1016 Class 2 Powertrain Controller State of Health Failure DTC U1041 Class 2 Anti-lock Brake Controller (ABS) State of Health DTC U1064 Class 2 Truck Body Controller (TBC) State of Health DTC U1096 Class 2 Instrument Panel Controller (IPC) State of Health DTC U1300 Serial Data Communication Link Low (Class 2) DTC U1301 Serial Data Communication Link High (Class 2) Section 6- INPUT AND OUTPUT FUNCTIONS 6-1. SPECIAL INPUT AND OUTPUT FUNCTIONS A. Input Functions B. Output Functions Section 7- GENERAL TROUBLESHOOTING OF PERFORMANCE COMPLAINTS 7-1. GENERAL TROUBLESHOOTING OF PERFORMANCE COMPLAINTS APPENDICES-INDEX APPENDIX A- DIAGNOSING INTERMITTENT DTCs A. Circuit Inspection B. Finding an Intermittent Fault Condition C. Recurring Conditions APPENDIX B- MAIN PRESSURE CHECK PROCEDURE B-1. MAIN PRESSURE CHECK PROCEDURE APPENDIX C- SOLENOID AND CLUTCH TABLE C-1. SOLENOID AND CLUTCH TABLE APPENDIX D- WIRE APPENDIX E- CONNECTOR REPAIR INFORMATION E-1. AFL AUTOMOTIVE 80F BOLT ASSIST CONNECTORS (TCM CONNECTORS) A. TCM Connector, Assembly 80W Bolt Assist (refer to Figure E1-A) B. TCM Connector, Assembly 80W Bolt Assist, Dir �A� 90 Deg Wire Dress (refer to Figure E-1B) C. Connector, Assembly 80F Bolt Assist, Dir �B� 90 Deg Wire Dress (refer to Figure E-1C) D. Terminal Removal E. Terminal Crimping E-2. AFL AUTOMOTIVE 80F CAM-ASSIST CONNECTORS (TCM CONNECTORS) A. Connector, Assembly 80F Cam-Assist, �A� Dir (refer to Figure E-2A) B. Connector, Assembly 80F Cam-Assist, �B� Dir (refer to Figure E-2B) C. Connector Removal D. Terminal Crimping E-3. AFL AUTOMOTIVE 24F TRANSMISSION CONNECTOR A. Connector B. Terminal Removal C. Terminal Crimping E-4. DELPHI-PACKARD MICRO PACK 100W CONNECTOR (MAIN TRANSMISSION CONNECTOR) A. Connector B. Terminal Removal-Main Transmission Connectors (refer to Figure E-4) C. Terminal Crimping E-5. DELPHI-PACKARD GT 150 SERIES CONNECTORS-PUSH-TO-SEAT (SPEED SENSORS) A. Connector B. Terminal Removal C. Terminal Crimping D. Terminal Installation E-6. INTERNAL WIRING HARNESS E-7. DELPHI-PACKARD WEATHERPACK CONNECTORS (TPS) A. Connector B. Terminal Removal C. Terminal Crimping Using Crimping Tool J 38125-6 D. Terminal Crimping Using Alternate Crimper Pliers J-35606 or J-38852 E-8. DEUTSCH IPD A. Connector B. Terminal Removal (refer to Figure E-8, View A) C. Terminal Crimping (refer to Figure E-8, View B) D. Terminal Insertion (all connectors except ECD bulkhead) E-9. DEUTSCH DT SERIES CONNECTORS (3-WAY J1939 CONNECTOR) A. Connector B. Terminal Removal (refer to Figure E-9) C. Terminal Crimping (refer to Figure E-9) D. Terminal Insertion E-10. REPAIR OF A BROKEN WIRE WITH IN-LINE BUTT SPLICE A. Connector Check Before Repair B. Special Tools C. Straight Lead Repair Procedure APPENDIX F- THROTTLE POSITION SENSOR ADJUSTMENT F-1. TPS ADJUSTMENT A. Description of Operation B. Throttle Position Sensor (TPS) Adjustment APPENDIX G- WELDING ON VEHICLE G-1. WELDING ON VEHICLE APPENDIX H- HYDRAULIC SCHEMATICS 1000-2000 Product Families Hydraulic Schematic - Neutral 1000-2000 Product Families Hydraulic Schematic - Reverse 1000-2000 Product Families Hydraulic Schematic - Default Reverse 1000-2000 Product Families Hydraulic Schematic - Default Forward 1000-2000 Product Families Hydraulic Schematic - First Range 1000-2000 Product Families Hydraulic Schematic - Second Range 1000-2000 Product Families Hydraulic Schematic - Third Range 1000-2000 Product Families Hydraulic Schematic - Fourth Range 1000-2000 Product Families Hydraulic Schematic - Fifth Range 1000-2000 Product Families Hydraulic Schematic - Sixth Range APPENDIX J- WIRING SCHEMATICS 1000-2000 Product Families Wiring Schematic (MY09 & Later) with Prognostics 