Allison Troubleshooting Manual Wtec Ii-21516A380010.pdf
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TS2470EN

	TITLE PAGE

	FOREWORD � How to Use This Manual

	IMPORTANT SAFETY NOTICE

	WARNINGS, CAUTIONS, AND NOTES

	TRADEMARKS USED IN THIS MANUAL

	SHIFT SELECTOR TERMS AND DISPLAY INDICATIONS

	TABLE OF CONTENTS

	SECTION 1�GENERAL DESCRIPTION

		1�1. TRANSMISSION

			Figure 1�1. WTEC II Electronic Control Components (Units Produced Before 9

			Figure 1�2. Electronic Control Unit Components (Units Produced 9

			Figure 1�3. Electronic Control Unit Block Diagram

		1�2. ELECTRONIC CONTROL UNIT (ECU)

			Figure 1�4. Electronic Control Unit (ECU)

		1�3. SHIFT SELECTOR

			Figure 1�5. Pushbutton Shift Selectors

			Figure 1�6. Six-Speed And Seven-Speed Lever Shift Selectors

		1�4. THROTTLE POSITION SENSOR

			Figure 1�7. Throttle Position Sensor (TPS)

		1�5. SPEED SENSORS

			Figure 1�8. Speed Sensors

		1�6. CONTROL MODULE

			Figure 1�9. Control Module

		1�7. WIRING HARNESSES

			Figure 1�10. WTEC II External Wiring Harness (Units Produced Before 9

			Figure 1�11. WTEC II External Wiring Harness (Units Produced 9

			Figure 1�12. WTEC II Internal Wiring Harness (Units Produced Before 9

			Figure 1�13. WTEC II Internal Wiring Harness (Units Produced 9

			Figure 1�14. WTEC II Internal Wiring Harness (Units Produced 11

		1�8. VEHICLE INTERFACE MODULE

			Figure 1�15. Vehicle Interface Module (VIM)

		1�9. TRANSID FEATURE

			Table 1�1. TransID 1 S

			Table 1�2. Software Level And TransID Compatibility

	SECTION 2�DEFINITIONS AND ABBREVIATIONS

		2�1. DO NOT SHIFT LIGHT

		2�2. ALLISON TRANSMISSION DIAGNOSTIC TOOLS

			Figure 2�1. Allison Transmission Diagnostic Tools

		2�3. 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. BEGINNING THE TROUBLESHOOTING PROCESS

	SECTION 4�WIRE TESTING PROCEDURES

		4�1. TESTING FOR OPENS, SHORTS BETWEEN WIRES, AND SHORTS-TO-GROUND

			Figure 4�1. Open Circuit

			Figure 4�2. Short Between Wires and to Ground

		4�2. TESTING AT TRANSMISSION CONNECTOR AND THE INTERNAL HARNESS FOROPENS, SHORTS BETWEEN WIRES, AND SHORTS-TO-GROUND

			Figure 4�3. Feedthrough Connector, Seal, and Internal Harness

			Figure 4�4. Testing Continuity

			Figure 4�5. Short Between Wires and to Ground

	SECTION 5�OIL LEVEL SENSOR

		5�1. ELECTRONIC FLUID LEVEL TEST (SHIFT SELECTOR)