1000-2000 Product Families Wiring Schematic (Pre-MY09) APPENDIX K- RESISTANCE VS. TEMPERATURE APPENDIX L- ELECTRONIC INTERFERENCE L-1. ELECTROMAGNETIC INTERFERENCE (EMI) L-2. GENERAL GUIDELINES FOR RADIO EQUIPMENT INSTALLATION A. Transmitter Installation B. Antenna Installation C. Antenna Cable Routing D. Radio Wiring and Connector Location E. Power and Ground Wire Routing F. Troubleshooting L-3. EXTERNALLY-GENERATED SPEED SENSOR SIGNALS A. Checking for Externally-Generated Speed Sensor Signals APPENDIX M- ALLISON DOC� FOR PC-SERVICE TOOL APPENDIX N- INPUT AND OUTPUT FUNCTIONS A. Input Functions B. Output Functions Input Function A. Secondary MODE INPUT (enabled by wire 142) Input Function C. PTO REQUEST (enabled by wire 143) Input Function E. Aux. Function Range Inhibit, Standard (enabled by wire 101) Guidelines for Selecting Input Function H, Engine Brake Enable and Preselect Request Input Function H1. Engine Brake and Preselect Request, Plus Engine Brake Enable Output-Exhaust Brake (enabled by input wire 102, output wire 104) Input Function H2. Engine Brake Enable and Preselect Request, Plus Engine Brake Enable Output-ECM-Controlled Exhaust Brake (enabled by input wire 102, output wire 104) Input Function I. European Engine Brake Enable and Preselect Request, Plus Engine Brake Enable Output-Exhaust Brake (input wire 102, output wire 104) Input Function L. Automatic Neutral-Single Input (enabled by input wire 101) Input Function L. Automatic Neutral-Single Input (enabled by input wire 123) Input Function V. Reverse Enable (enabled by wire 143) Guidelines for Implementing Input Function Y, ABS Response Input Function Y1. Anti-lock Brake Response (enabled by input wire 121) Input Function Y2. Anti-lock Brake Response, With Input From Brake Pressure Switch (enabled by input wire 121) Input Function Y3. Anti-lock Brake Response Via J1939 Communication Link (enabled by wire 121) Input Function AA. Service Brake Status (enabled by input wire 162) Input Function AH. Kickdown (enabled by input wire 122) Input Function AM. Reverse Inhibit with Preselect Request (enabled by wire 123) Input Function AR. Overdrive Disable (enabled by input wire 161) Input Function BQ. Pump Mode ( 3rd Lockup), Operator and Pump Activated (enabled by input wires 122 and 123, output wire 145) Input Function CA. Brake-Based Automatic Neutral for PTO (enabled by input wire 123 and J1939 service brake status) Input Function CB. Preselect Request (enabled by input wire 102) Guidelines for Selecting Input Function CC: High N Input Function CC1. High N Input Function CC2. High N Input Function CD. Automatic Neutral (Single Input), with Selector Override (enabled by input wire 162) Output Function A. Engine Brake Enable (activation wire 104) Output Function B. Sump Temperature Indicator (activation wire 164) Output Function C. Range Indicator (activation wire 145) Output Function D. Output Speed Indicator A (activation wire 105) Output Function G. PTO Enable Output (activation wire 150) Output Function S. Neutral Indicator for PTO (activation by wire 145) APPENDIX P- J1939 AND J2284 HARDWARE AND TCM CONNECTIONS P-1. J1939 HARDWARE AND TCM CONNECTIONS A. TCM J1939 Interface B. Traditional Stub C. Pass-Through D. Backbone Termination E. J1939 Network Overview P-2. J2284 HARDWARE AND CONNECTIONS A. TCM J2284 Interface B. TCM-Only Installation with SAE J1962 Diagnostic Connector C. Diagnostic Connector APPENDIX R- FLUID CHECK PROCEDURE A. Manual Fluid Check Procedure B. Cold Check Procedure C. Hot Check Procedure D. Consistency of Readings . Notice: This is a preview not fully updated, please download the full version at https://wimanual.com