		5�2. ELECTRONIC FLUID LEVEL TEST

	SECTION 6�DIAGNOSTIC CODES

		6�1. DIAGNOSTIC CODE MEMORY

			Table 6�1. Code List

		6�2. CODE READING AND CODE CLEARING

		6�3. DIAGNOSTIC CODE RESPONSE

		6�4. SHIFT SELECTOR DISPLAYS RELATED TO ACTIVE CODES

		6�5. DIAGNOSTIC CODE LIST AND DESCRIPTION

			Table 6�2. MD

		6�6. DIAGNOSTIC CODE TROUBLESHOOTING

			Figure 6�1. Control Module Solenoid Location

		CODE 13 XX�ECU INPUT VOLTAGE

			Figure 6�2. Code 13 Schematic Drawing

		CODE 14 XX�OIL LEVEL SENSOR

			Figure 6�3. Code 14 Schematic Drawing (Units Produced Before 9

			Figure 6�4. Code 14 Schematic Drawing (Units Produced 9

		CODE 21 XX�THROTTLE POSITION SENSOR FAULT OR ADJUSTMENT

			Figure 6�5. Code 21 Schematic Drawing (Units Produced Before 9

			Figure 6�6. Code 21 Schematic Drawing (Units Produced 9

		CODE 22 XX�SPEED SENSOR

			Figure 6�7. Code 22 Schematic Drawing (Units Produced Before 9

			Figure 6�8. Code 22 Schematic Drawing (Units Produced 9

		CODE 23 XX�SHIFT SELECTOR

			Figure 6�9. Code 23 Schematic Drawing

		CODE 24 XX�SUMP FLUID TEMPERATURE

			Figure 6�10. Code 24 Schematic Drawing (Units Produced Before 9

		CODE 25 XX�OUTPUT SPEED SENSOR, DETECTED AT ZERO SPEED,X RANGE

			Figure 6�13. Code 25 Schematic Drawing (Units Produced Before 9

		CODE 32 XX�C3 PRESSURE SWITCH

			Figure 6�15. Code 32 Schematic Drawing (Units Produced Before 9

		CODE 33 XX�SUMP OIL TEMPERATURE SENSOR

			Figure 6�17. Code 33 Schematic Drawing (Units Produced Before 9

		CODE 34 XX�EEPROM COMPATIBILITY OR CHECKSUM FAULT

		CODE 35 XX�POWER INTERRUPTION

			Figure 6�20. Code 35 Schematic Drawing

		CODE 36 XX�HARDWARE AND SOFTWARE NOT COMPATIBLE

		CODE 41 XX�OPEN OR SHORT-TO-GROUND IN SOLENOID CIRCUIT

		Figure 6�21. Code 41 Schematic Drawing (Units Produced Before 9

		CODE 42 XX�SHORT-TO-BATTERY IN SOLENOID CIRCUIT

			Figure 6�24. Code 42 Schematic Drawing (Units Produced Before 9

		CODE 43 XX�SOLENOID LOW SIDE CIRCUIT, OPEN DRIVER,OR WIRE SHORTED-TO-GROUND

			Figure 6�27. Code 43 Schematic Drawing (Units Produced Before 9

		CODE 44 XX�SHORT-TO-GROUND IN SOLENOID CIRCUIT

			Figure 6�29. Code 44 Schematic Drawing (Units Produced Before 9

		CODE 45 XX�OPEN CONDITION IN SOLENOID CIRCUIT

			Figure 6�32. Code 45 Schematic Drawing (Units Produced Before 9

		CODE 51 XX�OFFGOING RATIO TEST DURING SHIFT (TIE-UP TEST)

		CODE 52 XX�OFFGOING C3 PRESSURE SWITCH TEST DURING SHIFT

		CODE 53 XX�OFFGOING SPEED TEST (DURING SHIFT)

		CODE 54 XX�ONCOMING RATIO TEST (AFTER SHIFT)

		CODE 55 XX�ONCOMING C3 PRESSURE SWITCH (AFTER SHIFT)

		CODE 56 XX�RANGE VERIFICATION RATIO TEST (BETWEEN SHIFTS)

		CODE 57 XX�RANGE VERIFICATION C3 PRESSURE TEST(BETWEEN SHIFTS)

		CODE 61 XX�RETARDER FLUID HOT

		CODE 62 XX�RETARDER TEMPERATURE SENSOR

			Figure 6�36. Code 62 Schematic Drawing (Units Produced Before 9

		CODE 63 XX�INPUT FUNCTION FAULT

		CODE 64 XX�RETARDER MODULATION REQUEST DEVICE FAULT

			Figure 6�38. Code 64 Schematic Drawing (Units Produced Before 9

		CODE 65 XX�ENGINE RATING HIGH

		CODE 66 XX�SCI (SERIAL COMMUNICATION INTERFACE) FAULT

			Figure 6�40. Code 66 Schematic Drawing

		CODE 69 XX�ECU MALFUNCTION

	SECTION 7�INPUT AND OUTPUT FUNCTIONS

		A. INPUT FUNCTIONS

		B. OUTPUT FUNCTIONS

	SECTION 8�GENERAL TROUBLESHOOTING OFPERFORMANCE COMPLAINTS

		Table 8�1. Troubleshooting Performance Complaints

		Table 8�2. Resistance Module Troubleshooting Data

	APPENDICES (TABLE OF CONTENTS)

	APPENDIX A�IDENTIFICATION OF POTENTIAL CIRCUIT PROBLEMS

	APPENDIX B�TESTING CLUTCH PRESSURES

	APPENDIX C�SOLENOID AND CLUTCH CHART

	APPENDIX D�WIRE

		Figure D�1. ECU Connector �A�

		Figure D�2. ECU Connector �B�

		Foldout D�1. Bulkhead Connector Cross-Reference Chart

		Figure D�3. 31-Way Deutsch IPD Bulkhead Connector

		Figure D�4. Deutsch Bulkhead Connector, ECD (Plug

		Figure D�5. Cannon 37-Way FMTV Bulkhead Connector

		Figure D�6. Deutsch Transmission Connector, ECD (Plug

		Figure D�7. Transmission Connector (Before Model Year �95)

		Figure D�8. RSI Connector

		Figure D�9. Optional Deutsch Sensor Harness Connector

		Figure D�10. Speed Sensor Connector

		Figure D�11. Diagnostic Connector

		Figure D�12. Optional Deutsch Diagnostic Tool Connector

		Figure D�13. VIW (Amp) Connector

		Figure D�14. TPS Connector

		Figure D�15. Transfer Case Connector

		Figure D�16. Retarder Connector (MD

		Figure D�17. Retarder Connector (HD

		Figure D�18. Retarder Resistance Module

		Figure D�19. Retarder Temperature Sensor Connector (HD

		Foldout D�2. Customer-Furnished VIW

		Figure D�20. VIM Connector (Harness)

		Figure D�21. VIM Connector (Harness)

		Figure D�22. Ford 16-Way Transmission Bulkhead Connector*

		Figure D�23. Packard Metri-Pack VIM Connectors

		Figure D�24. Packard Weather Pack VIM Connectors

		Figure D�25. Navistar Deutsch DT Series VIW Connector

		Figure D�26. Dill VIW Connectors

		Figure D�27. Packard Metri-Pack Cab And Chassis Harness Connectors

		Figure D�28. Resistance Module Type 2�Single Pressure Switch

		Figure D�29. Resistance Module Type 3�Bendix E-10R Pedal

		Figure D�30. Resistance Module Type 5�Hand Lever

		Figure D�31. Resistance Module Type 7�Dedicated Pedal

		Figure D�32. Resistance Module Type 8�Three Pressure Switch

		Figure D�33. Resistance Module Type 9�Two Pressure Switch

		Figure D�34. End View of Oil Level Sensor Plug

	APPENDIX E�CONNECTOR PART NUMBERS, TERMINAL PARTNUMBERS, TOOL PART NUMBERS, AND REPAIR INSTRUCTIONS

		LIST OF SPECIAL TOOLS REQUIRED TO SERVICE WTEC II WIRING HARNESSES

		Figure E�1. Thomas & Betts ECU Connector, RSI Connector

		E�1. THOMAS & BETTS CONNECTORS (ECU AND RSI)

		Figure E�2. Packard Metri-Pack 150 Series Connectors�Pull-to-Seat (Internal

		E�2. Packard Metri-Pack 150 Series connectors�Pull-to-Seat (Internal

		Figure E�3A. Packard Metri-Pack 150 Series Connectors�Push-to-Seat (Former Oil Level Sensor)

		E�3. PACKARD METRI-PACK 150 SERIES CONNECTORS�PUSH-TO-SEAT(FORMER OIL LEVEL SENSOR) (Figure E�3A)

		Figure E�3B. Packard Metri-Pack 150 Series Connectors�Push-to-Seat (Current Oil Level Sensor)

		E�3B. PACKARD METRI-PACK 150 SERIES CONNECTORS�PUSH-TO-SEAT(CURRENT OIL LEVEL SENSOR) (Figure E�3B)

		Figure E�4. Packard Metri-Pack 280 Series Connectors�Pull-to-Seat (8-Way Freightliner; 5-Way Navistar CabHarness; 2-Way Navistar and Ford Cab Harness; Internal Harness Solenoid and C3 Pressure Switch)

		E�4. PACKARD METRI-PACK 280 SERIES CONNECTORS�PULL-TO-SEAT (8-WAYFREIGHTLINER; 5-WAY NAVISTAR CAB HARNESS; 2-WAY NAVISTAR ANDFORD CAB HARNESS; INTERNAL HARNESS SOLENOID AND C3 PRESSURESWITCH)

		Figure E�5. Packard Metri-Pack 280 Series Connectors�Push-to-Seat (Diagnostic Tool)

		E�5. PACKARD METRI-PACK 280 SERIES CONNECTORS�PUSH-TO-SEAT (DiagnosticTool Connector)

		Figure E�6. Packard Weather Pack Connectors (TPS; 3-Way RMR Sensor; HD Retarder Temperature; 6-Way Gillig VIM;4-Way RMR Device, Type 3; 3-Way RMR Device (Dedicated Pedal))

		E�6. PACKARD WEATHER PACK CONNECTORS (TPS; 3-WAY RMR SENSOR;HD RETARDER TEMPERATURE; 6-WAY GILLIG VIM; 4-WAY RMR DEVICE,TYPE 3; 3-WAY RMR DEVICE (DEDICATED PEDAL))

		Figure E�7. Terminal Crimping With Tool J 35606

		Figure E�8. Amp Products Connectors (16-Way VIW; 8-Way RMR Device (Hand Lever))

		E�7. AMP PRODUCTS CONNECTORS (16-WAY VIW; 8-WAY RMR DEVICE(HAND LEVER))

		Figure E�9. Deutsch IPD

		E�8. deutsch ipd

		Figure E�10. ITT Cannon Connectors�Crimped (37-Way FMTV Bulkhead; 6-Way Transfer Case; 8-Way MD Retarder)

		E�9. ITT Cannon Connectors�Crimped (37-Way FMTV Bulkhead;6-Way Transfer Case; 8-Way MD Retarder)

		Figure E�11. ITT Cannon Connectors�Soldered (2-Way HD Retarder)

		E�10. ITT CANNON CONNECTORS�SOLDERED (2-WAY HD RETARDER)

		Figure E�12. Deutsch DT Series Connectors (12-Way Navistar VIW)

		E�11. Deutsch DT Series Connectors (12-way navistar viw)

		Figure E�13. Dill Connectors (Freightliner 4-Way Fuse and 5-Way Relay VIW)

		E�12. DILL CONNECTORS (FREIGHTLINER 4-WAY FUSE AND 5-WAY RELAY VIW)

		Figure E�14. EPC Connectors (Ford 16-Way Bulkhead)

		E�13. EPC Connectors (Ford 16-Way Bulkhead)

		E�14. REPAIR OF A BROKEN WIRE WITH IN-LINE BUTT SPLICE

		Figure E�15. Crimper J 38125-8

		Figure E�16. Deutsch IPD

		E�15. deutsch ecd connectors (31-way bulkhead; 31-way feedthrough harness; 16-way optionalsensor harness; 6-way optional DIAGNOSTIC TOOL CONNECTOR)

		Figure E�17. Delphi-Packard (DHD) Connectors (31-Way); Crimping Tool

		E�16. DELPHI-PACKARD (DHD) 31-WAY CONNECTOR

		Figure E�18. Pin and Socket Extraction

		Figure E�19. Pin and Socket Insertion

		Figure E�20. Auxiliary Seal Orientation

		E�17. LIST OF MD

	APPENDIX F�THROTTLE POSITION SENSOR ADJUSTMENT

		A. Description of Operation

			Figure F�1. Throttle Position to Voltage Conversion

			Figure F�2. Throttle Position Determination Diagram

		B. Throttle Position Sensor (TPS) Adjustment

			Table F�1. Volts Versus Count for Throttle Sensor Display Reading

			Figure F�3. Throttle Position Sensor Adjustment

	APPENDIX G�MISCELLANEOUS ITEMS

		A. WELDING ON VEHICLE

		B. VEHICLE INTERFACE MODULE

			Figure G�1. Vehicle Interface Module (VIM)

			Figure G�2. VIM Components Location and Pin-Out Diagram

	APPENDIX H�HYDRAULIC SCHEMATICS

		Figure H�1. C2 Latch Valve Detail

		Figure H�2. Hydraulic Schematic�Neutral

		Figure H�3. Hydraulic Schematic�Reverse

		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�6th Range

		Figure H�10. MD 3070 Hydraulic Schematic�Neutral, Power On

		Figure H�11. MD 3070 Hydraulic Schematic� Reverse, Power On

		Figure H�12. MD 3070 Hydraulic Schematic�Lo MD, Power On

		Figure H�13. MD 3070 Hydraulic Schematic� 1st, Power On

		Figure H�14. MD 3070 Hydraulic Schematic�2nd, Power On

		Figure H�15. MD 3070 Hydraulic Schematic�3rd, Power On

		Figure H�16. MD 3070 Hydraulic Schematic�4th, Power On

		Figure H�17. MD 3070 Hydraulic Schematic�5th, Power On

		Figure H�18. MD 3070 Hydraulic Schematic�6th, Power On

		Figure H�19. MD

		Figure H�20. MD

		Figure H�21. MD

		Figure H�22. MD

		Figure H�23. HD

		Figure H�24. HD

	APPENDIX J�MD

		Foldout J�1. MD

		Foldout J�2. WTEC II TransID 1 Wiring Schematic (Began September, 1996)

	APPENDIX K�SOLENOID AND TEMPERATURE CHARTS

		Figure K�1. Temperature Sensor Chart

		Figure K�2. Solenoid Resistance vs.Temperature Chart

	APPENDIX L�EXTERNALLY-GENERATED ELECTRONIC INTERFERENCE

		1�1. ELECTROMAGNETIC

		1�2. GENERAL GUIDELINES FOR RADIO EQUIPMENT INSTALLATION

		1�3. EXTERNALLY-GENERATED SPEED SENSOR SIGNALS

	APPENDIX M�DIAGNOSTIC TREE FOR MD

		Figure M�1. Diagnostic Tree�MD

		Figure M�2. Diagnostic Tree�MD

	APPENDIX N�DIAGNOSTIC TOOL INFORMATION

	APPENDIX P�INPUT

		Figure P�1. Secondary Shift Schedule

		Figure P�2. D1 Selection

		Figure P�3. PTO Enable (Using �PTO� Switch)

		Figure P�4. PTO Enable (Using �MODE� Button)

		Figure P�5. Shift Selector Transition

		Figure P�6. Auxiliary Function Range Inhibit (Standard)

		Figure P�7. Auxiliary Function Range Inhibit (Special)

		Figure P�8. Auxiliary Hold

		Figure P�9. Engine Brake

		Figure P�10. Engine Brake

		Figure P�11. Fire Truck Pump Mode

		Figure P�12. Fire Truck Pump Mode (Optional)

		Figure P�13. Quick-To-Neutral Pump

		Figure P�14. Automatic Neutral for PTO (Standard)

		Figure P�15. Automatic Neutral for PTO (Special)

		Figure P�16. Automatic Neutral

		Figure P�17. Two Speed Axle Input and Output

		Figure P�18. Manual Lockup

		Figure P�19. Reverse Enable

		Figure P�20. Shift in Process

		Figure P�21. Anti-Lock Brake Response

		Figure P�22. Retarder Enable

		SERVICE BRAKE STATUS

		Figure P�23. Differential Clutch Request

		Figure P�24. Automatic Neutral for Refuse Packer and PTO Enable

		Figure P�25. Automatic Neutral for Refuse Packer and PTO Enable (Optional)

		Figure P�26. Kickdown

		Figure P�27. Fourth Lockup Pump Mode

		Figure P�28. Automatic Neutral for Refuse Packer and PTO Enable With Service Brake Status

		Figure P�29. Automatic Neutral for Refuse Packer and PTO Enable With Service Brake Status (Option 1)

		Figure P�30. Sump

		Figure P�31. Range Indicator

		Figure P�32. Output Speed Indicator�A

		Figure P�33. Output Speed Indicator�B

		Figure P�34. PTO Overspeed Indicator

		Figure P�35. Engine Overspeed Indicator

		Figure P�36. Lockup Indicator

		Figure P�37. Secondary Mode Indicator

		RETARDER INDICATOR

		Figure P�38. Neutral Indicator for PTO and PTO Enable



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